GYS GYSPOT 100R User manual

Taal: EngelsTaal: Engels
Handleiding
GY 019928
MSH equipment
Appelmarkt 7
1681 PE Zwaagdijk-Oost
Tel : [phone]
Fax : [phone]
Mail: [email protected] Website: www.msh-equipment.nl

www.gys.fr
USER MANUAL
V2.2
TABLE OF CONTENTS
1 - PRESENTATION, SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS ................................... 2
2 - DESCRIPTION .............................................................................................................................. 3
-Fro t pa el ........................................................................................................................................ 3
-Rear pa el ......................................................................................................................................... 3
-Clamps .............................................................................................................................................. 3
3 - INSTALLATION ............................................................................................................................. 4
4 –EQUIPMENT OPERATION ............................................................................................................... 5
-Key defi itio ..................................................................................................................................... 5
-Use of the C clamp............................................................................................................................. 6-7
-Use of the X clamp............................................................................................................................ 8-9
-Use of the si gle sided gu ................................................................................................................. 10
-Error ma ageme t ............................................................................................................................. 11
-Weldi g spots cou ter........................................................................................................................ 12
-Recordi g features (ide tificatio mode – user’s parameters) ............................................................... 13-14
-SD memory card ................................................................................................................................ 15
-GYSPOT software o PC ..................................................................................................................... 15-16
5 - PRECAUTIONS AND SERVICING ..................................................................................................... 17
-Relaceme t of caps/electrodes............................................................................................................ 17
-Clea i g or replaceme t of weldi g tools............................................................................................. 17
-purge of th ep eumatic filter............................................................................................................... 17
-mai te a ce of the ge erator............................................................................................................. 17
-Replaceme t a d adjustme t of X arms............................................................................................... 18
-Replaceme t a d adjustme t of C arms .............................................................................................. 19
6 – ASSEMBLY INSTRUCTIONS ........................................................................................................... 20-21
7 – TECHNICAL CHARACTERISTICS..................................................................................................... 22
8 - ANOMALIES / CAUSES / REMEDIES ................................................................................................ 23
9 - ICONS ......................................................................................................................................... 24
10 – DECLARATION OF CONFORMITY ................................................................................................. 24
11 – WARRANTY................................................................................................................................ 25
12 – CIRCUIT DIAGRAM ..................................................................................................................... 26-27
06
09
11
-
V2
.
2
Autres langues disponibles sur la carte SD.
Other languages available on the SD card.
Weitere auf SD-Karte verfügbare Sprachen.

2
Tha k you for your choice ! Before i stalli g a d usi g the product or before mai te a ce, please read carefully the followi g safety
recomme datio s i order to avoid accide ts to the users a d damage of the weldi g process.
GYS ca ot be held respo sible for the damages occurri g to perso s or belo gi gs, followi g the use of the machi e i the followi g
circumsta ces:
- Modificatio or disabli g of safety eleme ts,
- No -respect of the recomme datio s writte i the user ma ual,
- Modificatio of the characteristics of the product,
- Use of accessories other tha the GYS accessories , or accessories ot adapted to the machi e
- No -respect of the regulatio s a d particular dispositio s i the cou try where the machi e is i stalled.
1- PRESENTATION, SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS
This product has bee desig ed to carry out the followi g operatio s i car body workshops :
- Spot weldi g o metal sheets with a p eumatic clamp,
- Weldi g of metal sheets with a si gle sided gu ,
- Weldi g of ails, rivets, washers a d studs,
- Repair of bumps a d impacts (impacts of hail with the optio « quick repair”).
GENERALITIES
1. The operators must have followed up a appropriate trai i g.
2. The repair a d mai te a ce operatio s ca o ly be performed by qualified perso el.
3. The operator is respo sible for the respect of the car ma ufacturer’s recomme datio s, regardi g the protectio of the car electrical a d
electro ic equipme ts (car computer, car radio, alarm, air bag, etc…).
4. Before a y repair or mai te a ce operatio , the compressed air supply must be disco ected a d depressurized.
5. The electrodes, arms, as well as the other seco dary co ductors ca reach a very high temperature a d remai hot very lo g after havi g
stopped the machi e. Pay particular atte tio to the risks of serious bur s.
6. It is ecessary to make a regular preve tive mai te a ce o the machi e.
MAIN SUPPLY
1. Check whether the u it is correctly co ected to the earth a d that the co ectio to the earth is i good co ditio .
2. Check whether the workbe ch is co ected to the earth coupler.
3. Make sure that the operator has o co tact with the metal parts to be welded without a y protectio or with wet clothes.
4. Avoid bei g i co tact with the weldi g part.
5. Do ot make a y spot weldi g operatio s i very wet areas or o a wet floor.
6. Do ot weld with wor out cables. Make sure that there is o isolatio defect, or stripped cables or loose co ectio s, a d that there is o
cooli g liquid leaks.
7. Before performi g a y co trol or mai te a ce operatio , switch off a d disco ect the u it directly from the plug.
EYE AND BODY PROTECTION
1. Duri g the weldi g process, the operator must protect himself from possible projectio s of steel i fusio with clothes like : leather gloves,
weldi g apro s, safety shoes, weldi g helmets or glasses for filteri g radiatio s a d projectio s. Similarly, duri g gri di g or hammeri g operatio s,
the operator must wear eye protectio .
2. The tighte i g force of the clamp ca reach 550 daN. Keep away all body parts from the mobile eleme ts of the clamp to avoid a y risk of
squeezi g, of fi gers i particular.
3. Do ot wear ri gs, watches, or jewellery, which are curre t co ductors a d ca cause serious bur s.
4. All the protectio boards must be i good co ditio a d mai tai ed i place.
Never look at a weldi g arc without a y eye protectio .
Protect the e viro me t ear the product agai st projectio s a d reflectio s.
FIRE
1. Make sure that the sparks will ot cause fire, especially ear flammable material.
2. Check that fire exti guishers are ear the operator.
3. Use the product i a room with extractor fa s
4. Do ot weld o combustible or lubrica t co tai ers, eve empty, or o co tai ers co tai i g flammable material.
5. Do ot weld i a atmosphere charged with flammable gas or fuel fumes.
ELECTRO-MAGNETIC COMPATIBILITY
Near the spot-weldi g machi e, check whether :
- there are o other power supply cable, o co trol li es, o telepho e cables, o radio or TV receptio applia ces, o watches, o mobile pho es,
o mag etic cards, o computers or a y other electro ic applia ce.
- there are, i the surrou di gs, o perso s usi g active medical applia ces (pacemakers, acoustic prosthetics).
Pla extra protectio s if other products are to be used i the vici ity of the machi e.
This product is desig ed to be used i a i dustrial or professio al e viro me t, as defi ed i the CISPR11 publicatio . I a differe t e viro me t,
it might be difficult to e sure electromag etic compatibility.

3
CE MARKING
GYS testifies that this product has bee desig ed a d ma ufactured i co formity with the followi g Europea
sta dards :
- Low Voltage Directive 2006/95/EC i applicatio of the orm EN 62135-1
- Electromag etic Compatibility Directive EMC 2004/108/EC i applicatio of the orm EN 62135-2
- Machi es directive 2006/95/EC i applicatio of the orm EN 60204-1
2 – DESCRIPTION OF THE MACHINE
100R Fro t pa el
SD card reader Display board for
commu icatio with
the user
Rear pa el
32 A D-curve circuit breaker P eumatic filter, co ectio to the
p eumatic etwork system
X Clamp (for INVERTER GYSPOT 100R-X)
C clamp (for INVERTER GYSPOT 100R-C)
A : Close/Weld push butto
Locki g / U locki g C - Lever
C arm
Mobile electrode
Ha dle must be loose ed to
rotate the arm arou d its axis,
or to cha ge it
Over-ope i g of the
clamp
Close the clamp a d weld
Arm uts

4
3- INSTALLATION
Before use
Several verificatio s are ecessary before usi g the u it to e sure good performa ce of the machi e.
Here are the verificatio s to do :
-Check the electrical li e voltage : it should be 400V, 3 phases, with a 32 A delayed circuit breaker, curve D (or
fuse of aM type).
-Check the cross sectio of the cable goi g from the mai electrical board to the socket where the machi e will be
plugged : it should be 4x6 mm2. If this cable is lo ger tha 10m, use a co ductor size of 10mm². If you use a
electrical exte sio cord, use a 6mm² co ductor size (10mm² if electrical li e + exte sio cord total le gth is superior
to 10m).
-Co ect a 3 phase + earth plug (mi imum 32A) o the supply cable.
-Be careful: i order to avoid voltage drops which ca ge erate bad weldi g spots, you must ever have overloaded
electrical li es, or supply cable diameters which cross sectio are ot large e ough. Also, the mai s plugs must ot be
too far from the circuit breaker.
-If the machi e is ot sufficie tly supplied, it is ot possible to e sure a good weldi g quality.
-Check that the air compressed etwork ca deliver a mi imum of 7 bar (dry air), the co ect the compressed air
etwork o the back of the machi e. The machi e must ot be used o a air compressed etwork with a pressure
i ferior to 3 bar.
Assembli g clamp sta d a d earth cable
Arm sta d


 Assemble the arm sta d o the right side of the
machi e


 Assemble the X clamp ha dle


 Depe di g o the arm used, positio the clamp either
usi g the hook or usi g the clamp ha dle.
Earth cable Air co ector
Assemble the copper plate o the extremity of the earth cable Assemble the air co ector o the air filter.
This earth cable is to be used o ly with the si gle sided gu
Starti g the machi e
Switch ON the circuit breaker. The electro ic card starts a test a d i itialisatio cycle of the parameters duri g a period of
about 10 seco ds. At the e d of this cycle, the machi e is ready to be used.
Cooli g of the weldi g cables
The clamp a d si gle sided gu cables are cooled by blow air.
- Cooli g of the clamp cable :
The air is blow i to the clamp cable whe the user presses the trigger.
The air co ti ues to be blow i to the cable three mi utes after the last weldi g spot.
- Cooli g of the gu cable:
The air is blow i to the gu cable whe the user presses the trigger.
The air co ti ues to be blow i to the cable three mi utes after maki g the last spot with the gu .







5
4- EQUIPMENT OPERATION
Key defi itio


 key
- Pressi g this key allows to select the tool that will be
used : either clamp or si gle sided gu . For the BP.LCX
machi e, pressi g this key cha ges the mode from C clamp
to C clamp adjustme t, X clamp, X clamp adjustme t, a d
fi ally si gle sided gu . The clamp adjustme t mode allows
to close the clamp a d apply the programmed force o the
electrodes with a y curre t flowi g. This mode is used to
adjust the arms.
- Pressi g this key 2 seco ds allows to come back to
ormal mode from the other modes.
- Pressi g this key 2 seco ds bri gs the spot cou ter to
zero, whe it is displayed.
- Pressi g briefly twice this key erases the report that is
displayed o the scree , whe i the visualisatio mode.
- Pressi g briefly this key whe i program savi g mode
erases the selected program.
②
②②
② Save a report
More details ca be fou d o this fu ctio i the
correspo di g chapter.
The « record » key e ables or disables the report
savi g fu ctio .
The « visualize» key allows to read the seque ce of
spots performed.
③
③③
③ Use of the adva ced modes
The MODE key allows to avigate through 3 differe t
modes : STANDARD MODE, MULTISHEET MODE, MANUAL
MODE. A lo g press o the MODE key allows to e ter the
co figuratio mode, where the la guage a d date ca be
edited a d the sou d alarm activated for “curre t too low”
or “low pressure” messages. The up a d dow keys (i the
circle) allow to select the parameter to modify (sheet
thick ess, type of steel, arm used). The + a d – keys allow
to modify the parameter.
④
④④
④ Savi g parameters
The « save » key allows to save a user’s weldi g
parameters (mode, sheet thick ess, weldi g curre t,
weldi g time or electrode force).
The« ope » key allows to call back previously
saved weldi g setti gs. The machi e automatically goes to
ma ual mode, recalli g the saved parameters (curre t,
weldi g time, force) a d the tool used (clamp or gu ).
⑤
⑤⑤
⑤ Steel sheet thick ess
This setti g allows to select the thick ess of the steel sheets
to weld. The sheet thick ess ca be adjusted usi g the +
a d – keys (i the circle, positio 5). The thick ess ca be
selected amo gst the followi g preset values : 0.6, 0.8, 1.0,
1.2, 1.5, 1.8, 2.0, 2.5, 3.0 mm.
⑥
⑥⑥
⑥ Type of steel sheet
This setti g allows to select the type of steel sheet to weld,
amo gst 4 families : coated steel, HTS steel, UHTS steel,
BORON steel. This setti g ca be adjusted usi g the + a d
– keys (i the circle, positio 5).
⑦
⑦⑦
⑦ Arm used
Whe a clamp is used (either C or X), the user should
specify here the le gth of the arms fitted o the clamp, so
that the machi e will adjust automatically the air pressure
to get the requested electrode force.








6
Use of the p eumatic clamps
Whe usi g a p eumatic clamp, always disco ect the earth cable used i si gle sided gu mode from the
vehicle.
C clamp
Clamp adjustme t
The key allows to switch from o e tool to the ext, a d also
allows to e ter the clamp adjustme t mode. The clamp
adjustme t mode allows to close the clamp a d apply the selected
electrode force, without delivery of a y curre t. The clamp
remai s closed as lo g as the butto o the clamp is pressed. This
mode allows to check the alig me t of the electrodes a d the
good positio i g of the caps.
Pressi g duri g 2 seco ds the key takes back to the
“sta dard” mode.
Sta dard mode
This mode is the default mode whe the machi e starts. It
allows to easily perform a weldi g spot by selecti g :
-The tool to be used
-The thick ess of the sheets to be welded, to choose from 0.6,
0.8, 1.0, 1.2, 1.5, 1.8, 2.0, 2.5, 3.0.
-The type of steel to be welded (Coated steel, HTS steel, UHTS
steel, BORON steel) a d the arm used.
Pressi g the up a d dow key (i the circle) allows to avigate
from o e parameter to the ext (thick ess, type of steel, arm
used). Each parameter ca be adjusted by pressi g the + a d –
keys (i the circle).
Pressi g the close / weld butto allows to perform a weldi g spot, usi g the selected parameters.
If the i put air pressure is too low to reach the requested electrode force, the machi e will beep a d display, before the
weldi g spot, the followi g error message “Pressure too low”. Pressi g agai o the butto allows to force the executio of
the weldi g spot, which will be performed with the air pressure available.
If the weldi g curre t measured duri g the spot is 6% less tha the setti g, the machi e will display, whe the spot is
completed, a error message “Curre t too low”, war i g that the weldi g spot should be checked.
I a y case, a message is displayed at the e d of the weldi g spot showi g the measured weldi g curre t a d electrode
force. This message is displayed o the scree u til a key is pressed o the co trol pa el, or u til a ew weldi g spot is
performed, by pressi g the B butto o the clamp.
Multisheet mode
This mode allows to precisely specify the thick ess a d type of each sheet of a assembly of 2 or 3 sheets.
Usi g the up a d dow keys (i the circle) allows to select the
parameters for each sheet. Whe the parameters for each
sheet are highlighted, the sheet thick ess a d type of steel
parameters ca be adjusted usi g the + a d – keys (i the
circle).
The parameters to be adjusted i this mode are:
-The thick ess of each sheet to be welded : to choose
betwee the values 0.6, 0.8, 1.0, 1.2, 1.5, 1.8, 2.0, 2.5, 3.0
mm.
-The type of steel for each sheet : coated steel, HTS steel,
UHTS steel, BORON steel.
-I order to activate sheet 3, press the up a d dow keys (i
the circle) to highlight sheet 3; the use the + a d – keys (i
the circle) to select the sheet thick ess a d type of steel.

7
If the i put air pressure is too low to reach the requested electrode force, the machi e will beep a d display, before the
weldi g spot, the followi g error message “Pressure too low”. Pressi g agai o the butto allows to force the executio of
the weldi g spot, which will be performed with the air pressure available.
If the weldi g curre t measured duri g the spot is 6% less tha the setti g, the machi e will display, whe the spot is
completed, a error message “Curre t too low”, war i g that the weldi g spot should be checked.
I a y case, a message is displayed at the e d of the weldi g spot showi g the measured weldi g curre t a d electrode
force. This message is displayed o the scree u til a key is pressed o the co trol pa el, or u til a ew weldi g spot is
performed, by pressi g the B butto o the clamp.
Pressi g duri g 2 seco ds the key takes back to the « sta dard » mode.
Auto mode
The automatic mode is optio al, it ca be co figured i the setup me u which is activated by pressi g the “mode” butto
for 2 seco ds (mode auto o /off).
This mode is ide tical to the sta dard mode, except that the user ca defi e the
elasticity limit of the sheet. This limit (Re) ca be ide tified usi g a metal tester
like Gysteel Visio .
Re : 1-10 refers to mild steels.
Re : 11-18 refers to HSS/THSS.
Re : 19-35 refers to UHSS.
Re : 36-99 refers to boro steel.
♦ Thick ess of metal sheets : 0.6, 0.8, 1.0, 1.2, 1.5, 1.8, 2.0, 2.5, 3.0.
♦ The arm type which is used.
The parameters of thick ess, elasticity, type of arm ca be highlighted usi g the  or  keys,
A d adjusted usi g + a d – keys.
Pressi g the close/weldi g butto allows to perform a weldi g spot, usi g the parameters displayed.
Pressi g duri g 2 seco ds the key takes back to the « sta dard » mode.
Ma ual mode
This mode allows the user to ma ually select the weldi g parameters, followi g i structio s from a ma ufacturer for
example.
The setti gs proposed by default i the ma ual mode correspo d
to the setti gs automatically selected by the sta dard mode
(thick ess a d type of sheet, electrode force, arm).
The parameters ca be adjusted usi g the + a d – keys (i the
circle). The up a d dow keys allow to avigate from o e
parameter to the ext :
- Weldi g curre t (2000 to 10000 A, by steps of 100 A). Display is
i kA (thousa d amps).
- Weldi g time (from 100 to 850 ms, by steps of 10ms). Display i
milliseco ds.
- Electrode force (from 100 to 500 daN, by steps of 5 daN).
Display i decaNewto s.
- arm used o the clamp (arm umber a d le gth)
If the i put air pressure is too low to reach the requested electrode force, the machi e will beep a d display, before the
weldi g spot, the followi g error message “Pressure too low”. Pressi g agai o the butto allows to force the executio of
the weldi g spot, which will be performed with the air pressure available.
If the weldi g curre t measured duri g the spot is 6% less tha the setti g, the machi e will display, whe the spot is
completed, a error message “Curre t too low”, war i g that the weldi g spot should be checked.
I a y case, a message is displayed at the e d of the weldi g spot showi g the measured weldi g curre t a d electrode
force. This message is displayed o the scree u til a key is pressed o the co trol pa el, or u til a ew weldi g spot is
performed, by pressi g the B butto o the clamp.
Pressi g duri g 2 seco ds the key takes back to the « sta dard » mode.

8
X Clamp
Clamp adjustme t
The key allows to switch from o e tool to the ext, a d also
allows to e ter the clamp adjustme t mode. The clamp
adjustme t mode allows to close the clamp a d apply the selected
electrode force, without delivery of a y curre t. The clamp
remai s closed as lo g as the butto o the clamp is pressed. This
mode allows to check the alig me t of the electrodes a d the
good positio i g of the caps.
Sta dard mode
This mode is the default mode whe the machi e starts. Il It allows to easily perform a weldi g spot by selecti g :
-The tool to be used
- The thick ess of the sheets to be welded, to choose from 0.6,
0.8, 1.0, 1.2, 1.5, 1.8, 2.0, 2.5, 3.0.
-The type of steel to be welded (Coated steel, HTS steel, UHTS
steel, BORON steel) a d the arm used.
Pressi g the up a d dow key (i the circle) allows to avigate
from o e parameter to the ext (thick ess, type of steel, arm
used). Each parameter ca be adjusted by pressi g the + a d –
keys (i the circle).
Pressi g the close/weld butto o the clamp allows to perform a
weldi g spot, usi g the selected parameters.
If the i put air pressure is too low to reach the requested electrode force, the machi e will beep a d display, before the
weldi g spot, the followi g error message “Pressure too low”. Pressi g agai o the butto allows to force the executio of
the weldi g spot, which will be performed with the air pressure available.
If the weldi g curre t measured duri g the spot is 6% less tha the setti g, the machi e will display, whe the spot is
completed, a error message “Curre t too low”, war i g that the weldi g spot should be checked.
I a y case, a message is displayed at the e d of the weldi g spot showi g the measured weldi g curre t a d electrode
force. This message is displayed o the scree u til a key is pressed o the co trol pa el, or u til a ew weldi g spot is
performed, by pressi g the B butto o the clamp.
Multisheet mode
This mode allows to precisely specify the thick ess a d type of each sheet of a assembly of 2 or 3 sheets.
Usi g the up a d dow keys (i the circle) allows to select the
parameters for each sheet. Whe the parameters for each sheet
are highlighted, the sheet thick ess a d type of steel parameters
ca be adjusted usi g the + a d – keys (i the circle).
The parameters to be adjusted i this mode are :
-The thick ess of each sheet to be welded : to choose betwee
the values 0.6, 0.8, 1.0, 1.2, 1.5, 1.8, 2.0, 2.5, 3.0 mm.
-The type of steel for each sheet : coated steel, HTS steel, UHTS
steel, BORON steel.
I order to activate sheet 3, press the up a d dow keys (i the
circle) to highlight sheet 3; the use the + a d – keys (i the
circle) to select the sheet thick ess a d type of steel.
If the i put air pressure is too low to reach the requested electrode force, the machi e will beep a d display, before the
weldi g spot, the followi g error message “Pressure too low”. Pressi g agai o the butto allows to force the executio of
the weldi g spot, which will be performed with the air pressure available.
If the weldi g curre t measured duri g the spot is 6% less tha the setti g, the machi e will display, whe the spot is
completed, a error message “Curre t too low”, war i g that the weldi g spot should be checked.

9
I a y case, a message is displayed at the e d of the weldi g spot showi g the measured weldi g curre t a d electrode
force. This message is displayed o the scree u til a key is pressed o the co trol pa el, or u til a ew weldi g spot is
performed, by pressi g the B butto o the clamp.
Pressi g duri g 2 seco ds the key takes back to the « sta dard » mode.
Auto mode
The automatic mode is optio al, it ca be co figured i the setup me u which is activated by pressi g the “mode” butto
for 2 seco ds (mode auto o /off).
This mode is ide tical to the sta dard mode, except that the user ca defi e the
elasticity limit of the sheet. This limit (Re) ca be ide tified usi g a metal tester
like Gysteel Visio .
Re : 1-10 refers to mild steels.
Re : 11-18 refers to HSS/THSS.
Re : 19-35 refers to UHSS.
Re : 36-99 refers to boro steel.
♦ Thick ess of metal sheets : 0.6, 0.8, 1.0, 1.2, 1.5, 1.8, 2.0, 2.5, 3.0.
♦ The arm type which is used.
The parameters of thick ess, elasticity, type of arm ca be highlighted usi g the  or  keys,
A d adjusted usi g + a d – keys.
Pressi g the close/weldi g butto allows to perform a weldi g spot, usi g the parameters displayed.
Pressi g duri g 2 seco ds the key takes back to the « sta dard » mode.
Ma ual mode
This mode allows the user to ma ually select the weldi g parameters, followi g i structio s from a ma ufacturer for
example.
The setti gs proposed by default i the ma ual mode correspo d to
the setti gs automatically selected by the sta dard mode (thick ess
a d type of sheet, electrode force, arm).
The parameters ca be adjusted usi g the + a d – keys (i the
circle). The up a d dow keys allow to avigate from o e
parameter to the ext :
- Weldi g curre t (2000 to 10000 A, by steps of 100 A). Display is
i kA (thousa d amps).
- Weldi g time (from 100 to 850 ms, by steps of 10ms). Display i
milliseco ds.
- Electrode force (from 100 to 500 daN, by steps of 5 daN). Display
i decaNewto .
- arm used o the clamp (arm umber a d le gth).
If the i put air pressure is too low to reach the requested electrode force, the machi e will beep a d display, before the
weldi g spot, the followi g error message “Pressure too low”. Pressi g agai o the butto allows to force the executio of
the weldi g spot, which will be performed with the air pressure available.
If the weldi g curre t measured duri g the spot is 6% less tha the setti g, the machi e will display, whe the spot is
completed, a error message “Curre t too low”, war i g that the weldi g spot should be checked.
I a y case, a message is displayed at the e d of the weldi g spot showi g the measured weldi g curre t a d electrode
force. This message is displayed o the scree u til a key is pressed o the co trol pa el, or u til a ew weldi g spot is
performed, by pressi g the B butto o the clamp.
Pressi g duri g 2 seco ds the key takes back to the « sta dard » mode.

10
Use of the si gle sided gu
♦ Co ect the copper plate to the ge erator’s earth cable.
♦ Firmly fix the earth plate as ear as possible to the weldi g area.
I case of mo opoi t weldi g with the si gle sided gu , always fix the earth plate o the sheet that is ot i co tact with
the weldi g electrode (such that the weldi g curre t will flow the 2 sheets to be welded).
♦ Select the GUN tool usi g key, or pulli g the gu ’s trigger.
♦ The default parameter is star weldi g i sta dard mode .
-
Never let the i ertia hammer at the e d of the gu if this o e is hu g to the bala cer.
The si gle sided gu ca be used i sta dard or ma ual mode.
♦ I ormal mode, the si gle sided gu will be limited to steel sheets of thick ess 1.5mm maximum.
With the si gle sided gu , the operator ca choose betwee a variety of tools (mo opoi t weldi g, star weldi g, stud
weldi g, rivet weldi g, washer weldi g, carbo shri ki g, stitch weldi g) The selectio of the tool is performed usi g the +
a d - keys.
I ma ual mode, the maximum permitted weldi g curre t is 9 kA duri g a period that will ot exceed 600 ms. This is why it
is ot possible to select higher values for these parameters.
Select the thick ess of the sheets to be welded o the machi e, usi g the + a d – keys. It is possible to modify the
parameters for curre t a d time i ma ual mode
Pressi g duri g 2 seco ds the key takes back to the « sta dard » mode.
The highlighti g allows to select the parameter to adjust. Each parameter ca be adjusted usi g the + a d – keys. The up
a d dow keys allow to move from o e parameter to the ext .
WARNING :
The clamp a d the gu of the u it are co ected to the same curre t source. This mea s that whe you use o e of these 2
tools, there is also power o the seco d tool. The tool which is ot used must therefore be placed o its sta d o the trolley
(clamps sta d located o the side of the trolley a d gu sta d located o the T-Shape bala cer).
I case these i structio s are ot respected, severe damage ca occur to the ge erator tools. Sparks a d metal projectio s
ca occur.
!

11
Error ma ageme t
Differe t eve ts might cause the appeara ce of error messages.
They ca be classified i three categories :
-The messages that war the user, of overheati g, or a lack of
electrode force or weldi g curre t, etc… These messages appear o
the scree , a d remai u til a key is pressed.
-the defects that correspo d to a bad i stallatio (air pressure,
electrical power supply)
-The messages that i form of major failures, such as material
failure. These defects cause the display of a error message that
blocks the machi e.
-The thermal protectio makes use of a thermistor o the diode
bridge, which block the use of the machi e, a d displays the
message “overheati g”.
Curre t too low
If the weldi g curre t obtai ed duri g the weldi g spot is 6% less
tha the curre t setti g, the machi e displays, o ce the weldi g
spot is performed, a error message “Curre t too low”, war i g
that the weldi g spot should be checked.
I a y case, a message is displayed at the e d of the weldi g spot
showi g the actual measured weldi g curre t. This message is
displayed o the scree u til a key is pressed o the co trol pa el,
or u til a ew weldi g spot is performed, by pressi g the butto o
the clamp.
If the machi e ca ot deliver the requested curre t, the the
followi g message appears. The weldi g spot is ot performed,
a d the message must be ack owledged to perform a weldi g
spot.
I sufficie t air pressure
If the i put air pressure is too low to reach the requested electrode force, the machi e will beep a d display, before the
weldi g spot, the followi g error message “I sufficie t Pressure”.
Pressi g agai o the butto allows to force the executio of the weldi g spot, which will be performed with the air pressure
available. If the actual measured clampi g force is too low, the the machi e will display the followi g message “Low
Pressure”.

12
Weldi g spot cou ter
A weldi g spot cou ter allows to cou t the umber of spots performed with the same caps. If the weldi g spot is performed
without a y problem, the followi g message appears.
The cou ter is displayed o the top left cor er of the scree . Pressi g the key for two seco ds resets this cou ter to
zero, after the caps have bee replaced.
If more tha 200 weldi g spots are do e with the same caps, the the machi e will display a war i g message. I this
case, the war i g message “Do co trol caps” is also recorded i the traceability report. You ca defi e the threshold
umber of spots, 200 by default.
Recordi g features
The log report allows to save the characteristics of the weldi g spots performed with the clamp. It is available from all
modes, by simply pressi g the keys located below the ico “REPORTING”.
The user weldi g parameters mode is also available from all modes, by pressi g the keys below the ico “MEMORY”.
LOG report
Recordi g a report allows to save the characteristics of a series of
weldi g spots, a d save them o the SD memory card, such that they
ca be tra sferred to a y sta dard PC. GYS provides a software to read
the SD card, a d edit reports. This GYSPOT software is stored i the SD
card, together with a copy of the user ma ual.
By default, this fu ctio is disabled at the start of the machi e.
Pressi g the key a d the “mode” key allows to start recordi g i the
selected log file. Pressi g agai the record key will stop the record.
The log file thus created co tai s : a ide tifier e tered by the user, as well as, for each weldi g spot performed, the tool
used, the arms used, a d the setti gs of the machi e (weldi g curre t a d electrode force). It also co tai s the possible
error messages that have bee displayed duri g the record : I low, P low.
Use the + a d – keys, as well as the up a d dow keys to e ter the ide tifier. If a previously existi g ide tifier is e tered,
the machi e will save the ew weldi g spot characteristics at the e d of the file, without erasi g a y i formatio from the
file.
The key allows to recover a report previously saved a d to read it o the scree .
Before visualizi g a report, the record must be stopped by pressi g the key.
The “mode” key allows to exit the report visualisatio mode .
To erase the co te t of a report, display it o the scree The , press the key
usi g the« visualize » key. The followi g message appears o the scree :
Whe the tria gle sig is displayed, pressi g key a seco d time defi itively erases the co te ts of the report displayed
o the scree . The tria gle sig disappears from the scree after 3 seco ds

13
Ide tificatio mode :
If the ide tificatio mode is set to "ON", the you should e ter
all required fields of the repair order to the weldi g poi ts if
the machi e will issue the "defect ide tificatio .
To e able a d disable the ide tificatio mode, i sert a SD
card reader i the ide tificatio of BP i stead of the SD card
that co tai s the programs.
The scree below setup is activated by pressi g for 2 seco ds
o the mode butto .
Whe the SD card "ide tificatio " is i serted a d you select
"ide tify ON" THEN supervisio followi g scree appears.
This scree allows you to make the fields
“registratio , vehicle make, vehicle model, vehicle ide tificatio
umber "required whe e teri g the repair order.
To exit the scree , you must press the mode key for 2
seco ds. The you must put the SD card that co tai s the
program i to your BP card reader.
List of scree s that allow you to e ter a repair order :
Whe a job umber has already bee created, it ca ot be cha ged or deleted o the BP. To remove it you must use the
software GYSPOT PC. You ca create up to 100 job umbers.
Display : ‘Job umber‘ Display : ‘User ID‘
Keys 'left' a d 'right' moves the cursor i the field.
The up a d dow butto s allow you to cha ge the letters or umbers
The short press the Esc key clears the field.
The mode butto allows scrolli g fields for the modificatio or readi g.
Display : ‘Registratio ’ (optio al) Display : ‘Vehicle make’ (optio al)

14
Display : ‘Vehicle model‘ (optio al) Display : Chassis umber (optio al)
catalogue
Whe co sulti g jobs with the View key , the scree CATALOG appears :
The page umber is displayed (13 maxi)
Keys 'left' a d 'right' are used to cha ge the page. The up a d dow keys are used to select the ext or previous Job
umber. The “mode” key allows displayi g the selected repair order.
The "mode" key is used to leave from viewi g the report .
♦ The library ma ageme t of the SD card ca ha dle SD cards> 2 GB.
♦ Each job has a associated log file xxx.dat. (where xxx = id from 001 to 100). I every report, the maximum recorded
spot welds is 500. the job umber a d the user id of the file are displayed.
♦ No. The page is show i the top left.
♦ All jobs are stored i the file catalog.GYS.
♦ It co tai s the total umber of job, ame of each job a d user id (max 100 jobs).
User weldi g parameter record
The savi g of user weldi g parameters allows to save the preferred weldi g parameters for differe t users of the machi e.
20 user profiles ca be saved. Each of them co tai s the followi g setti gs : tool, arm, weldi g curre t, weldi g time,
electrode force).
A user ca save his preferred parameters for the clamp or si gle sided gu .
The save key allows to record the setti gs curre tly used i ma ual mode (weldi g curre t, weldi g time, electrode
force). The 20 user profiles are the displayed with either a ide tifier, for those that are already used, or « --- » for those
that are still available.
Use the + a d – keys, as well as the up a d dow keys, to e ter the ide tifier. Whe e teri g a previously used ide tifier,
the machi e will erase the previous setti gs saved.
The « Ope » key allows to access the user profiles previously saved. Selecti g a empty user profile has o effect.
Pressi g briefly the key erases the selected program i the list of saved programs.
The “mode” key allows to exit the program selectio mode, a d makes the machi e e ter the ma ual mode where the
parameters a d the tool saved i the program are recalled.
To disable a progam, simply cha ge the value of a parameter i the ma ual mode, sta dard mode or mutisheet mode, or
simply cha ge tool by pressi g key .

15
SD memory card
SD card refere ce : 050914
This card allows the user to tra sfer files from the machi e to a PC to :
-collect log reports i order to keep traceability of his work, a d possibly show it to a i sura ce compa y.
-Update weldi g parameters, add ew me u la guages.
-A copy of the GYSPOT software to collect a d edit the traceability reports is stored o the SD card.
-A copy of the user ma ual is also stored o the SD card.
The memory space will allow savi g the characteristics of more tha 1 000
weldi g spots.
The machi e ca operate without a y SD card i ma ual mode o ly.
If the memory card is ot i serted i the card reader, the the followi g
message is displayed.
Importa t : Switch off the machi e, i sert the SD card, a d switch the
machi e ON agai . The machi e shall be switched off before removi g the
SD card from the reader i deed data o the SD card ca be destroyed.
GYSPOT SOFTWARE FOR PC
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, Danish, Finnish, talian, Russian, Swedish, Turkish.
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 information :
Company name
Adress/ Postal code/ Town
Telephone/ Fax
Email/ Website/ 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 Active 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.
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 Archive 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 .

16
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 ard.
Beware, during a purge operation, the reports that have not yet been imported in the software will be
automatically imported.
Filling the information of a report
The following information can be automatically added on each report :
Operator, Brand, Vehicle model
Registration, First registration,
Chassis number, Operation, Remarks.
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
To export a report in PDF format, select a report, and click on icon .
A print preview appears. Click on icon .
Example of report :

17
5- PRECAUTIONS AND SERVICING
User training
Operators must have a appropriate qualificatio for the use of the machi e i order to get the best of the u it a d to make
satisfyi g work (e.g. : car-body repair trai i g).
Preparation of the parts to assemble :
It is esse tial to gri d, clea a d to accost the part to be welded.
I case of a protectio applicatio , first verify that it is co ducti g by testi g a sample.
Single sided gun welding
Before repairi g a vehicle, check that the car ma ufacturer authorizes the weldi g process you have chose .
Use of the under fender arm
The maximum pressure is 200 DaN.
X clamp’s nuts circular joints
I side the 2 tighte i g arms uts (see descriptio of the clamp), there are 2 circular joi ts which have to be replaced i
case of leaks or every 6 mo ths. These 2 circular joi ts are ecessary to avoid risks of cooli g liquid leaks.
These joi ts have a diameter of d=25, fla ge=4. Duri g replaceme t, it is advised to add copper grease o these joi ts to
ease i sertio of the arms (copper grease refere ce : ref. 050440).
Purge of the pneumatic filter
Regularly drai the dehumidifier filter placed o the rear side of the u it.
Generator maintenance
The mai te a ce a d the repair of the curre t ge erator must be do e by a appoi ted a d GYS trai ed tech icia . A y
mai te a ce operatio do e by a other perso will ca cel the warra ty co ditio s. GYS ca ot be held respo sible for
damages or accide ts which happe subseque tly to operatio s performed by people exterior to GYS
leaning or replacement of the welding tools
A y weldi g tool is degraded after a certai period of use. However all tools must stay clea i order to get the best
performa ce of the u it. Whe usi g the u it i p eumatic clamp mode, check the good state of the CAPS electrodes (flat,
rou ded or bevelled). If this is ot the case, clea them with sa dpaper (fi e grai ) or replace them (see refere ce o the
u it).
For a use i si gle sided gu mode, it is ecessary to check the state of the tools : stars, mo opoi t electrode, carbide
electrode, a d if they look i bad co ditio s clea or replace them.
Replacement of the caps/electrodes :
▪To guara tee a efficie t weldi g spot, it is ecessary to replace the caps every 200 spots, usi g the dedicated tool.
▪It is forbidde to gri d the caps.
▪Assemble the caps with copper grease (ref. 050440)
▪A type caps (ref. 049987)
▪F type caps (ref. 049970)
▪Bevelled caps (ref. 049994)
▪Several combi atio s are possible
War i g : The caps must be i perfect li e. If ot,
check that the electrodes are i li e. (cf. replaceme t
of arms p. 18 a d 19).

18
Replacement or adjustment of X- lamp arms
Whe cha gi g the arms, place the clamp o its sta d, a d proceed as follows:
-The machi e must be switched off.
-Screw off the tighte i g screw of the arms uts.
-Take the other arms, put some grease all arou d the arm’s extremity (use special “copper grease”).
-Put the arms back agai st mecha ical stop. Adjust them so that both electrodes face each other. The screw
both screws of the arms uts (couple 15 Nm).
X clamp overheating
Number of spots before the machi e stops due to overheati g default
0,6mm 0,8mm 1mm 1,2mm 1,5mm 1,8mm 2mm 2,5mm 3mm
STEEL 77 65 55 46 37 31 28 23 20
HSS 60 50 44 39 33 27 25 21 18
UHSS 45 37 33 30 25 21 19 16 14
BORON 50 44 39 35 28 24 20 17 15
The time for cooling the clamp can reach 15mn.
Number of spots betwee 2 stops due to overheati g default
0,6mm 0,8mm 1mm 1,2mm 1,5mm 1,8mm 2mm 2,5mm 3mm
STEEL 23 20 16 15 14 13 12 10 8
HSS 18 16 14 13 12 11 10 8 7
UHSS 14 12 11 10 9 8 7 6 5
BORON 16 14 13 12 10 9 8 7 6

19
Replacement or adjustment of - lamp arms :
-
Proceed as follows :
-U screw the ha dle (A)
-U screw the screw mai tai i g the arm a d the clamp (B).
-Remove the arm form the clamp (C).
-Take a other arm a d i sert it i the clamp; put some copper
grease o the extremity of the arm
-Screw to assemble arm a d clamp (B)
-Screw the ha dle agai
clamp mobile electrode setup :
Proceed as follows :
1. The machi e must be switched off.
2. U leashi g the movable electrode of the ut by u screwi g
the locki g ha dle (A).
3. Adjust the positio of the movable electrode by slidi g
through the sleeve (B).
4. ope i g betwee the 2 caps (C) should be about 20 mm.
5. Set the movable electrode i the ut tighte i g the locki g
ha dle (A).
Types of arms for the clamp
clamp overheating
Nombre de poi ts ava t la première coupure thermique
0,6mm 0,8mm 1mm 1,2mm 1,5mm 1,8mm 2mm 2,5mm 3mm
ACIER 110 90 76 61 48 39 36 22 18
HLE 90 75 62 48 38 32 26 18 15
UHLE 62 48 44 36 28 23 19 15 12
BORON 75 60 47 40 33 25 22 16 13
The time for cooling the clamp can reach 15mn.
Number of spots betwee 2 stops due to overheati g default
0,6mm 0,8mm 1mm 1,2mm 1,5mm 1,8mm 2mm 2,5mm 3mm
ACIER 64 56 42 32 20 16 14 10 8
HLE 54 36 32 22 16 13 12 10 8
UHLE 32 22 18 15 12 10 9 8 7
BORON 42 36 20 16 14 11 10 8 7
C
B
A
A
B
C
Ref 052253
8 bar / 120 daN
8 bar /
300
daN
8 bar /
300
daN
8 bar /
300
daN
RC4