GYS S40 Mise à jour : 13/07/04

MANUAL INSTRUCTION FOR SPOT WELDING MACHINES GYSPOT INVERTER 93 R

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Thank you for your choice ! Before installing and using the product, please read carefully the following recommendations of safety in order to avoid accidents to the users and damages of the welding process. GYS can’t be responsible for the damages occurred to persons or things, which derive from the use of the machine in following circumstances : - Modification or neutralization of safety elements, - Non-respect of the recommendations written in the manual instruction, - Modification of the characteristics on the product, - Use of the accessories, which are different from the ones delivered by GYS, - Non-respect of the regulating and particular dispositions where the machine is settled. I / PRESENTATION This product has been designed to carry out the following operations in car body workshop : - Spot welding machine on sheet metals with gun, - Welding of sheet metals with gun, - Welding of nails, rivets, discs and pins, - Suppression of bumps and impacts (impacts of hail with the option « quick repair”).

II / SAFETY STANDARDS AND GENERAL PRECAUTIONS GENERALITIES 1. Before disassembling the product’s body, plug out the lead cable. 2. The operators must have the appropriate qualification. 3. The operation of servicing can only be controlled by qualified technicians. 4. The operator is responsible for respect of the car manufacturer’ recommendations, concerning the protection of electrical and electronic procedures (car computer, car radio, alarm, air bag, etc…). 5. Before an operation of servicing, the power supply with compressed air must be cut off and off loaded. 6. The electrodes, arms, and the other secondary conductors can reach a very high temperature and remain hot very long after having stopped the machine. Be careful : high risk of burns. 7. It is necessary to make a regular preventive maintenance. ELECTRICITY 1. Check that the unit must be connected to the earth coupler and that the connection to the earth is in good condition. 2. Check that the workbench is connected to the earth coupler. 3. Make sure that the operator has no contact with the metal parts to be welded without any protection or with wet clothes. 4. Avoid being in contact with the welding part. 5. Don’t make spot welding operations in very wet areas or on a wet floor. 6. Don’t weld with worn out cables. Check that there is no default with the isolation with stripped cables or with loose connections. 7. Switch off the unit before replacing the electrodes. 8. Before controlling or repairing, please disconnect the unit directly to the level of the plug.

PROTECTION OF EYES AND BODY 1. During the welding process, the process must be protected from the eventual flashes of the electrical arc with protection clothes like leather gloves, welding aprons, safety shoes, welding helmets or glasses for filtering radiations and projections. As well during operations of rubbing and hammering, the operator must protect his eyes. 2. The force of tightening of the clamp can reach 550 DaN. Keep away all body parts from the mobile elements to avoid risks of tightening. 3. Don’t keep rings, watches, or jewellery, which are current lead and can create burns. 4. All the protection board must be in good condition and maintained in place. Never look at an arc of welding without any protection of your eyes. Protect the environment near the product against projections and reflections.

SMOKES AND GAZ Welding operations can cause the emission of toxic smokes and harmful metallic dusts. Use the device in a sheltered place equipped with smoke aspirators. The operator must wear an anti smoke mask. The welding material must be degreased and cleaned in order to limit the toxic gas during the welding process.

FIRE

1. 2. 3. 4. 5.

Check that the sparks don’t cause fire especially near inflammable material. Check that fire extinguishers are not too far from the operator. Leave the product in a place with air movers. Don’t weld neither on containers of combustibles and lubricants, even empty, nor on containers with inflammable material. Don’t weld in an atmosphere full with inflammable gas or fuel steam.

ELECTRO-MAGNETIC COMPATIBILITY Near the spot-welding, check: there is neither no other power supply cable nor control lines, nor phone cables, nor radio or TV reception appliances, nor watches, nor mobile phones, nor magnetic cards, nor computers or any other electronic appliance. there is in the surroundings (minimum 3 meters of each point of the product) no persons using active medical appliances (pacemakers, acoustic prosthetics). Make supplementary protections if other products are used in the same environment.

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III / NORM CE This product has been designed with respect of the European standards. - Directive Low Voltage 73/23 CEE of 19th February 1973 (decree n°95-1081 of 3rd October 1995). - Directive electromagnetic compatibility 89/336 CEE of 3rd May 1989. - Directive machines under pressure 97/23 CEE of 29th November 1999. IV / CONNECTIONS OF POWER SUPPLY CABLES Electricity : GYSPOT INVERTER 93 R Three phases 400V 50/60Hz.

GYSPOT INVERTER 93 R

Protection of the line : GYSPOT INVERTER 93 R : circuit breaker 32A curve D or fuse 32A type aM. Case of malfunction : If the product releases the circuit breaker of the protection of installation, please check that you have the right calibre and the adequate type of circuit breaker (curve D absolutely). Compressed air : Connect a compressed air pipe to the purifier behind the product. The service pressure can’t be over 10 bars. The product can’t be used on an air network with a pressure under 3 bars. V/ SETTING OF THE MACHINE Connect the product to a connecting box (400V) : 3 phases + earth connection and make sure that the circuit breaker is switched over on the position OFF. If you use an electric extension cable, you must forecast a conductor section of 6 mm2. (10 mm2 if the extension cable is above 10m) . Put the pressure of compressed air on 5 Bars with the button of adjustment under the manometer foreside. Pull out the lever of the circuit breaker of the circuit breaker of backside (position ON). Blow down regularly the filter of deshumificator at the backside of the product.

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The electronic card begins a cycle of tests and initialisation of the parameters that last about 10 seconds. At the end of the cycle, the automatic ventilation of the cables is starting and the machine can be used. BE CAREFULL: The clamp and the gun of the product are connected to the same source of current. It means that when you use one of the two tools, there is a presence of voltage on the 2nd tool. The tool that is not used must be placed on the forecast support on the trolley (support of clamp on the 2 sides of the trolley and support gun on the mast arm). If you don’t respect this recommendation, very important damages can be created to the tools of the generator and there is a risk of sparks and a projection of metal in fusion (danger for the user). MAINTENANCE : The maintenance and repair of the generator of current can be done by a technician GYS. All the interventions in this generator done by another person will cause the cancellation of conditions of guarantee. The firm GYS declines its responsibility of any incident or accident that could occur before the intervention. VI/ DESCRIPTION OF THE FUNCTION OF THE PRODUCT Electronic Board on the front side 1 - Indicator of thickness of the steel sheet to weld.

2 – Indicator of decrementatio n of the different parameters

3 – Indicator of incrementation of the different parameters

A - Welding of mild steel sheets (clamp and gun) B - Welding of treated steel sheets (clamp and gun).

H – Indicators of modification of power or time parameter

C - Welding of boron steel sheets (clamp and gun).

G – Display of information for the operator

D – Forced ventilation (clamp and gun).

E - Selection of tool CLAMP.

F - Selection of tool GUN. And selection of the accessory used with tool gun

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Use of the gun -

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Connect the earth clamp to the spade terminal of the cable of generator. Fix firmly the earth clamp as near the place to weld as possible In the case of single point with gun, place the earth clamp on the steel sheet that is not in contact with the welding electrode (in order to make the current circulate between the 2 steel sheets to be welded). Select the tool GUN with the button f. Single point welding: choose the type of steel sheet to weld with the button A, B or C. Other process: choose the accessory used with the button F. 1 – Withdrawal of the impacts 2 – Smoothing of bumps 3 – Graphite pen 4 – Welding of pins 5 – Welding of rivets 6 – Welding of nuts 7 – Welding by a cord with the serrated roller

- Adjust the generator by showing the thickness of the steel sheet thanks to keys 2 and 3. It is possible to modify the power and time parameters by pressing on keys H and to modify with keys 2 and 3. Use of a pneumatic clamp - When you use the pneumatic clamp, disconnect always from the vehicle the earth clamp used in mode gun. - Adjust and tighten the arm of the clamp after having perfectly set in line the electrodes facing each other. - Adjust the air pressure to 5 bars for arms of 170 mm. Increase the pressure of one bar per 100 mm of added lengths. - Select the tool « CLAMP » with the button E. - Choose the type of steel sheet to weld with the buttons A, B or C. - Adjust the generator by showing the thickness of the steel sheet thanks to keys 2 and 3. It is possible to modify the power and time parameters by pressing on keys H and to modify with keys 2 and 3. VII/ OTHER FUNCTIONS OF THE ELECTRONIC CARD The electronic card offers possibilities of adjusting or other functions. Choice of the language For a special use, you can change the language ( initially in French ) with the following process: Press on the key “3” and engage the circuit breaker behind the unit at the same time. The message “FRENCH + TO CHANGE” appears. Release key 3. Select the language (French, English, German, Spanish) by pressing the key 3. Once you have chosen the language, let the product reboot.

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Recovery of the registered parameters It is possible to retrieve the last data of the user by using the following procedure when you apply voltage. - Press simultaneously the button H and engage the circuit breaker behind the unit, until the following message appears : « Restitution of user’s parameters » Setting of the arms of the clamp To set with precision the arm of the clamp, it is necessary to close the clamp, and attention that the generator doesn’t make any point. Press the button E during 2 seconds. The message « SETTING OF CLAMP » appears. If you press the gate terminal on the clamp, you can set the arms and pay attention that no current goes out from the generator. To go back to the normal mode, press one more time during 2 seconds on the button E Cooling of the cable The cables are cooled with compressed air. The cooling can be “permanent” or “controlled” by an internal temperature sensor. When you switch on the machine, the cooling of the cables is “controlled”. When the cables are cold, it is possible to stop the airflow by pressing the buttons D. It is possible to force the cooling by pressing the button D A thermal protection prevents from forbidding the use of the product in case of over heat. The message « ARRET SURCHAUFFE MACHINE !!! » appears.

Recommendation : In case of an intensive use, you should maintain the cooling of the cables permanently. It is also recommended to leave the machine switched on to allow the cooling of the cables.

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