Fytech FY-8L User manual

Owner’s Manual
FY-8L
The equipment is approved by following car manufacturers (China)

1、Safety Precautions Symbols
2、Symbols and Definitions
3、Accessories and Spare Parts List
4、Installation
1)、Sp ecifications
2)、D uty Cycle and Overhea ting
3)、Machine Installation
4)、Se lecting a Location
5)、Co nnecting Input Power
5、Operation
1)、Con trols
2)、Welding Gun and Adaptors
3)、Various Oper ations
a、Spo t Welding
b、Washer Welding
c、Tr iangle Washer Welding
d、Carbon Rod He ating
e、Wav e Form Wire Welding
f、Cupules
6、Ma intenance
1、Ex ploded View
2、Tr oubleshooting
7、El ectrical Diagra m
8、Pa cking List
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Contents

Page.1
Safety Precautions Symbols
Protect yourself and others f rom inj ury,
read and follow these precaut ions be fore
installation and operatio n.
Ex p lod ing p art s c an in jur e .Al w ays w ear a f a ce
sh i eld a nd lo ng sl e eve s。
St ati c ca n d am age P C bo ard s
1、Pu t on gr ou n de d wri st s tra p be f or e
ha ndi ng b o ar ds or p ar ts。
2、Us e pro pe r s ta tic -p roo f ba g s an d box es t o
st ore，move or s hi p P C bo ard s。
1、We ar ap pr o ve d fac e sh iel d or sa fe ty go gg l es
wi th si de s h ie lds。
2、We ar pr op e r bo dy pr ot ect ion t o pr ote ct s k in。
Do n ot we ld i n t he h eig ht！
Read instructions.
1、Read owner's Ma nua l be f or e usi ng o r ser vi c in g
un it。
2、Use only manufacturer’s supplied replacement。
Fl yin g me t al c an in ju re ey es。
1) Wea r sa f et y gla ss es wi th si de s hie ld s o r fa ce
sh iel d。
1、Ma gne ti c f ie lds c an a ffe ct pa ce mak er s .
Pa cem ak e r we are rs k eep a way .
2、We are rs s h ou ld co ns ult t hei r do cto r be f or e
go ing n ea r p la sma a rc c utt in g o pe rat io n s。
Ov e rus e can c aus e o ver hea t in g
Al l ow co oli ng pe r iod , fol l ow r a ted d uty c y cle
before starting to we l d aga in.
El ect ri c s ho ck ca n ki ll:
1、Do n ot to uc h l iv e ele ct ric al p a rt s。
2、We ar dr y, h ol e-f re e ins ul a ti ng gl ov e s an d
bo dy pr ot e ct ion .
3、Do n ot wr ap e l ec tri ca l cab le a r ou nd yo ur
bo dy.
4、Gr oun d th e w or kpi ec e wit h a go o d el ect r-
ic al gr ou n d。
Ey e pro te c ti on fo r we ldi ng :
Cu rre nt l e ve l in am pe rag e Mi n im um sh ad e
Nu mbe r
30-150A---------- --- -- -- - -- -- - -- -- - #8
150-300A--------------------------- # 10
30 0-5 00 A -- ------------------------- #12
Nev e r cut o n p res s uri z ed cyl inde r.
Maintenance regularly！
Fa cto ry s a fe ty！
Fi re or e xp l os ion h az ard .
Do n ot lo ca t e un it on ,o ver ,o r n ea r com bu s ti be
su rfa ce s .D o not i ns tal l un i t ne ar fl am m ab les .
Re mov e al l f la mma bl es of t he w e ld ing a re a .
Fa lli ng u n it c an ca us e inj ur y .
Th e hea t fr o m th e wor kp iec e ca n c au se se ri o us
bu rns。
Fu mes a nd g a se s can b e ha zar dou s
we ldi ng p r od uce s fu mes a nd g a se s. Breathing
th ese f um e s an d gas es c an be h az a rd ous
to y our h ea l th .
If inside,ventilate the area.
Do n ot we ld i n a c on fin ed s pac e onl y if i t
is w ell v en t il ate d.
Pr ote ct y o ur sel f Warn others

Definitions
Symbols and Definitions
U1
U0
U2
I2
s1
HZ
A
V
Rated w e l d i n g
current
Prima r y v o l t a ge
Rated n o l o a d
volta g e ( A a v erage)
Conve n t i o n a l
load vo l t a g e
Power rating,
product o f vo l ta ge
and current(KVA)
Her t z
Amperes
Volts
IP
X
I1max
I1eff
~
1
Rated m a x i m u m
suppl y c u r r e n t
Maximum effective
supply current
De gre e of p r ot ect io n
Singl e p h a s e
Duty cycle
Direct current
Constant current
Temperature
V
S
I
O
Su ita bl e f or s ome
ha zar do u s lo cat io ns
Volta g e i n p u t
Lo w air p re s su re
li ght
On
Off
Protective earth
(Ground)
Input
＋－
%
Adjust air/gas
pressure
Percent
Increase
Line co n n e c t i on
Loose s h i e l d c u p
Autom a t i c
Manua l
Page.2
Do not d o this

Accessories And Spare parts
Accessories and Spare Parts List:
Waveform electrode tip
NO.F010
NO.F013
Co nt ro l tr an sf or me r
NO.F025
Pn eu m at ic v acu um c upu le
NO .F 0 01
Hook puller
NO.F004
Kriptol
NO.F007
St ud
NO.F016
Manual cupule
NO.F019
Back wheel
NO.F022
Sp ot we ld i ng e lec tr ode
tip NO.F008
Washer adaptor
NO .F0 11
Fr ont p ar t o f ho ok pu ll er
NO.F014
Washer
NO.F017
Welding gun
NO.F020
Pull hammer
NO.F002
Ho ok
NO.F005
Ve rti ca l s po t wel di ng
pu ll ha mm e r NO .F0 03
Waveform wire
NO.F006
Carbon rod adaptor
NO.F009
Electrode holder
NO.F012
Triangle wasler
NO.F015
Ground wire clamp
NO.F018
Fr ont w he e l
NO.F021
Ci rcu it b o ar d
NO.F028
Remark:
1)、Optionnal orders for above accessories and components are
available.
2)、Model and parts number required when ordering parts from
your local distributor.
Page.3
Trianger washer adaptor
Digitial dispiay NO. F 0 23 Time adjustment NO.F024
A.C.contactor N O .F 0 26 Tools box NO .F 02 7

Installation
Page.4
Single pha se 220V
50/60Hz
0-99ms
Stepless
0.8+1.2
620*450*980
21KW
5400A
55A
Continuity
180kg
80kg
FY-8L
AC1V-10V C a rbon rod h eating
AC6V-1 2V Washe r fusion
AC1V-1 3V Butt we ld
1、specifications
Input voltage
Output voltage
Input power
Input current
Operation way
Time regulation system
Currenf Regulafion
Vacuum cupule device
Dimension(mm)
Parameters
Instant max.current
One side welding
thickness(mm)
Weight
Model
Single phase380V
50/60Hz
0-99ms
Stepless
0.8+1.0
620*450*980
20KW
5200A
51A
Continuity
150kg
78kg
FY-7L
AC1V-1 0V Carbo n rod heating
AC6V-1 0V Washe r fusion
AC1V-1 2V Butt we ld
Single phase
220V 50/60Hz
0-99ms
A.B.C
19KW
5000A
620*450*980
AC6V-1 0V Carbo n r od heating
AC1V-1 2V Washe r f usion
AC1V-1 3V Butt we l d
50A
Continuity
150kg
70kg
0.8+0.8
FY-6L

2、Duty Cycle and Overheating
Duty cycle is percentage of 10 minutes that unit can weld at
rated load without overheating.
The welder is equipped with over-hert protection.On exceeding the
critical temperature,the welder will be stopped automaticlly.The
welder can be used again after cooling down.
Page.5
Overheating Sto p w ork i ng Wai t f ift e en mi n ute s
for u n it to c o ol
Red u ce am p era g e or
reduce duty cycle
Wel d again
0
15
A

3、Machine Installation
1)open the package and find out the owner's manual。
2)Check the supplied accessories according to packing list
that attached to this manual.
3)Properly install this equipment as following diagram.Inspect
the unit for any problems.If so,contact your local distributor
or service agency.To locate a distributor or service agency.
Page.6

Page.7
4、Selecting a Location
1)Select a correct location to place the unit.
2)Determine input power cord length according to its actual
operation requirement .Make sure that the supply cable is at
2
least 6mm indiameter
3)Do not move or operate unit where it could tip.
4)Use cart or unit handle to move unit .Do not pull the cords
to move unit.

5、Connecting Input Power
2
1、Inp u t pow e r cor d（n ot le s s than 6 mm
cop p er co r d）.
2、Ove r -cu r ren t p rot e ctio n.
3、Dis c onn e ct de v ice l i ne ter mina ls.
4、Gro u nd wi r e L1/ L 2 inp u t cond ucto rs.
Ins t all a tio n m ust m e et all N atio nal an d
Local Codes---hav e only q uali fied p e rso n s
mak e t his i n sta l lat i on.
Dis c onn e ct an d l ock o ut/t agou nt inp ut pow er
bef o re co n nec t ing i n put co nduc tors f rom
unit.
Sel e ct ty p e and s i ze of o v er-c urre nt
protection.
Clo s e and s e cur e d oor o n d isco nnec t devi ce .
Remove lockout/tagout device,and place
swi t ch in t h e "on" position.
4
Page.8
3
1
2
L1
L2
1

Operation
1、Controls
Page.9
1、Time Display
2、Power Display
3、Time--Decrease
4、Time ---Increase
5、Power ---Decrease
6、Power----Increase
7、Automatic/Manual
8、Welding Programs
9、Enter
10、Power Indicator
11、Overheat Indicator
12、Manual Indicator
13、Automatic Indicator
14、Weld Gun Working indicator
15、Enter Indicator
Operation
1、Properly make input connections
2、Turn on the welder.Push the Weld Programs
button to select the desirous weld procedure.
3、Set Automatic/ Manual.Adjust weld time and
power.
4、In Manual mode,weld time means the switching
time of welder which is controlled by the user.(Note:
Automatic mode is generally recommended in
using,The time control is accurate to 0.01 second. )
5、Set weld time and power.Push "Enter"
button."Enter Indicator " is on.
6、Welder is now enters into the work state.Welding
is available.
7、To prevent damage to the welder caused by
overheating,the system will automatically shut off
the welder when a pre-programmed temperature is
reached .Do not turn off the welder.Wait unit the
indicator goes off(usually(5-10min).
1
2
3
4
5
6
7
89
10
11
12
13
14
15
16
17
16、Weld Gun Cable
17、Ground Cable

2、Welding Gun and Adaptors
Page.10
1
2
1、Electrode holder
2、Trigger
Single-Sided applications
5、Tighten up the holder
4、Installed the
fixed shank
2、Put ground cable
into the welded washers
1、 Weld 2 washers on metal
workpiece ,as close to
welding area as possible.
3、Located the holder
on the welded washers
Car b o Rod S h rin k ing
OT Wa s her W e ldi n g
Was h er We l din g
Stud Welding
Sin g le- s ide d W eld i ng
Wav e f orm W i re We l din g
Pul l ing S p ot Ha m mer
Connection of ground cable

Set Mode switch
3、Operation
Con n ect s p ot we l din g
electrode tip with w e ldi n g
gun and tighten.
App r oxi m ate l y a 90°angle
to th e w ork e pie c e sur f ace.
Put on pressure and pre ss tri gger .
F008+F020
Set correct time.
、
Remark:
1、Set t ing a m per a ge to o h igh or t ime to o long c an cau se wor kpie ce sur f ace ( v ehi c le body)damage .
Ple a se we l d oth e r wor k piec es for p ract ice be fore a ctua l oper a tio n s.
2、Set t ing c o rre c t amp e rage a nd tim e acco rdin g to the w orkp iece t h ick n ess .
3、Con t inu i ng an o the r o pera tion i s appl icab le aft er the se pro c edu r es fi n ish e d .If no t, ple ase
shu t o ff th e m ain p o wer s u pply a nd swi tch of f the unit .
Page.11
a、spot welding
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
(Pos i tio n C i s rec o mme n d).
Set c o rre c t pow e r

Con n ect w a she r a dap t or with
wel d ing g u n and t i ght e n,
Install washer.
Remark:
1、Set t ing a m per a ge to o h igh or t ime to o long c an cau se wor kpie ce sur f ace ( v ehi c le body)damage .
Ple a se we l d oth e r wor k piec es for p ract ice be fore a ctua l oper a tio n s.
2、Set t ing c o rre c t amp e rage a nd tim e acco rdin g to the w orkp iece t h ick n ess .
3、Con t inu i ng an o the r o pera tion i s appl icab le aft er the se pro c edu r es fi n ish e d .if no t, ple ase
shu t o ff th e m ain p o wer s u pply a nd swi tch of f the un it.
F017+F011+F020
b、Washer Welding
Set c o rre c t tim e .
3、Operation
Page.12
Set Mode switch
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
App r oxi m ate l y a 90° a ngle t o the
dent.Put o n p res s ure a n d pre s s
trigger.
Rem o ve we l din g g un.H o ok the w ashe r with
pul l h amm e r.Sl i de th e h amme r to opp osit e
dir e cti o n to pu l l out t h e dent .
(Pos i tio n A o rB is recommend) .
Set c o rre c t pow e r

Con n ect t r ian g el wa s her
pul l h amm e r wit h w eld i ng gun .
Sli d e the h a mme r t o opp o site
direction to pul l the de nt
F003+F020
c、Triangle Washer Welding
Set c o rre c t tim e . App r oxi m ate l y a 90° a n gle to
the d e nt, p ut on p r ess u re
and p r ess t r igg e r.
3、Operation
Remark:
1、Set t ing a m per a ge to o h igh or t ime to o long c an cau se wor kpie ce sur f ace ( v ehi c le body)damage .
Ple a se we l d oth e r wor k piec es for p ract ice be fore a ctua l oper a tio n s.
2、Set t ing c o rre c t amp e rage a nd tim e acco rdin g to the w orkp iece t h ick n ess
3.Tri a ngl e washer welding can r e pla c e washer welding.It can draw out the concavity direc tly
after weld ed.
4、Con t inu i ng an o the r o pera tion i s appl icab le aft er the se pro c edu r es fi n ish e d .If no t, ple ase
shu t o ff th e m ain p o wer s u pply a nd swi tch of f the un it.
Page.13
Set Mode swit ch
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
(Pos i tio n A i s rec o mme n d).
Set c o rre c t pow e r

F00 7 +F0 0 9+F 0 20
d、Carbon rod Heating
3、Operation
Set c o rre c t tim e
Remark:
1、Set t ing a m per a ge to o h igh or t ime to o long c an cau se wor kpie ce sur f ace v e hic l e body)damage .
Ple a se we l d oth e r wor k piec es for p ract ice be fore a ctua l oper a tio n s.
2、Set t ing c o rre c t amp e rage a nd tim e acco rdin g to the w orkp iece t h ick n ess .
3、Con t inu i ng an o the r o pera tion i s appl icab le aft er the se pro c edu r es fi n ish e d .If no t, ple ase
shu t o ff th e m ain p o wer s u pply a nd swi tch of f the un it..
Page.14
Set Mode switch
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
Con n ect c a rbo n r od an d
car b on ro d a dap t or wi t h
wel d ing g u n.
Tur n c arb o n rod c l ock w ise to h eat
up th e e nti r e con v exi t y surf ace.
Coo l t he su r fac e w ith a w e t
rag o r c omp r ess e d air .
(Pos i tio n A i s rec o mme n d).
Set c o rre c t pow e r

Con n ect w a ve form wire ele ctro d e
tip w i th we l din g g un.
F006+F010+020
e、
3、Operation
Set correct time.
Remark:
1、Set t ing a m per a ge to o h igh or t ime to o long c an cau se wor kpie ce sur f ace ( v ehi c le bo d y)da mage .
Ple a se we l d oth e r wor k piec es for p ract ice be fore a ctua l oper a tio n s.
2、Set t ing c o rre c t amp e rage a nd tim e acco rdin g to the w orkp iece t h ick n ess .
3、Con t inu i ng an o the r o pera tion i s appl icab le aft er the se pro c edu r es fi n ish e d .If no t ,ple ase
shu t o ff th e m ain p o wer s u pply a nd swi tch of f the un it.
Wave Form Wire Welding
Page.15
Set Mode swit ch
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
Connect hook puller with pull hammer.
Hoo k wave form wire and slide the
hammer to pull out the dent.
Place a wave form wire
horizontally on the dent.
Approximately a 90°angle
to wave form wire.Put o n
pressure andpress trigger.
(Position A is recommend).
Set c o rre c t pow e r

f、Cupules
3、Operation
Page.16
Manual operating cupule:
1、Connect manual cupule with
pull hammer.
2、Push manual cupule in to lock
the cupule on the dent.
3、Slide the hammer to opposite direction
to pull the dent out.
Pneumatic vacuum cupule:
1、Connect gas/air supply with the adaptor
of cupule.
2、Open the valve ,sticking cupule to the
dent.
3、Slide the hammer to opposite direction
pull the dent out.
4、Cupule falls off when close the valve.

Maintenance
1、Exploded view
Page.17
Voltmeter
Curre n t a d j u s tment switch
A.C.contactor Conti o l t r a n s former
Main tr a n s f o r mer
Main tr a n s f o r mer
Contr o l c i r c u it board
Lef t s ide vie w
Rig ht side vi e w

2、Troubleshooting
Reason Remedy
No welding output
(1)Conne c t e d p o w er supply
incorrectly.
(2)Power s w i t c h i n "off"
posit i o n
（1）Connect power supply according
to manufacturer’s instructions.
（2）Place power switch in “on”
position.
Trigger not working
（1）Trigger damage d .
（2）Gun control wire b r o k e n .
（3）Control wire plu g l o o s e n .
(4)Mode sw i t c h i n i n correct
position.
（1）Replace trigger.
（2）Co n n e c t a gain or replace i f n e c -
essar y .
(3)Co n n e ct control wire p l u g a g a i n.
(4)Place Mod e s witc h i n c o r r e c t pos-
ition .
(1)Aamperage too low
(2)Weld time too short.
(3)Input power cord did not
meet the requirement.
(4)Ground clamp bad contact.
(1)Inc r e a s e a m perage setting
(2)In c r e a s e t ime setting.
(3)Re p l a c e i n put power cord.
(4)Ch a n g e g r o und clamp locati o n .
Piercing workpiece
(1)Outpu t a m p e r a ge too high.
(2)Weld ti m e t o o l o n g.
(3) Bad c o ntact of electr o d e t i p o r
washe r w i t h w o r kpiece.
(1)Red u c e a m p e rage setting.
(2)Rr d u c e w e l d time.
(3)Re m o v e c o a ting from materi a l
reduc e a d d e d p r essure.
Carbon rod working
unstable
(1)Car b o n r o d o r workpiece i s d i r t y
(2)Incor r e c t a m p erage and time
setti n g .
(1)Polish carbon rod and
workpieces before welding
(2)Set amperage and time according to
workpiece thickness.
Welder stop working
while operation
(1)Tr i g g e r p l ug loosen.
(2)Gu n c o n t r o l wire broken.
(3)Ov e r h e a t i ng.
(1)Ch e c k gun co n t r o l wire and
trigg e r p l u g .
(2)Wait fo r t e m p e r ature cool down .
Maintenance
Trouble
Poor weld
.
.
Page.18