Fytech FY-9000A User manual

Owner’s Manual
FY-9000A
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)、Specifications
2)、Duty Cycle and Overheating
3)、Machine Installation
4)、Selecting a Location
5)、Connecting Input Power
5、Operation
1)、Controls
2)、Welding Gun and Adaptors
3)、Various Operations
a、Spot Welding
b、Washer Welding
c、Triangle Washer Welding
d、Carbon Rod Heating
e、Wriggle Form Wire Welding
f、Cupules
6、Maintenance
1、Exploded View
2、Troubleshooting
7、Electrical Diagram
8、Packing List
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Contents

Safety Precautions Symbols
Protect yourself and others from injury,
read and follow these precautions before
installation and operation.
Fire or explosion hazard.
Do not locate unit on,over,or near combustibe
surfaces.Do not install unit near flammables.
Exploding parts can injure.Always wear a face
shield and long sleeves。
Static can damage PC boards
1、Put on grounded wrist strap before
handing boards or parts。
2、Use proper static-proof bags and boxes to
store，move or ship PC boards。
1、Wear approved face shield or safety goggles
with side shields。
2、Wear proper body protection to protect skin。
Do not weld in the height！
Read instructions.
1、Read owner's Manual before using or servicing
unit。
2、Use only manufacturer’s supplied replacement。
Flying metal can injure eyes。
1)Wear safety glasses with side shields or face
shield。
1、Magnetic fields can affect pacemakers.
Pacemaker wearers keep away.
2、Wearers should consult their doctor before
going near plasma arc cutting operations。
Overuse can cause overheating
Allow cooling period ,follow rated duty cycle
before starting to weld again.
Cylinders can explode if damaged.
Gas cylinders contain gas under high pressure.
If damaged,a cylinder can explode .Be sure to
treat them carefully.
Electric shock can kill:
1、Do not touch live electrical parts。
2、Wear dry,hole-free insulating gloves and
body protection.
3、Do not wrap electrical cable around your
body.
4、Ground the workpiece with a good electr-
ical ground。
Keep away from the torch tip.
Remove all flammables of the welding area.
Falling unit can cause injury.
Eye protection for welding:
Current level in amperage Minimum shade
Number
30-150A---------- -- --- -- --- -- -- - -- - #8
150-300A--------- -- --- -- --- -- -- - -- - #10
300-500A------- --- -- -- - -- -- - -- -- --- #12
The heat from the workpiece can cause serious
burns。
Never cut on pressurized cylinder.
Maintenance regularly！
Factory safety！
Page.1
Keep away from moving parts such as fans.
Fumes and gases can be hazardous
welding produces fumes and gases. Breathing
these fumes and gases can be hazardous
to your health .
If inside,ventilate the area.
Do not weld in a confined space only if it
is well ventilated.
Moving parts can cause injury.
Protect yourself Warn others

Definitions
Symbols and Definitions
U1
U0
U2
I2
s1
HZ
A
V
Rated welding
current
Primary voltage
Rated no load
voltage(Aaverage)
Conventional
load voltage
Power rating,
product of voltage
and current(KVA)
Hertz
Amperes
Volts
IP
X
I1max
I1eff
~
1
Rated maximum
supply current
Maximum effective
supply current
Degree of protection
Single phase
Duty cycle
Direct current
Constant crrent
Temperature
V
S
I
O
Suitable for some
hazardous locations
Voltage input
Low air pressure
light
On
Off
Protective earth
(Ground)
Input
＋－
%
Adjust air/gas
pressure
Percent
Increase
Line connection
Loose shield cup
Automatic
Manual
Page.2
Do not do this

Accessories And Spare parts
Accessories and Spare Parts List:
Waveform electrode tip
NO.F010
NO.F013
Control transformer
NO.F025
Pneumatic vacuum cupule
NO.F001
Claw puller
NO.F004
Carbon Cod
NO.F007
Stud
NO.F016
Manual cupule
NO.F019
Back wheel
NO.F022
Spot welding electrode
tip NO.F008
Washer adaptor
NO.F011
Front part of puller
NO.F014
Washer
NO.F017
Welding gun
NO.F020
Pull hammer
NO.F002
Hook
NO.F005
Vertical spot welding
pull hammer NO.F003
Wriggle
NO.F006
Kriptol adaptor
NO.F009
Electrode holder
NO.F012
Triangle wasler
NO.F015
Ground wire clamp
NO.F018
Front wheel
NO.F021
Circuit board
NO.F028
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
Trianger washer adaptor

1、specifications
Installation
Page.4
Input voltage
Output voltage
Input power( )KW
Input current(A)
Operation way
Time regulation system
Operation place
Vacuum cupule device(kg)
Dimension(mm)
Instant max.current
One side welding
thickness(mm)
Weight
22
Electronic timer,continuity
0-99ms
Infinity
1.0+1.2
720*600*1550
Single phase 220V 50/60HZ
5800
180
86
Carbon Rod heating AC6V-10V Washer welding AC1V-12V double-side welding AC1V-13V
57
(A)
(Kg)

2、Duty Cycle and Overheating
Duty cycle is percentage of 10 minutes that unit can weld at
rated load without overheating.
If unit overheat,output stops ,and cooling fan runs .Wait fif-
teen minutes for unit to cool.Reduce amperage or duty cycle be-
fore welding.
Page.5
Overheating Stop working Wait fifteen minutes
for unit to cool
Reduce amperage or
reduce duty cycle
Weld again
0
15
A

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

4、Selecting a Location
1)Select a correct location to place the unit。
2)Determine input power cord length according to its actual o-
peration requirement.Input power cord must have a minimum
2
inside diameter of 6mm 。
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.
Page.7

5、Connecting Input Power
2
1、Input power cord（not less than 6mm
copper cord）.
2、Over-current protection.
3、Disconnect device line terminals.
4、Ground wire L1/L2 input conductors.
Installation must meet all National and
Local Codes---have only qualified persons
make this installation.
Disconnect and lockout/tagount input power
before connecting input conductors from
unit.
Select type and size of over-current
protection.
Close and secure door on disconnect device .
Remove lockout/tagout device,and place
switch in the "on" position.
4
Page.8
3
2
L1
L2
1
1
The power supply must have a ground connection.
The welder must also be connected to circuit breaker.
The power supply must have a ground connection.
The welder must also be connected to circuit breaker.
The machine must be grounded(earthed) properly to prevent
accidental electrical shock.
If you need to open the machine case(after work everyday,make sure to
turn off the external power source and turn off the power switch on the
machine.
Power connection and installation must meet all
National and Local standards(Circuit breaker must be
installed).Only qualified persons are allowed to make
this installation.

Operation
1、Controls
Page.9
1
2
3
4
5
6
7
89
10
11
12
13
14
15
16
17
18
1、Time Display
2、Power Display
3、Time--Decrease
4、Time ---Increase
5、Power ---Decrease
6、Power----Increase
7、Welding Programs
8、 Automatic
9、Manual
10、Power Indicator
11、Overheat Indicator
12、Manual Indicator
13、Automatic Indicator
14、Weld Gun Working indicator
15、Enter Indicator
16、Power Switch
17、Weld Gun Cable
18、Ground Cable
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).

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
Carbo Rod Shrinking
OT Washer Welding
Washer Welding
Stud Welding
Single-sided Welding
Wave form Wire Welding
Pulling Spot Hammer
Connection of negative wire

3、Operation
Page.11
a、spot welding
Set Mode switch
Connect spot welding
electrode tip with welding
gun and tighten.
Approximately a 90°angle
to the workepiece surface.
Put on pressure and press trigger.
F008+F020
Set correct time.
Remark:
1、Setting amperage too high or time too long can cause workpiece surface (vehicle body)damage .
Please weld other workpieces for practice before actual operations.
2、Setting correct amperage and time according to the workpiece thickness.
3、Continuing another operation is applicable after these procedures finished .If not, please
shut off the main power supply and switch off the unit.
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
(Position C is recommend).
Set correct power

b、Washer Welding
3、Operation
Page.12
Connect washer adaptor with
welding gun and tighten,
Install washer.
Remark:
1、Setting amperage too high or time too long can cause workpiece surface (vehicle body)damage .
Please weld other workpieces for practice before actual operations.
2、Setting correct amperage and time according to the workpiece thickness.
3、Continuing another operation is applicable after these procedures finished .if not, please
shut off the main power supply and switch off the unit.
F017+F011+F020
Set correct time.Set Mode switch
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
Approximately a 90°angle to the
dent.Put on pressure and press
trigger.
Remove welding gun.Hook the washer with
pull hammer.Slide the hammer to opposite
direction to pull out the dent .
(Position A orB is recommend).
Set correct power

c、Triangle Washer Welding
3、Operation
Page.13
Connect triangel washer
pull hammer with welding gun.
Slide the hammer to opposite
direction to pull the dent
F003+F020
Set correct time. Approximately a 90° angle to
the dent,put on pressure
and press trigger.
Remark:
1、Setting amperage too high or time too long can cause workpiece surface (vehicle body)damage .
Please weld other workpieces for practice before actual operations.
2、Setting correct amperage and time according to the workpiece thickness
3.Triangle washer welding can replace washer welding.It can draw out the concavity directly
after welded.
4、Continuing another operation is applicable after these procedures finished .If not, please
shut off the main power supply and switch off the unit.
Set Mode switch
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
(Position A is recommend).
Set correct power

D、Carbon rod Heating
3、Operation
Page.14
F007+F009+F020
Set correct time
Remark:
1、Setting amperage too high or time too long can cause workpiece surface vehicle body)damage .
Please weld other workpieces for practice before actual operations.
2、Setting correct amperage and time according to the workpiece thickness.
3、Continuing another operation is applicable after these procedures finished .If not, please
shut off the main power supply and switch off the unit..
Set Mode switch
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
Connect carbon rod and
carbon rod adaptor with
welding gun.
Turn carbon rod clockwise to heat
up the entire convexity surface.
Cool the surface with a wet
rag or compressed air.
(Position A is recommend).
Set correct power

e、
3、Operation
Wriggle Form Wire Welding
Page.15
Connect wave form wire electrode
tip with welding gun.
F006+F010+020
Set correct time.
Remark:
1、Setting amperage too high or time too long can cause workpiece surface (vehicle body)damage .
Please weld other workpieces for practice before actual operations.
2、Setting correct amperage and time according to the workpiece thickness.
3、Continuing another operation is applicable after these procedures finished .If not ,please
shut off the main power supply and switch off the unit.
Set Mode switch
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 andpress trigger.
(Position A is recommend).
Set correct power

Manual operating cupule:
1、Connect manual operating cupule with
pull hammer.
2、Push manual operating cupule in to lock
the cupule on the concavity.
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
to draw the concavity out.
4、Cupule falls off when close the valve.
f、Cupules
3、Operation
Page.16

Maintenance
1、Exploded view
Page.17
Resistor
Circuit board
Main power switch
Silicon control
Control transformer
Main transformer
Left side view
Resistor
Control transformer
Main transformer
Right side view
继电器
风扇
风扇
Capacitor and small resistor

2、Troubleshooting
Reason Remedy
No weld output
(1)
incorrectly.
(2)Power switch in off
position
Connected power supply (1)Connect power supply according
to manufacturer’s instructions.
(2)Place power switch in “on”
position.
Trigger not working
(1)
(2)Gun control wire broken.
(3)Control wire plug loosen.
(4)Mode switch in incorrect
position.
Trigger damaged.
(1)
(2)Connect again or replace if nec-
essary.
(3)Connect control wire plug again.
(4)Place Mode switch in correct pos-
ition.
Replace trigger.
(1)
(2)Weld time too short.
(3)Input power cord did not
meet the requirement.
(4)Ground clamp bad contact.
Aamperage too low
(1)
(2)Increase time setting.
(3)Replace input power cord.
(4)Change ground clamp location.
Increase amperage setting
Piercing workpiece
(1)
(2)Weld time too long.
(3) Bad contact of electrode tip or
washer with workpiece.
Output amperage too high.(1)R
(2)Rrduce weld time.
(3)Remove coating from material
reduce added pressure.
educe amperage setting.
Kriptol working
unstable
(1)
did not polish.
(2)Incorrect amperage and time
setting.
Kriptol did not polish,workpieces (1)
(2)Set amperage and time according to
workpiece thickness.
Polish kriptol and workpieces
Unit stop working
while operation
(1)
(2)Gun control wire broken.
(3)Over heating.
Trigger plug loosen.
(1)
trigger plug.
(2)Wait for temperature cool down.
Check gun control wire and
Maintenance
Trouble
Poor weld
.
.
Page.18