G.I.KRAFT GI12117 User manual

USER MANUAL
GI12117

1、Safety Precautions Symbols
2、Symbols and Definitions
3、Accessories and Spare Parts List
4、Installation
1) 、
Specifications
2) 、 Duty
Cycle and verheating
3) 、
Machine Installation
4) 、
Selecting a Location
5) 、
Connecting Input Power
5 、
peration
1) 、
Controls
2) 、
Welding Gun and Adaptors
3) 、
Various perations
a 、
Spot Welding
b 、
Washer Welding
c 、 Triangle
Washer Welding
d 、
Carbon Rod Heating
e 、
Wriggle Form Wire Welding
f 、
Cupules
6 、 Maintenance
1) 、 Troubleshooting
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
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 。
veruse 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
I
1max
I
1eff
~
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
n
ff
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
Control transformer
Pneumatic vacuum cupule
Claw puller
Carbon Cod
Stud
Manual cupule
Back wheel
Spot welding electrode
tip
Washer adaptor
Front part of puller
Washer
Welding gun
Pull hammer
Hook
Vertical spot welding
pull hammer
Wriggle
Kriptol adaptor
Electrode holder
Triangle wasler
Ground wire clamp
Front wheel
Circuit board
Remark:
1) 、 ptional 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
utput voltage
Input power
Max i nput current
peration way
Time regulation system
Weight
Dimensions
max instant current
ne side welding thickness
Installation
Input voltage
Page.4
Model
18KW
Electronic timing
0-99s
0.8+1.2mm
AC380V three phase
50Hz
1-13V
2200A
10.5kg
370*230*280mm
54A/18A
GI12117

2、Duty Cycle and verheating
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
verheating Stop working Wait fifteen minutes
for unit to cool
Reduce amperage or
reduce duty cycle
Weld again
0
15
A

3、Machine Installation
1) pen 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 、 ver-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.
Page.8
3
2
L1
L2
3
L3
AC 380V
AC 220V

peration
1 、 Controls
Page.9
1. Power indicator
2. Error indicator
3. verheat indicator
4. Gun trigger indicator
5. Spot welding time display
6. Power percentage display
7/8. Spot welding time adjustment
9/10. Power percentage adjustment
1. Connect input power properly and safely
2. Turn on the power switch, select different functions through
function selection buttons according to required working mode.
3. Appropriately adjust welding time and power according to actual
situation.
4. After setting the parameters, the machine enters into standby
mode and is ready to weld.
5. When the temperature exceeds normal working temperature, the
temperature indicator will light and overload protection will
start. Wait a few minutes until the indicator is off, then use the
machine again.
6. The error indicator will light when the machine goes wrong, and
the machine enters into automatic protection mode. Cut off the
power supply then check, use the machine again until the problems
are solved.
Instruction:
1
2
3
4
5 6
7
8
9
10
11
12

Page.10
2 、 Welding Gun and Adaptors
1
2
Single-Sided applications
1 、 Electrode holder
2 、 Trigger
Carbo Rod Shrinking
T Washer Welding
Washer Welding
Stud Welding
Single-sided Welding
Wave form Wire Welding
Pulling Spot Hammer
Connection of negative wire
5. Tighten the screw to
securely fix the clamp.
2. Put the ground cable onto
the welded washers.
3. Place the earth
clamp over the
welded washers.
4. Insert the bolt
through the
washers and
clamp.
1.Weld two washers onto the dented
area that needs repairing.

3 、 peration
Page.11
a、spot welding
Select welding function
Connect spot welding
electrode tip with welding
gun and tighten.
Approximately a 90°angle
to the workepiece surface.
Put on pressure and press trigger.
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 、 peration
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.
Set correct time. Select welding function
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 、 peration
Page.13
Connect triangel washer
pull hammer with welding gun.
Slide the hammer to opposite
direction to pull the dent
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.
Select welding function
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 、 peration
Page.14
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..
Select welding function
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 、 peration
Wriggle Form Wire Welding
Page.15
Connect wave form wire electrode
tip with welding gun.
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.
Select welding function
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 、 pen 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 、 peration
Page.16

2 、 Troubleshooting
Reason Remedy
No weld output
(1)Connected power supply
incorrectly.
(2)Power switch in off
position
（1）Connect power supply according
to manufacturer’s instructions.
（2）
Place power switch in “on”
position.
Trigger not working
（ 1 ） Trigger damaged.
（ 2 ）
G un control wire broken.
（ 3 ）
Co ntrol wire plug loosen.
(4)Mode switch in incorrect
position.
（1）Replace trigger.
（2）Connect again or replace if nec-
essary.
(3)Connect control wire plug again.
(4)Place Mode switch in correct 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) Increase amperage setting
(2)Increase time setting.
(3)Replace input power cord.
(4) C hange ground clamp location.
Piercing workpiece
(1 ) utput amperage too high.
(2)Weld time too long.
(3) Bad contact of electrode tip or
washer with workpiece.
(1)Reduce amperage setting.
(2)Rrduce weld time.
(3)Remove coating from material
reduce added pressure.
Kriptol working
unstable
(1)Kriptol did not polish,workpieces
did not polish.
(2) I ncorrect amperage and time
setting.
(1 ) Polish kriptol and workpieces
(2) S et amperage and time according to
workpiece thickness.
Unit stop working
while operation
(1)Trigger plug loosen.
(2)Gun control wire broken.
(3) ver heating.
(1)Check gun control wire and
trigger plug.
(2)Wait for temperature cool down.
Maintenance
Trouble
Poor weld
.
.
Page.17