Fytech FY-9000 User manual

Owner’s Manual
FY-9000
The equipment is approved by a number of car manufacturers

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、Pac king 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 do u 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
Degree of protection
Singl e p h a s e
Duty cycle
Direct current
Constant crrent
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 n ot do t hi s

Accessories And Spare parts
Accessories and Spare Parts List:
Remark:
1)、Optional orders for above accessories and components are
available.
2)、Model and parts number required when ordering parts from
your local distributor.
Page.3
Waveform electrode tip
NO.F010
NO.F013
Control transformer
NO.F025
Pn eu m at ic v acu um c upu le
NO .F 0 01
Claw puller
NO.F004
Carbon Cod
NO.F007
St ud
NO.F016
Ma nua l cu p ul e
NO.F019
Back wheel
NO.F022
Spot welding electrode
tip NO.F008
Washer adaptor
NO .F0 11
Fr ont p ar t o f pu lle r
NO.F014
Washer
NO.F017
Welding gun
NO.F020
Pull hammer
NO.F002
Ho ok
NO.F005
Vertical spot welding
pull hammer NO.F003
Wriggle
NO.F006
Carbon rod adaptor
NO.F009
Electrode holder
NO.F012
Triangle wasler
NO.F015
Ground wire clamp
NO.F018
Front wheel
NO.F021
Circuit board
NO.F028
Trianger washer adaptor

22KW
Electronic timer,continuity
0-9 9 ms
Inf i nit y
1.0+1.2(mm)
720*600*1550(mm)
AC1V-13V
5800A
180kg
86kg
Kr ipt ol h e at ing A C6 V-1 0V w a sh er we ld i ng A C1V -1 2 V do ubl e- sid e wel di ng AC 1V - 13 V
57A
1、specifications
Output voltage
Input power
Input curr ent
Operation way
Time regu lati on sys tem
Operation place
Vacuum cupu le device
Dimension
Instant max.current
One side welding thickness
Weight
Installation
Input voltage
Page.4
380V 50/60HZ

2、Duty Cycle and Overheating
Duty cycle is percentage of 10 minutes that unit can weld at
rated load without overheating.
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
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.

3、Machine Installation
1)Open the package and find out the owner's manual。
2)Check the supplied of 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
2
L1
L2
1
1

Operation
1、Controls
Page.9
1
2
3 4 5
8
11
12
13
9
10
67
1、LCD Display
2、Time adjustment(Increase)
3、Time adjustment(Decrease)
4、Current adjustment(Increase)
5、Current adjustment(Decrease)
6、Left
7、Up
8、Enter/return
9、Right
10、Down
11、Power switch
12、Negative outside wire
13、Welding gun Output Cable

Page.10
2、Welding Gun and Adaptors
1
2
Single-Sided applications
5、Tighten up the holder
4、Installed the
fixed shank
2、Put negative wire
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
1、Electrode holder
2、Trigger
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 negative wire

Page.11
3、Operation
Con n ect s p ot we l din g
electrode tip with w e ldi n g
gun a n d tig h ten .
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 c o rre c t amp e rag e .
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 face ( 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 atio 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 hick n ess .
3、Con t inu i ng an o the r o pera tion i s avai labl e afte r this p roce dure f i nis h ed .I f n ot, pl ease
shu t o ff th e m ain p o wer s u pply a nd swi tch of f the unit .
%
a、spot welding
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.

Page.12
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 face ( 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 atio 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 hick n ess .
3、Con t inu i ng an o the r o pera tion i s avai labl e afte r this p roce dure f i nis h ed .i f n ot, p l ease
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 .
Set c o rre c t amp e rag e .
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 tri g ger .
3、Operation
%
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
Rem o ve we l din g g un.H o ok the
was h er wi t h pul l h amm e r.Slide
the h a mme r t o opp o sit e dire ctio n
to pu l l out t h e den t .

Page.13
Con n ect t r ian g el wa s her
pul l h amm e r wit h w eld i ng gun .
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.
Sli d e the h a mme r t o opp o site
direction to pul l the de nt out .
F003+F020
c、Triangle Washer Welding
Set c o rre c t tim e .
Set c o rre c t amp e rag e .
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 face ( 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 atio 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 hick n ess
3.Tri a ngl e washer welding can r e pla c e washer welding.It can pull out the dent directly
aft e r wel d ed.
4、Con t inu i ng an o the r o pera tion i s avai labl e afte r this p roce dure f i nis h ed .I f n ot, p l ease
shu t o ff th e m ain p o wer s u pply a nd swi tch of f the un it.
%
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.

Page.14
Con n ect c a rbo n r od an d
carbon rod ad apto r with
welding gun.
Carbon rod turning in
clockwise to heat up
the stretched panel
Use c o ld wa t er or w e t rag
to co o l dow n t he he a ted a r ea
tha t m ake s t he st r etc h ed pan el
shrunken as normal status.
F00 7 +F0 0 9+F 0 20
d、Carbon rod Heating
3、Operation
Set c o rre c t amp e rag e .
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 face ( 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 atio 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 hick n ess .
3、Con t inu i ng an o the r o pera tion i s avai labl e afte r this p roce dure f i nis h ed .I f n ot, p l ease
shu t o ff th e m ain p o wer s u pply a nd swi tch of f the un it..
%
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.

Page.15
Con n ect w r igg l e wir e electrode
tip w i th we l din g g un.
F006+F010+020
e、
3、Operation
Set c o rre c t amp e rag e .
Se t co rr ect 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 face ( 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 atio 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 hick n ess .
3、Con t inu i ng an o the r o pera tion i s avai labl e afte r this p roce dure f i nis h ed .I f n ot ,p l ease
shu t o ff th e m ain p o wer s u pply a nd swi tch of f the un it.
Wriggle Form Wire Welding
%
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.
Hook 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 on pressure and
press trigger.

3、Operation
Page.16
f、Cupules
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
Resis t o r
Circu i t b o a r d
Main po w e r s w i t ch
Silic o n c o n t r ol
Contr o l t r a n s former
Main tr a n s f o r mer
Left si d e v i e w
Resis t o r
Contr o l t r a n s former
Main tr a n s f o r mer
Right s i d e v i e w
继电器
风扇
风扇
Capacitor and small resistor

2、Troubleshooting
Maintenance
Page.18
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 o ff
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）Gu n c ontrol wire brok e n .
（3）Co n trol wire plug loo 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 g ain 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)Cha n g e g r o u nd clamp locatio n .
Piercing workpiece
(1)output a m p e r a g e too high.
(2)Weld tim e t o o l o n g .
(3)Bad cont a c t o f e l e ctrode tip or
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 w orkpiece is dirt y
(2)Incorr e c t a m p e rage and time
setti n g .
(1Polish carbon rod and workpieces
(2)Set amperage and time according to
workpiece thickness.
)
Unit 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)Check gun c o ntrol wire and
trigg e r p l u g .
(2)Wait fo r t e m p e r ature cool down.
Trouble
Poor weld
.
.