Fytech FY-9028 User manual

Owner’s Manual
9028

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 Heating
e、Wriggle For m Wire Welding
f、Quick puller
g、Cr ossbar Lifter
h、Cupules
6、Ma intenance
1、Ex ploded View
2、Tr oubleshooting
7、El ectrical Diagra m
8、Pac king List
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Contents

Safety Precautions Symbols
Pro tect you r self an d o thers f r om injur y,
rea d a nd foll o w these p r ecaut i ons befo re
ins tallat i on and op e ratio n .
Explo din g par ts ca n inj ure .Alw ays w ear a f ace
sh iel d and l ong s lee ves。
St at ic c a n da ma ge P C b oa rd s
1、Pu t on g ro u nd ed w ri s t st ra p be f or e
ha nd in g b oa rd s or p a rt s。
2、Us e pr op e r st at ic - pr oo f ba g s an d bo xe s t o
st or e，move or s hi p PC b o ar ds。
1、We ar a pp r ov ed f ac e s hi el d or s a fe ty g ogg le s
wi th s id e s hi el ds。
2、We ar p ro p er b od y pr o te ct io n t o pr ot ect s ki n。
Do n ot w el d i n th e he ig h t！
Read instructions.
1、Read owner's Man ua l be f or e us in g o r se rv ic i ng
un it。
2、Use only manufacturer’s supplied replacement。
Fl yi ng m e ta l ca n in j ur e ey es。
1) We ar s a fe ty g la s se s wi th s i de s hi eld s or f ac e
sh ie ld。
1、Ma gn et i c fi el ds c a n af fe ct p a ce ma ker s.
Pa ce ma k er w ea re r s ke ep a wa y .
2、We ar er s s ho ul d co n su lt t he i r do ct or be fo re
go in g ne a r pl as ma a r c cu tt in g o pe ra ti o ns。
Ov eru se ca n cau se ov erh eat ing
Al low c ool ing p eri od ,f oll ow ra ted d uty c ycl e
before starting to w eld a gai n.
El ec tr i c sh oc k ca n k il l:
1、Do n ot t ou c h li ve e le c tr ic al p a rt s。
2、We ar d ry , ho le -f r ee i ns ul a ti ng g lo v es a nd
bo dy p ro t ec ti on .
3、Do n ot w ra p e le ct ri c al c ab le a r ou nd y ou r
bo dy .
4、Gr ou nd t h e wo rk pi e ce w it h a go o d el ec tr -
ic al g ro u nd。
Ey e pr ot e ct io n fo r w el di ng :
Cu rr en t l ev el i n am p er ag e Mi n im um s ha d e
Nu mb er
30-150A----------- --- -- - -- - -- - -- - -- # 8
150-300A--------------------------- #1 0
30 0- 50 0 A- -- -- -- - -- - -- --- --- --- ----- #12
Nev e r cut o n p res s uri z ed cyl inde r.
Maintenance regularly！
Fa ct or y s af et y！
Page.1
Fi re o r ex p lo si on h a za rd .
Do n ot l oc a te u ni t on , ov er ,o r n ea r co mb u st ib e
su rf ac e s. Do n ot i n st al l un i t ne ar f la m ma bl es.
Re mo ve a l l fl am ma b le s of t he w e ld in g ar e a.
Fa ll in g u ni t ca n ca u se i nj ur y .
Th e he at f r om t he w or k pi ec e ca n c au se s er i ou s
bu rn s。
Fu me s an d g as es c an b e h az ar do u s
we ld in g p ro du ce s f um es a nd g a se s. Breathing
th es e fu m es a nd g as e s ca n be h az a rd ou s
to y ou r he a lt h .
If inside,ventilate the area.
Do n ot w el d i n a co nf in e d sp ac e on l y if i t
is w el l ve n ti la te d .
Pr ot ec t y ou rs el f Warn others

Definitions
Symbols and Definitions
U1
U0
U2
I2
s1
HZ
A
V
Rat e d w e l d i ng
current
Pri m a r y v o l tage
Rat e d n o l o a d
vol t a g e ( A average)
Con v e n t i o nal
loa d v o l t a g e
Power rating,
product o f v ol ta ge
and current(KVA)
Her t z
Amperes
Volts
IP
X
I1max
I1eff
~
1
Rat e d m a x i m um
sup p l y c u r r ent
Maximum effective
supply current
Degree of protection
Sin g l e p h a s e
Duty cycle
Direct current
Constant crrent
Temperature
V
S
I
O
Su it ab l e fo r so me
ha za rd o us l oc at i on s
Vol t a g e i n p ut
Lo w ai r pr e ss ur e
li gh t
On
Off
Protective earth
(Ground)
Input
＋－
%
Adjust air/gas
pressure
Percent
Increase
Lin e c o n n e c tion
Loo s e s h i e l d cup
Aut o m a t i c
Man u a l
Page.2
Do n ot d o th i s

Accessories And Spare parts
Accessories and Spare Parts List:
Remark:
1)、Op t ional o r ders fo r a bove acc essori es and com ponent s are
ava ilable .
2)、Mo d el and pa r ts numb e r requi r ed when or dering p arts fro m
you r local di s tribu t or.
Page.3
Description
matic cupule
-
( )
raction pin (long)
-
-
Trolley
Professional spot welder
Polishing machine
Tool box
Car body repair kit
Quick puller
Pneu
Small pneumatic cupule
Manual cupule
Wrench for welding gun
Multi hook claw
Wavy wire
OT washer
10mm Washer
12mm Washer
Stud 0.6mm
Triangle washer
Carbon rod
Wavy wire electrode tip flat
OT washer connector
Washer connector
Stud connector
Triangle washer connector
Carbon rod connector
Spot weld electrode tip
Air hose connector
Hook
Pulling hammer with hook
Dent pulling spot hammer
“T” pothook (long)
“T” pothook (short)
Crow bar
1250mm Crossbar lifter with 4 stands
850mm Crossbar lifter with 4 stands
750mm Crossbar lifter with 2 stands
Hooker for crossbar lifter
6-hook claw for crossbar lifter
4-hook claw for crossbar lifter
T
Traction pin (short)
4-hook chained claw for crossbar lifter
Water proof socket
Earth clamp
Common caster
Caster with brake
Wheel screw
Dent repair glue pulling kit With O type washer 20pcs
Hot air gun
Glue gun
Glue stick
Portable multi-hook puller
No.
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Remarks

10KW
Electronic timer,continuity
0-9 9 ms
Inf i nit y
1.0+1.2(mm)
100 0 *52 0 0*1 5 60( m m)
Sin g le ph a se 23 0 V 50H Z
AC1V-13V
5800A
180kg
Kr ip to l h ea ti ng A C 6V -1 0V w a sh er w el d in g AC 1V- 12 V do ubl e- si de we ld in g AC1V-13V
57A
1、specifications
Output voltage
Input power
Max i. nput current
Operation way
Time reg ulat ion sy stem
Operation place
Vacuum cup ule device
Dimension
Instant max .current
One side welding thickness
Installation
Input voltage
Page.4

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 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.
Pag e .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 in diameter
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 o nly q u ali f ied pe rson 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 .
Rem o ve lo c kou t /ta g out de vice ,and p lace
swi t ch in t h e "on" position.
Page.8
4
3
1
2
L1
L2
1
The powersupply must have a ground connection.
The welder must also be connected to circuit breaker.
The m a chine m u st be gro u nded( e arthed )
properly to prevent accidental electrical
shock.
If yo u n eed to op e n the mac h ine case (after
wor k e very da y ,make s u re to tur n o ff the
ext e rnal po w er sour c e and tur n o ff the pow er
swi t ch on the m a chine .
The p o wer s upp l y mus t h ave a gr ound c onne ctio n.
The w e lde r m ust a l so be c o nnec ted to c ircu it bre aker .

Operation
1、Controls
Page.9
1
2
3
4
5
6
78
9
10
1. LCD display
2. Current decrease
3. Current increase
4. Time decrease
5. Time increase
6. Function selection
7. Earth cable
8. Gun cable
9. Gun testing button
10. Trigger control cable

2、Welding Gun and Adaptors
Page.10
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
Washer Welding
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
OT Wa s her W e ldi n g

3、Operation
Con n ect s p ot we l din g
electrode tip wi th wel ding
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 a nd 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, p l ease
shu t o ff th e m ain p o wer s u pply a nd swi tch of f the uni t .
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.

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 .
3、Operation
Page.12
%
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
was h er wi t h pul l h amm e r.Slide
the hammer to opposite direction
to pu l l out t h e den t .

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 pu ll the d ent ou t.
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 rep lace washer welding.I t 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.
Page.13
%
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
carbon rod a dapt or wit h
welding gun.
Carbon rod turning in
clockwise to heat up
the stretched panel
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..
Page.14
%
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
Coo l t he su r fac e w ith a w e t
rag o r c omp r ess e d air .

Con n ect w r igg l e wir e electrode
tip w i th we l din g g un.
Connect claw to slide hammer.
Hook the wriggle wire w i th slide
hammer and pull out the dent
Set a wriggle wire up righ t
on the dent.Approximately
a 90°angleto wringgle fo r m
wire.Put on pressure and
press trigger.
F006+F010+020
e、
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 bo d y)d a 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
Page.15
%
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.

Squeeze the lever to
pull the panel
f、Quick Puller
%
Connect quick puller to
welding gun
Touch the dent area by
the electrode of q u i c k puller.
Put o n p ressure and press trigger
3、Operation
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
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 bo d y)d a 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.
Page.16

Select a suitable puller. Put the
puller in fixed position,Hook up
OT washers with the claw of puller,
Adjust the nut of puller.Squeeze
the lever to pull out large dent
area with full control
g、Crossbar Lifter
%
Connect OT washer a d apt e r
with welding gun and tighter u p
Put a n O T washer i n t o adapter
Approximately a 90°angle t o
the den t area.Put on pressure
and press trigger
3、Operation
Connect negative outside wire
to a clean,paint-free location
on metal workpiece,as close to
welding area as possible.
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 bo d y)d a 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、According to actual c o ndi t ion s t o sel e ct a suitable puller for r epai ring
4、The nut of the puller i s to adjust the u p a nd down moving range o f the main axle
5、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.
Page.17

h、Cupules
3、Operation
Page.18
Manual operating cupule:
1、Connect manual operating cupule with
pull hammer.
2、Pul l the dent are a out gently
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 p ul l th e dent out.
Pneumatic vacuum cupule:
1、Connect gas/air supply with the adaptor
of c up ul e.
2、Open the valve ,sticking cupule to the
de nt .
3、Slide the hammer to opposite direction
pu ll t he d ent out.
4、Cupule falls off when close the valve.