GYS GySpot GY 019652 User manual

Taal: EngelsTaal: Engels
Handleiding
GYS GySpot inverter
GY 019652, GY 019669 en GY 019676
MSH equipment
Appelmarkt 7
1681 PE Zwaagdijk-Oost
Tel: [phone]
Fax: [phone]
Mail: [email protected] Website: www.msh-equipment.nl

USER MANUAL
V1.00.02
TABLE OF CONTENTS
1- PRESENTATION, SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS ........................... 2
2- DESCRIPTION OF THE MACHINE .............................................................................................................. 3
-BP Font pan l ............................................................................................................ 3
-BP Back pan l............................................................................................................ 3
-X-Clamp.................................................................................................................... 3
-C-Clamp.................................................................................................................... 4
3- INSTALLATION OF THE MACHINE ............................................................................................................ 4
-B for us ................................................................................................................. 4
-Ass mbling th clamp handl , clamp stand, and th arth clamp (acc ssori s bag).............. 5
-Filling of th cooling liquid tank .................................................................................... 5
-Starting th machin ................................................................................................... 5
4- PRODUCT OPERATION ................................................................................................................................ 6
-K y d finition............................................................................................................. 6
-C clamp mod s (standard / manual / multish t / clamp adjustm nt)................................. 7-8
-X clamp mod s (standard / manual / multish t / clamp adjustm nt)................................. 9-10
-Us of th singl sid d gun.......................................................................................... 11
-Error manag m nt...................................................................................................... 11
-W lding spot count r .................................................................................................. 12
-R cording f atur s (log r port – us r programs) ............................................................. 13
-SD m mory card ........................................................................................................ 14
-GYSPOT softwar ....................................................................................................... 15
-Us of th singl sid d gun.......................................................................................... 17
-Us of th pn umatic clamps ....................................................................................... 17
5- PRECAUTIONSOF USE AND MAINTENANCE ........................................................................................... 18
-Us r training.............................................................................................................. 18
-Pr paration of th parts to ass mbl ............................................................................. 19
-Singl sid d gun w lding ............................................................................................. 19
-Us of th und r pan l arms ........................................................................................ 19
-Nuts circular joints...................................................................................................... 19
-R plac m nt or adjustm nt of X clamp arms.................................................................. 19
-R plac m nt or adjustm nt of C clamp arms.................................................................. 20
-Typ of arms for th C-clamp ...................................................................................... 21
-Us of th C2 arm ...................................................................................................... 22
-R plac m nt of th caps and l ctrod s ........................................................................ 23
-L v l and ffici ncy of th cooling liquid ........................................................................ 23
-cl aning or r plac m nt of th w lding tools .................................................................. 23
-purging of th pn umatic filt r ..................................................................................... 23
-maint nanc of th g n rator ...................................................................................... 23
6- CHARACTERISTICS ....................................................................................................................................... 24
-
S102
Last updat 21/04/2008
Autres langues disponibles sur la carte SD.
Other languages available on the SD card.
Weitere auf SD-Karte verfügbare Sprachen.

2
Thank you for your choic ! B for installing and using th product or b for maint nanc , pl as r ad car fully th following saf ty
r comm ndations in ord r to avoid accid nts to th us rs and damag of th w lding proc ss.
GYS cannot b h ld r sponsibl for th damag s occurring to p rsons or b longings, following th us of th machin in th following
circumstanc s:
- Modification or disabling of saf ty l m nts,
- Non-r sp ct of th r comm ndations writt n in th us r manual,
- Modification of th charact ristics of th product,
- Us of acc ssori s oth r than th GYS acc ssori s , or acc ssori s not adapt d to th machin
- Non-r sp ct of th r gulations and particular dispositions in th country wh r th machin is install d.
1- PRESENTATION, SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS
This product has b n d sign d to carry out th following op rations in car body workshops :
- Spot w lding on m tal sh ts with a pn umatic clamp,
- W lding of m tal sh ts with a singl sid d gun,
- W lding of nails, riv ts, wash rs and studs,
- R pair of bumps and impacts (impacts of hail with th option « quick r pair”).
GENERALITIES
1. Th op rators must hav follow d up an appropriat training.
2. Th r pair and maint nanc op rations can only b p rform d by qualifi d p rsonn l.
3. Th op rator is r sponsibl for th r sp ct of th car manufactur r’s r comm ndations, r garding th prot ction of th car l ctrical and
l ctronic quipm nts (car comput r, car radio, alarm, air bag, tc…).
4. B for any r pair or maint nanc op ration, th compr ss d air supply must b disconn ct d and d pr ssuriz d.
5. Th l ctrod s, arms, as w ll as th oth r s condary conductors can r ach a v ry high t mp ratur and r main hot v ry long aft r having
stopp d th machin . Pay particular att ntion to th risks of s rious burns.
6. It is n c ssary to mak a r gular pr v ntiv maint nanc on th machin .
MAINS SUPPLY
1. Ch ck wh th r th unit is corr ctly conn ct d to th arth and that th conn ction to th arth is in good condition.
2. Ch ck wh th r th workb nch is conn ct d to th arth coupl r.
3. Mak sur that th op rator has no contact with th m tal parts to b w ld d without any prot ction or with w t cloth s.
4. Avoid b ing in contact with th w lding part.
5. Do not mak any spot w lding op rations in v ry w t ar as or on a w t floor.
6. Do not w ld with worn out cabl s. Mak sur that th r is no isolation d f ct, nor stripp d cabl s nor loos conn ctions, and that th r is no
cooling liquid l aks.
7. B for p rforming any control or maint nanc op ration, switch off and disconn ct th unit dir ctly from th plug.
EYE AND BODY PROTECTION
1. During th w lding proc ss, th op rator must prot ct hims lf from possibl proj ctions of st l in fusion with cloth s lik : l ath r glov s,
w lding aprons, saf ty sho s, w lding h lm ts or glass s for filt ring radiations and proj ctions. Similarly, during grinding or hamm ring op rations,
th op rator must w ar y prot ction.
2. Th tight ning forc of th clamp can r ach 550 daN. K p away all body parts from th mobil l m nts of th clamp to avoid any risk of
squ zing, of fing rs in particular.
3. Do not w ar rings, watch s, or j w ll ry, which ar curr nt conductors and can caus s rious burns.
4. All th prot ction boards must b in good condition and maintain d in plac .
N v r look at a w lding arc without any y prot ction.
Prot ct th nvironm nt n ar th product against proj ctions and r fl ctions.
FIRE
1. Mak sur that th sparks will not caus fir , sp cially n ar flammabl mat rial.
2. Ch ck that fir xtinguish rs ar n ar th op rator.
3. Us th product in a room with xtractor fans
4. Do not w ld on combustibl or lubricant contain rs, v n mpty, nor on contain rs containing flammabl mat rial.
5. Do not w ld in an atmosph r charg d with flammabl gas or fu l fum s.
ELECTRO-MAGNETIC COMPATIBILITY
N ar th spot-w lding machin , ch ck wh th r :
- th r ar no oth r pow r supply cabl , no control lin s, no t l phon cabl s, no radio or TV r c ption applianc s, no watch s, no mobil phon s,
no magn tic cards, no comput rs nor any oth r l ctronic applianc .
- th r ar , in th surroundings, no p rsons using activ m dical applianc s (pac mak rs, acoustic prosth tics).
Plan xtra prot ctions if oth r products ar to b us d in th vicinity of th machin .
This product is d sign d to b us d in an industrial or prof ssional nvironm nt, as d fin d in th CISPR11 publication. In a diff r nt nvironm nt,
it might b difficult to nsur l ctromagn tic compatibility.

3/25
CE MARK
GYS t stifi s that this product has b n d sign d and manufactur d in conformity with th following Europ an standards :
- Low Voltag Dir ctiv 2006/95/EC in application of th norm EN 50063 and EN 50178
- El ctromagn tic Compatibility Dir ctiv EMC 2004/108/EC in application of th norm EN 62135-2
- Machin s dir ctiv 98/37/EC in application of th norm EN 60204-1
- E xposur of work rs to l ctromagn tic fi lds dir ctiv 2004/40/EC dat d April 29
th
2004
2 – DESCRIPTION OF THE MACHINE
BP Fro t pa el
SD Card R ad r Display board for
communication with th
us r
BP Rear pa el
Fan with dust-proof filt r 32A D-curv circuit br ak r Pn umatic filt r, conn ction
to th pn umatic n twork
syst m
X Clamp (for GYSPOT INVERTER BP.X or BP.CX machi es)
Arms nuts
A. Ov r-op ning of th
clamp
B. Clos th clamp
and w ld
C. R mot control for
thickn ss of sh t
D. R mot control for
choic of st l

4/25
C Clamp (for BP.C or BP.CX machi es)
A. Clos / W ld
B. R mot control of th
sh t’s thickn ss
Locking /unlocking C - l v r
C arm
Mobil l ctrod
3- INSTALLATION OF THE MACHINE
Before use
S v ral v rifications ar n c ssary b for using th unit to nsur good p rformanc of th machin .
H r ar th v rifications to do :
-Ch ck th l ctrical lin voltag : it should b 400V, 3 phas s, with a 32 A delayed circuit breaker, curve D
(or fuse of aM type).
-Ch ck th cross s ction of th cabl going from th main l ctrical board to th sock t wh r th machin will
b plugg d : it should b 4x6 mm2. If this cabl is long r than 10m, us a conductor siz of 10mm². If you us
an l ctrical xt nsion cord, us a 6mm² conductor siz (10mm² if l ctrical lin + xt nsion cord total l ngth is
sup rior to 10m).
-Conn ct a 3 phase + earth plug (minimum 32A) on th supply cabl .
-B car ful: in ord r to avoid voltag drops which can g n rat bad w lding spots, you must n v r hav
ov rload d l ctrical lin s, nor supply cabl diam t rs which cross s ction ar not larg nough. Also, th mains
plugs must not b too far from th circuit br ak r.
-If th machin is not suffici ntly suppli d, it is not possibl to nsur a good w lding quality.
-Ch ck that th air compressed n twork can d liv r a mi imum of 7 bars (dry air), th n conn ct th
compr ss d air n twork on th back of th machin . Th machin must not b us d on an air compr ss d
n twork with a pr ssur inf rior to 3 bars.

5/25
Assembli g the clamp ha dle, clamp sta d a d earth cable (accessories bag)
X clamps (BP.LX and BP.LCX)


 Ass mbl th clamp stand on th right or l ft sid of
th machin


 Ass mbl th clamp handl on th l ft or right sid of
th clamp, d p nding on th pr f rr d choic .


 D p nding on th arms us d, position th clamp ith r
using th hook or using th clamp handl (s l ft).
C clamp (BP.LC and BP.LCX)


 Ass mbl th c-clamp stand on th right hand sid of th machin using th
thr M6x16 provid d scr ws.


 Ass mbl th handl on th l ft hand sid of th clamp.
Earth cabl ( BP.LX / BP.LC / BP.LCX)
Ass mbl th copp r plat on th xtr mity of th arth cabl
Air conn ctor
Ass mbl th air conn ctor on
th air filt r.
Filli g of the cooli g liquid ta k
To fill th cooling liquid in th tank, pl as proc d as follows :
-put th pn umatic clamp on its stand
-pour cooling liquid in th tank to r ach th maximum l v l indicat d on th tank (~30 litr s).
Starti g the machi e
Switch ON th circuit br ak r. Th l ctronic card starts a t st and initialisation cycl of th param t rs during a p riod of
about 10 s conds. At th nd of this cycl , th machin is r ady to b us d.
Wh n th machin starts to work, liquid circulat s in th cabl s. Check that there are o leaks.



















6/25
4- PRODUCT OPERATION
Key definition


 Key
- Pr ssing this k y allows to s l ct th tool that will b
us d : ith r clamp or singl sid d gun. For th BP.LCX
machin , pr ssing this k y chang s th mod from C clamp
to C clamp adjustm nt, X clamp, X clamp adjustm nt, and
finally singl sid d gun. Th clamp adjustm nt mod allows
to clos th clamp and apply th programm d forc on th
l ctrod s with any curr nt flowing. This mod is us d to
adjust th arms.
- Pr ssing this k y 2 s conds allows to com back to
normal mod from th oth r mod s.
- Pr ssing this k y 2 s conds brings th spot count r to
z ro, wh n it is display d.
- Pr ssing bri fly twic this k y ras s th r port that is
display d on th scr n, wh n in th visualisation mod .
- Pr ssing bri fly this k y wh n in program saving mod
ras s th s l ct d program.


 Steel sheet thick ess
This s tting allows to s l ct th thickn ss of th st l sh ts
to w ld. Th sh t thickn ss can b adjust d using th +
and – k ys (in th circl , position 5). Th thickn ss can b
s l ct d amongst th following pr s t valu s : 0.6, 0.8, 1.0,
1.2, 1.5, 1.8, 2.0, 2.5, 3.0 mm.


 Type of steel sheet
This s tting allows to s l ct th typ of st l sh t to w ld,
amongst 4 famili s : coat d st l, HTS st l, UHTS st l,
BORON st l. This s tting can b adjust d using th + and
– k ys (in th circl , position 5).


 Arm used
Wh n a clamp is us d ( ith r C or X), th us r should
sp cify h r th l ngth of th arms fitt d on th clamp, so
that th machin will adjust automatically th air pr ssur
to g t th r qu st d l ctrod forc .


 Use of the adva ced modes
Th MODE k y allows to navigat through 3 diff r nt
mod s : STANDARD MODE, MULTISHEET MODE, MANUAL
MODE. A long pr ss on th MODE k y allows to nt r th
configuration mod , wh r th languag and dat can b
dit d and th sound alarm activat d for “curr nt too low”
or “low pr ssur ” m ssag s. Th up and down k ys (in th
circl ) allow to s l ct th param t r to modify (sh t
thickn ss, typ of st l, arm us d). Th + and – k ys allow
to modify th param t r.


 Save a report
Mor d tails can b found on this function in th
corr sponding chapt r.
Th « r cord » k y allows to nabl or disabl th
saving of a r port.
Th « visualis » k y allows to r ad th s qu nc of
spots p rform d.


 Savi g of user weldi g parameters
Th « sav » k y allows to sav us r w lding
param t rs (mod , sh t thickn ss, w lding curr nt,
w lding tim or l ctrod forc )
Th “op n” k y allows to call back pr viously
sav d w lding s ttings. Th machin automatically go s to
manual mod , r calling th sav d param t rs (curr nt,
w lding tim , forc ) and th tool us d (clamp or gun).








7/25
C clamp modes
STANDARD Mode
This mod is th d fault mod wh n th machin starts.
It allows to asily p rform a w lding spot by s l cting :
-Th tool to b us d
-Th thickn ss of th sh ts to b w ld d, to choos from
0.6, 0.8, 1.0, 1.2, 1.5, 1.8, 2.0, 2.5, 3.0.
-Th typ of st l to b w ld d (Coat d st l, HTS st l,
UHTS st l, BORON st l)
-Th arm us d.
Pr ssing th up and down k y (in th circl ) allows to
navigat from on param t r to th n xt (thickn ss, typ
of st l, arm us d). Each param t r can b adjust d by
pr ssing th + and – k ys (in th circl ).
Button A on th clamp allows to r mot ly chang th
thickn ss of th sh ts to b w ld d.
Button B on th clamp allows to mak a w lding spot using
th s l ct d param t rs.
If th input air pr ssur is too low to r ach th r qu st d
l ctrod forc , th machin will b p and display, b for
th w lding spot, th following rror m ssag “Pr ssur
too low”. Pr ssing again on th button allows to forc th
x cution of th w lding spot, which will b p rform d with
th air pr ssur availabl .
If th w lding curr nt m asur d during th spot is 6% l ss
than th s tting, th machin will display, wh n th spot is
compl t d, an rror m ssag “Curr nt too low”, warning
that th w lding spot should b ch ck d.
In any cas , a m ssag is display d at th nd of th
w lding spot showing th m asur d w lding curr nt and
l ctrod forc . This m ssag is display d on th scr n
until a k y is pr ss d on th control pan l, or until a n w
w lding spot is p rform d, by pr ssing th B button on th
clamp.
MULTISHEET Mode
This mod allows to pr cis ly sp cify th thickn ss and
typ of ach sh t of an ass mbly of 2 or 3 sh ts.
Using th up and down k ys (in th circl ) allows to s l ct
th param t rs for ach sh t. Wh n th param t rs for
ach sh t ar highlight d, th sh t thickn ss and typ of
st l param t rs can b adjust d using th + and – k ys
(in th circl ).
Th param t rs to b adjust d in this mod ar :
-Th thickn ss of ach sh t to b w ld d : to choos
b tw n th valu s 0.6, 0.8, 1.0, 1.2, 1.5, 1.8, 2.0, 2.5,
3.0 mm.
-Th typ of st l for ach sh t : coat d st l, HTS
st l, UHTS st l, BORON st l.
-In ord r to activat sh t 3, pr ss th up and down k ys
(in th circl ) to highlight sh t 3; th n us th + and –
k ys (in th circl ) to s l ct th sh t thickn ss and typ
of st l.
If th input air pr ssur is too low to r ach th r qu st d
l ctrod forc , th machin will b p and display, b for
th w lding spot, th following rror m ssag “Pr ssur
too low”. Pr ssing again on th button allows to forc th
x cution of th w lding spot, which will b p rform d with
th air pr ssur availabl .
If th w lding curr nt m asur d during th spot is 6% l ss
than th s tting, th machin will display, wh n th spot is
compl t d, an rror m ssag “Curr nt too low”, warning
that th w lding spot should b ch ck d.
In any cas , a m ssag is display d at th nd of th
w lding spot showing th m asur d w lding curr nt and
l ctrod forc . This m ssag is display d on th scr n
until a k y is pr ss d on th control pan l, or until a n w
w lding spot is p rform d, by pr ssing th B button on th
clamp.
Pr ssing during 2 s conds th k y allows to com
back to th “normal” mod .

8/25
MANUAL Mode
This mod allows th us r to manually s l ct th w lding
param t rs, following instructions from a manufactur r for
xampl . Th s ttings propos d by d fault in th manual
mod corr spond to th s ttings automatically s l ct d by
th standard mod (thickn ss and typ of sh t, l ctrod
forc , arm).
Wh n nt ring this mod , th param t r s l ct d by
d fault is th w lding curr nt.
Th param t rs can b adjust d using th + and – k ys (in
th circl ). Th up and down k ys allow to navigat from
on param t r to th n xt :
- W lding curr nt (2000 to 13000 A, by st ps of 100 A).
Display is in kA (thousand amps).
- W lding tim (from 100 to 8500 ms, by st ps of 10ms).
Display in millis conds.
- El ctrod forc (from 100 to 550 daN, by st ps of 5
daN). Display in d caN wtons.
- arm us d on th clamp (arm numb r and l ngth).
If th input air pr ssur is too low to r ach th r qu st d
l ctrod forc , th machin will b p and display, b for
th w lding spot, th following rror m ssag “Pr ssur
too low”. Pr ssing again on th button allows to forc th
x cution of th w lding spot, which will b p rform d with
th air pr ssur availabl .
If th w lding curr nt m asur d during th spot is 6% l ss
than th s tting, th machin will display, wh n th spot is
compl t d, an rror m ssag “Curr nt too low”, warning
that th w lding spot should b ch ck d.
In any cas , a m ssag is display d at th nd of th
w lding spot showing th m asur d w lding curr nt and
l ctrod forc . This m ssag is display d on th scr n
until a k y is pr ss d on th control pan l, or until a n w
w lding spot is p rform d, by pr ssing th B button on th
clamp.
Pr ssing during 2 s conds th k y allows to com
back to th “normal” mod .
Clamp adjustme t
Th k y allows to switch from on tool to th n xt,
and also allows to nt r th clamp adjustm nt mod . Th
clamp adjustm nt mod allows to clos th clamp and
apply th s l ct d l ctrod forc , without d liv ry of any
curr nt. Th clamp r mains clos d as long as th button on
th clamp is pr ss d. This mod allows to ch ck th
alignm nt of th l ctrod s and th good positioning of th
caps.
Pr ssing during 2 s conds th k y allows to com
back to th “normal” mod .

9/25
X-clamp modes
STANDARD Mode
This mod is th d fault mod wh n th machin starts.
It allows to asily p rform a w lding spot by s l cting :
-Th tool to b us d
-Th thickn ss of th sh ts to b w ld d, to choos from
0.6, 0.8, 1.0, 1.2, 1.5, 1.8, 2.0, 2.5, 3.0.
-Th typ of st l to b w ld d (Coat d st l, HTS st l,
UHTS st l, BORON st l)
-Th arm us d.
Pr ssing th up and down k y (in th circl ) allows to
navigat from on param t r to th n xt (thickn ss, typ
of st l, arm us d). Each param t r can b adjust d by
pr ssing th + and – k ys (in th circl ).
Button C on th clamp allows to r mot ly chang th
thickn ss of th sh ts to b w ld d.
Button D on th clamp allows to r mot ly chang th typ
of st l.
Pr ssing button B (clos / w ld) allows to mak a w lding
spot using th s l ct d param t rs.
If th input air pr ssur is too low to r ach th r qu st d
l ctrod forc , th machin will b p and display, b for
th w lding spot, th following rror m ssag “Pr ssur
too low”. Pr ssing again on th button allows to forc th
x cution of th w lding spot, which will b p rform d with
th air pr ssur availabl .
If th w lding curr nt m asur d during th spot is 6% l ss
than th s tting, th machin will display, wh n th spot is
compl t d, an rror m ssag “Curr nt too low”, warning
that th w lding spot should b ch ck d.
In any cas , a m ssag is display d at th nd of th
w lding spot showing th m asur d w lding curr nt and
l ctrod forc . This m ssag is display d on th scr n
until a k y is pr ss d on th control pan l, or until a n w
w lding spot is p rform d, by pr ssing th B button on th
clamp.
MULTISHEET Mode
This mod allows to pr cis ly sp cify th thickn ss and
typ of ach sh t of an ass mbly of 2 or 3 sh ts.
Using th up and down k ys (in th circl ) allows to s l ct
th param t rs for ach sh t. Wh n th param t rs for
ach sh t ar highlight d, th sh t thickn ss and typ of
st l param t rs can b adjust d using th + and – k ys
(in th circl ).
Th param t rs to b adjust d in this mod ar :
-Th thickn ss of ach sh t to b w ld d : to choos
b tw n th valu s 0.6, 0.8, 1.0, 1.2, 1.5, 1.8, 2.0, 2.5,
3.0 mm.
-Th typ of st l for ach sh t : coat d st l, HTS
st l, UHTS st l, BORON st l.
-In ord r to activat sh t 3, pr ss th up and down k ys
(in th circl ) to highlight sh t 3; th n us th + and –
k ys (in th circl ) to s l ct th sh t thickn ss and typ
of st l.
If th input air pr ssur is too low to r ach th r qu st d
l ctrod forc , th machin will b p and display, b for
th w lding spot, th following rror m ssag “Pr ssur
too low”. Pr ssing again on th button allows to forc th
x cution of th w lding spot, which will b p rform d with
th air pr ssur availabl .
If th w lding curr nt m asur d during th spot is 6% l ss
than th s tting, th machin will display, wh n th spot is
compl t d, an rror m ssag “Curr nt too low”, warning
that th w lding spot should b ch ck d.
In any cas , a m ssag is display d at th nd of th
w lding spot showing th m asur d w lding curr nt and
l ctrod forc . This m ssag is display d on th scr n
until a k y is pr ss d on th control pan l, or until a n w
w lding spot is p rform d, by pr ssing th B button on th
clamp.
Pr ssing during 2 s conds th k y allows to com
back to th “normal” mod .

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MANUAL Mode
This mod allows th us r to manually s l ct th w lding
param t rs, following instructions from a manufactur r for
xampl . Th s ttings propos d by d fault in th manual
mod corr spond to th s ttings automatically s l ct d by
th standard mod (thickn ss and typ of sh t, l ctrod
forc , arm).
Wh n nt ring this mod , th param t r s l ct d by
d fault is th w lding curr nt.
Th param t rs can b adjust d using th + and – k ys (in
th circl ). Th up and down k ys allow to navigat from
on param t r to th n xt :
- W lding curr nt (2000 to 13000 A, by st ps of 100 A).
Display is in kA (thousand amps).
- W lding tim (from 100 to 8500 ms, by st ps of 10ms).
Display in millis conds.
- El ctrod forc (from 100 to 550 daN, by st ps of 5
daN). Display in d caN wtons.
- arm us d on th clamp (arm numb r and l ngth).
If th input air pr ssur is too low to r ach th r qu st d
l ctrod forc , th machin will b p and display, b for
th w lding spot, th following rror m ssag “Pr ssur
too low”. Pr ssing again on th button allows to forc th
x cution of th w lding spot, which will b p rform d with
th air pr ssur availabl .
If th w lding curr nt m asur d during th spot is 6% l ss
than th s tting, th machin will display, wh n th spot is
compl t d, an rror m ssag “Curr nt too low”, warning
that th w lding spot should b ch ck d.
In any cas , a m ssag is display d at th nd of th
w lding spot showing th m asur d w lding curr nt and
l ctrod forc . This m ssag is display d on th scr n
until a k y is pr ss d on th control pan l, or until a n w
w lding spot is p rform d, by pr ssing th B button on th
clamp.
Pr ssing during 2 s conds th k y allows to com
back to th “normal” mod .
Clamp adjustme t
Th k y allows to switch from on tool to th n xt,
and also allows to nt r th clamp adjustm nt mod . Th
clamp adjustm nt mod allows to clos th clamp and
apply th s l ct d l ctrod forc , without d liv ry of any
curr nt. Th clamp r mains clos d as long as th button on
th clamp is pr ss d. This mod allows to ch ck th
alignm nt of th l ctrod s and th good positioning of th
caps.

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Use of si gle sided gu
Th singl sid d gun can b us d in standard or manual
mod . In normal mod , th singl sid d gun will b limit d
to st l sh ts of thickn ss 1.5mm maximum.
With th singl sid d gun, th op rator can choos
b tw n a vari ty of tools (monopoint w lding, star
w lding, stud w lding, riv t w lding, wash r w lding,
carbon shrinking, stitch w lding) Th s l ction of th tool is
p rform d using th + and - k ys.
In manual mod , th maximum p rmitt d w lding curr nt
is 9 kA during a p riod that will not xc d 600 ms. This is
why it is not possibl to s l ct high r valu s for th s
param t rs.
Pr ssing during 2 s conds th k y allows to com
back to th “normal” mod .
Th highlighting allows to s l ct th param t r to adjust.
Each param t r can b adjust d using th + and – k ys.
Th up and down k ys allow to mov from on param t r
to th n xt.
Error Ma ageme t
Diff r nt v nts might caus th app aranc of rror
m ssag s. Th y can b classifi d in thr cat gori s :
- th m ssag s that warn th us r, of ov rh ating, or a
lack of l ctrod forc or w lding curr nt, tc… Th s
m ssag s app ar on th scr n, and r main until a k y is
pr ss d.
- th d f cts that corr spond to a bad installation (air
pr ssur , l ctrical pow r supply)
- th m ssag s that inform of major failur s, such as IGBT
failur , bad charging of th pow r capacitors, tc… Th s
d f cts caus th display of an rror m ssag that blocks
th machin .
- th th rmal prot ction mak s us of a th rmistor on th
diod bridg , which block th us of th machin , and
displays th m ssag “ov rh ating”.
Curre t too low
If th w lding curr nt obtain d during th w lding spot is
6% l ss than th curr nt s tting, th machin displays,
onc th w lding spot is p rform d, an rror m ssag
“Curr nt too low”, warning that th w lding spot should b
ch ck d.
In any cas , a m ssag is display d at th nd of th
w lding spot showing th actual m asur d w lding curr nt.
This m ssag is display d on th scr n until a k y is
pr ss d on th control pan l, or until a n w w lding spot is
p rform d, by pr ssing th button on th clamp.
If th machin cannot d liv r th r qu st d curr nt, th n
th following m ssag app ars. Th w lding spot is not
p rform d, and th m ssag must b acknowl dg d to
p rform a w lding spot.
I sufficie t air pressure
If th input air pr ssur is too low to r ach th r qu st d
l ctrod forc , th machin will b p and display, b for
th w lding spot, th following rror m ssag “Insuffici nt
Pr ssur ”.

12/25
Pr ssing again on th button allows to forc th x cution
of th w lding spot, which will b p rform d with th air
pr ssur availabl . If th actual m asur d clamping forc is
too low, th n th machin will display th following
m ssag “Low Pr ssur ”.
Weldi g spot cou ter
A w lding spot count r allows to count th numb r of spots
p rform d with th sam caps. If th w lding spot is
p rform d without any probl m, th following m ssag
app ars.
Th count r is display d on th top l ft corn r of th
scr n. Pr ssing th k y r s ts this count r to z ro,
aft r th caps hav b n r plac d.
If mor than 200 w lding spots ar don with th sam
caps, th n th machin will display a warning m ssag . In
this cas , th warning m ssag “Do control caps” is also
r cord d in th trac ability r port.

13/25
Recordi g features
Th log r port allows to sav th charact ristics of th w lding spots p rform d with th clamp. It is availabl from all
mod s, by simply pr ssing th k ys locat d b low th icon “REPORTING”.
Th us r w lding param t rs mod is also availabl from all mod s, by pr ssing th k ys b low th icon “MEMORY”
LOG Report
R cording a r port allows to sav th charact ristics of a
s ri s of w lding spots, and sav th m on th SD m mory
card, such that th y can b transf rr d to any standard PC.
GYS provid s a softwar to r ad th SD card, and dit
r ports. This GYSPOT softwar is stor d in th SD card,
tog th r with a copy of th us r manual.
By d fault, this function is disabl d at th start of th
machin . Pr ssing th k y and th “mod ” k y
allows to start r cording in th s l ct d log fil . Pr ssing
again th r cord k y will stop th r cord.
Th log fil thus cr at d contains : an id ntifi r nt r d by
th us r, as w ll as, for ach w lding spot p rform d, th
tool us d, th arms us d, and th s ttings of th machin
(w lding curr nt and l ctrod forc ). It also contains th
possibl rror m ssag s that hav b n display d during
th r cord : I low, P low.
Us th + and – k ys, as w ll as th up and down k ys to
nt r th id ntifi r. If a pr viously xisting id ntifi r is
nt r d, th machin will sav th n w w lding spot
charact ristics at th nd of th fil , without rasing any
information from th fil .
Th k y allows to r cov r a r port pr viously sav d
and to r ad it on th scr n.
B for visualizing a r port, th r cord must b stopp d by
pr ssing th k y.
Th “mod ” k y allows to xit th r port visualisation
mod .
To ras th cont nts of a r port, display it on th scr n ,
using th “visualiz ” k y . Th n, pr ss k y .
Th following m ssag app ars on th scr n :
Wh n th triangl sign is display d, pr ssing k y a
s cond tim d finitiv ly ras s th cont nts of th r port
display d on th scr n. Th triangl sign disapp ars from
th scr n aft r 3 s conds.
User weldi g parameter record
Th saving of us r w lding param t rs allows to sav th
pr f rr d w lding param t rs for diff r nt us rs of th
machin . 20 us r profil s can b sav d. Each of th m
contains th following s ttings : tool, arm, w lding curr nt,
w lding tim , l ctrod forc ).
A us r can sav his pr f rr d param t rs for th clamp or
singl sid d gun.
Two k ys allow to navigat in this mod :

14/25
Th sav k y allows to r cord th s ttings
curr ntly us d in manual mod (w lding curr nt, w lding
tim , l ctrod forc ). Th 20 us r profil s ar th n
display d with ith r an id ntifi r, for thos that ar
alr ady us d, or « --- » for thos that ar still availabl .
Us th + and – k ys, as w ll as th up and down k ys, to
nt r th id ntifi r. Wh n nt ring a pr viously us d
id ntifi r, th machin will ras th pr vious s ttings
sav d.
Th « Op n » k y allows to acc ss th us r profil s
pr viously sav d. S l cting an mpty us r profil has no
ff ct.
Pr ssing bri fly th k y ras s th s l ct d program
in th list of sav d programs.
Th “mod ” k y allows to xit th program s l ction mod ,
and mak s th machin nt r th manual mod wh r th
param t rs and th tool sav d in th program ar r call d.
To disabl a progam, simply chang th valu of a
param t r in th manual mod , standard mod or
mutish t mod , or simply chang tool by pr ssing k y
.
SD Memory card
SD Card r f r nc : 050914
This card allows th us r to transf r fil s from th machin
to a PC to :
-coll ct log r ports in ord r to k p trac ability
of his work, and possibly show it to an
insuranc company.
-Updat w lding param t rs, add n w m nu
languag s.
A copy of th GYSPOT softwar to coll ct and dit th
trac ability r ports is stor d on th SD card.
A copy of th us r manual is also stor d on th SD card.
Th m mory spac will allow saving th charact ristics of
mor than 65 000 w lding spots.
Th machin can op rat without any SD card in manual
mod only.
If th m mory card is not ins rt d in th card r ad r, th n
th following m ssag is display d :
Switch off th machin , ins rt th SD card, and switch th
machin ON again.

15/25
GYSPOT software for PC
GYSPOT Software
The purpose of this software is to allow the user to edit or save reports of the welding
spots performed on a car body repair with a GYSPOT machine equipped with an SD card reader.
n order to use this software, the PC (Personal Computer) must be equipped with an SD memory
card reader.
Language selection
The software proposes several languages. By default, the following languages are available :
French
English
German
Spanish
Dutch
To select a language, click on Options, and then on Languages in the menus.
Beware, once the language is selected, the user should exit and enter again the GYSPOT software
for the new language to be considered.
User identity
n order to customize the information that appears on the reports, the user should fill some data
in the software. To enter this data, click in the menus on Options, and then on Identity. A new
window then appears with the following informations :
Company Name
Address
Postal code
Town
Telephone
Fax
E-mail
Web site
Logo
This information will then automatically be displayed on the reports.
Import log reports saved on the SD card
n order to import on the PC log reports of welding spots performed with the GYSPOT machine,
insert the SD memory card in the card reader of your PC, and then start the GYSPOT software.
Then, select the reader where your memory card is inserted, and click on the import icon
When the import is completed, the welding spots performed are sorted by an identifier of the
repair order. This identifier corresponds to the name of the report in the spot welding machine.
This identifier is displayed in the ctive tab.
When all the reports have been imported, it is possible to perform a search, edit or archive each
report. To visualize the characteristics of welding spots in a report, select the report; the
characteristics of each spot appear in a table.

16/25
To perform a search, fill the search field, and click on icon .
To edit a report, select the report, and click on icon .
To archive a report, select the report and click on icon .
Beware, the imported reports cannot be deleted if they have not been previously archived.
Visualize log reports of welding spots
To visualise log reports, click on the rchive tab. The reports are sorted by year and month. To
visualise the characteristics of the welding spot performed, select a report : the data
corresponding to each welding spot appears in a table.
For the archived reports, it is possible to perform a search, edit or delete a report.
Beware, a report which is archived, and then deleted, will be imported again in the next import
operation in case the SD card has not been blanked.
To perform a search, fill the search field, and click on icon .
To edit a report, select the report, and click on icon .
To delete a report, select the report, and click on icon .
Purge of the SD card
A purge operation on the SD card will erase all the reports previously saved on the SD card.
To purge the SD card, insert the SD card in the reader of your PC and, in the menus, click on
Options and Purge SD Card.
Beware, during a purge operation, the reports that have not yet been imported in the software
will be automatically imported.
Filling the informations of a report
The following information can be automatically added on each report :
Operator Vehicle
Repair Order Registration
Report Date First registration
Remarks Operation
To fill this data, select a report and enter this information in the header of the report.
Print a report
To print a report, select the report and click on icon . A print preview appears. Click on icon
.
Export in PDF format

17/25
To export a report in PDF format, select a report, and click on icon . A print preview appears.
Click on icon .
Exampl of a r port :
Use of the si gle sided gu
- Conn ct th copp r plat onto th g n rator arth cabl .
- Firmly fix th arth plat as n ar as possibl to th w lding ar a.
In cas of monopoint w lding with th singl sid d gun, always fix th arth plat on th sh t that is not in contact with
th w lding l ctrod (such that th w lding curr nt will flow th 2 sh ts to b w ld d).
-S l ct th GUN tool using th ESC k y.
-Singl sid w lding : choos th typ of sh t to w ld using th up and down k ys, and th + and – k ys.
- Oth r proc ss s : highlight th acc ssory param t r using th up and down k ys, and s l ct th tool by pr ssing th +
and – k ys.
1 – Withdrawal of impacts
2 – Smoothing of d nts
3 – Carbon shrinking
4 – Studs w lding
5 – Riv ts w lding
6 – Bolts w lding
7 – Stitch w lding
- s l ct th thickn ss of th sh ts to b w ld d on th machin , using th + and – k ys. It is possibl to modify th
param t rs for curr nt and tim in manual mod .
Use of p eumatic clamps
Wh n using th pn umatic clamp, always disconn ct from th v hicl th arth plat us d in singl sid d gun w lding.
For th GYSPOT BP.LCX, s l ct th typ of clamp that you will us using th ESC k y on th front pan l.
!

18/25
BP-LCX : for th good op ration of th cooling liquid syst m, it is ss ntial that both clamps (C and X) ar
quipp d with th ir r sp ctiv arms, and that th pip s ar prop rly conn ct d on th ir r sp ctiv conn ctors to
nsur th flow of th cooling liquid.
X Clamp
- Adjust and tight n th arms of th clamp, in ord r to hav th l ctrod s p rf ctly align d (coupl : 15 Nm).
- S l ct th clamp adjustm nt mod to adjust th alignm nt of th l ctrod s
- Th clamping forc is calculat d by th machin , consid ring th forc s tting or th thickn ss of th sh ts s l ct d.
Maximum clamping forc
ARMS Maximum PRESSURE i bars GYS REFERENCE (set of 2 arms)
L=120 copp r 8 bars 050501
L=220 copp r 8 bars 050518
L=350 ov r midth copp r 8 bars 050525
Copp r und r f nd r 5 bars 050549
L=440 ov r midth aluminium 8 bars 050532
R comm nd d param t rs for mild st l sh ts :
Sheet Thick ess (i mm) Recomme ded Force (i daN) Arms Le gth (i mm) Air Pressure (i bars)
From 0,4 to 0,8 100 to 200 120 2 to 3
From 0,4 to 0,8 100 to 200 220 2 to 4
From 0,4 to 0,8 100 to 200 440 5 to 7
From 1 to 2 150 to 300 120 3 to 3,5
From 1 to 2 150 to 300 220 3 to 6
From 1 to 2 150 to 300 440 6 to 7
Mor than 2 300 to 550 120 4 to 7
Mor than 2 230 to 550 220 6 to 8
C Clamp
- Tight n th C-clamp using th locking l v r and ch ck that th scr w b tw n th arm and th clamp is corr ctly
tight n d.
- Th clamping forc is calculat d by th machin , consid ring th forc s tting or th thickn ss of th sh ts s l ct d.
Maximum Clamping Forc
ARMS Max. Clampi g Force (daN) Maximum Pressure i bars GYS REFERENCE
C1 550 daN 8 bars 019140
C2 550 daN 8 bars 019133
C3 550 daN 8 bars 019157
C4 550 daN 8 bars 019164
C5 550 daN 8 bars 019294
C6 550 daN 8 bars 019775
R comm nd d param t rs for mild st l m tal sh ts :
Sheet Thick ess (i mm) Type of Arm Air Pressure (i bars) Clampi g force (i daN)
From 0,4 to 0,8 C1-C2-C3-C4-C5-C6 3 100 à 200
1 to 2 C1-C2-C3-C4-C5-C6 3,5 to 4 150 à 300
2 to 3 C1-C2-C3-C4-C5 4 to 8 300 à 550
WARNING :
Th clamps and th gun of th unit ar conn ct d to th sam curr nt sourc . This m ans that wh n you us on of th s
2 tools, th r is also pow r on th s cond tool. Th tool which is not us d must th r for b plac d on its stand on th
troll y (clamps stand locat d on th sid of th troll y and gun stand locat d on th T-Shap balanc r).
In cas th s instructions ar not r sp ct d, s v r damag can occur to th g n rator tools. Sparks and m tal proj ctions
can occur (DANGEROUS FOR THE USER).

19/25
5- PRECAUTIONS AND SERVICING
User trai i g
Op rators must hav an appropriat qualification for th us of th machin in ord r to g t th b st of th unit and to mak
satisfying work ( .g. : car-body r pair training).
Preparatio of the parts to assemble
It is ss ntial to grind, cl an and to accost th part to b w ld d.
In cas of a prot ction application, first v rify that it is conducting by t sting a sampl .
Si gle sided gu weldi g
B for r pairing a v hicl , ch ck that th car manufactur r authoriz s th w lding proc ss you hav chos n.
Use of the u der fe der arm
Consid ring th strong locking pr ssur of th clamp, th air compr ss d pr ssur should b low r d to 4 bars.
WARNING : a pr ssur high r than 5 bars can caus th d struction of th arms s t and th r for m tal proj ctions that
might caus body damag to th op rator.
Nuts circular joi ts
Insid th 2 tight ning arms nuts (s d scription of th clamp), th r ar 2 circular joints which hav to b r plac d in
cas of l aks or v ry 6 months. Th s 2 circular joints ar n c ssary to avoid risks of cooling liquid l aks.
Th s joints hav a diam t r of d=25, flang =4. During r plac m nt, it is advis d to add copp r gr as on th s joints to
as ins rtion of th arms (copp r gr as r f r nc : r f. 050440)
 Replaceme t or adjustme t of X-Clamp arms :
Wh n changing th arms, plac th clamp on its stand, and proc d as follows :
-Switch off th machin
-Put th clamps abov th cooling liquid l v l in th tank.
-Tak a r cipi nt of about 1 litr to coll ct th wat r pouring from th arm.
-Scr w off th tight ning scr w of th arms nuts.
-Tak th arms off and coll ct th liquid in th arms.
-Tak th oth r arms, put som gr as all around th arm’s xtr mity (us sp cial “copp r gr as ”).
-Ch ck th pr s nc of th circular joint (wash r D=25, flang of 4) and ch ck its good stat .
-Put th arms back against m chanical stop. Adjust th m so that both l ctrod s fac ach oth r. Th n scr w
both scr ws of th arms nuts (coupl 15 Nm).
-Ch ck th l v l of cooling liquid.
-Switch ON th machin
Wh n you adjust th arms, proc d as follows :
To pr cis ly adjust th arms clamps, it is n c ssary to clos th clamps without th g n rator making a w lding point. In
ord r to do this, pr ss on th “Esc” k y to nt r th clamp adjustm nt mod . Th m ssag « CLAMPS ADJUSTMENT »
app ars. By pr ssing th clos button on th clamps, you can adjust th arms as no curr nt is suppli d by th g n rator. To
com back to normal mod , pr ss th “Esc” k y again.
WARNING : if th arms ar not corr ctly tight n d during th cooling liquid circulation, th arms can b j ct d from th ir
housings and may cr at mat rial or body damag s.