Manual

ManualsBrandsGys ManualsCAR BODY MACHINESGYSPOT INVERTER BP. LX

14/10/2019

TABLE OF CONTENTS V4

1- PRESENTATION, SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS ........................................................ 2

2- DESCRIPTION OF THE MACHINE ........................................................................................................................... 3

3- INSTALLATION OF THE MACHINE ......................................................................................................................... 5

4- PRODUCT OPERATION ......................................................................................................................................... 7

Key definition ................................................................................................................................................ 7

Recommendations on the use of welding modes ............................................................................................. 8

Use of C clamp modes ................................................................................................................................... 9-12

Use of X clamp modes ................................................................................................................................... 12-14

Use of the single sided gun ............................................................................................................................ 14

Error management ........................................................................................................................................ 15

Welding spot counter .................................................................................................................................... 16

Recording features (log report – user ID mode – users programs) ................................................................... 16-18

SD memory card ........................................................................................................................................... 19

GYSPOT software .......................................................................................................................................... 19-22

5- PRECAUTIONS and SERVICING ............................................................................................................................. 23

User training ................................................................................................................................................. 23

Preparation of the parts to assemble .............................................................................................................. 23

Single sided gun welding ............................................................................................................................... 23

Use of the under panel arms .......................................................................................................................... 23

Nuts circular joints ........................................................................................................................................ 23

Replacement of the caps and electrodes ......................................................................................................... 23

Level and efficiency of the cooling liquid ......................................................................................................... 23

Cleaning or replacement of the welding tools .................................................................................................. 23

Purging of the pneumatic filter ....................................................................................................................... 23

Generator maintenance ................................................................................................................................. 23

Replacement or adjustment of C clamp arms .................................................................................................. 24-26

Replacement or adjustment of X clamp arms .................................................................................................. 26-27

6 – SYMPTOMS / REASONS / SOLUTIONS .................................................................................................................. 28

7 – DECLARATION OF CONFORMITY ......................................................................................................................... 29

8 - WARRANTY ......................................................................................................................................................... 29

9 – CIRCUIT DIAGRAM ............................................................................................................................................. 30-32

10 - CHARACTERISTICS ............................................................................................................................................ 33

11 - PICTOGRAMS .................................................................................................................................................... 33

Autres langues disponibles sur la carte SD.

Other languages are available on the SD card.

Weitere auf SD-Karte verfügbare Sprachen.

Summary of content (34 pages)

PAGE 1
TABLE OF CONTENTS V4 1234- PRESENTATION, SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS ........................................................ 2 DESCRIPTION OF THE MACHINE........................................................................................................................... 3 INSTALLATION OF THE MACHINE ......................................................................................................................... 5 PRODUCT OPERATION ........................................
PAGE 2
Thank you for your choice! Before installing and using the product or before maintenance, please read carefully the following safety recommendations in order to avoid accidents to the users and damage of the welding process.
PAGE 3
2 – DESCRIPTION OF THE MACHINE BP Front panel SD card reader Display board for communication with the user BP rear panel Fan with dust-proof filter 32 A D curve circuit breaker Pneumatic filter, connection to the pneumatic network X clamp (for BP.LX or BP.LCX) B button : Remote control for the thickness of the sheet A button : Remote control to choose the metal steel Over-opening of the clamp Close the clamp and weld Arms nuts C clamp (for BP.LC or BP.
PAGE 4
Assembling the clamp handle, clamp stand and earth cable (accessories bag) C clamp (BP.LC, BP.LCX) Assemble the handle on the left hand side of the clamp. X clamps (BP.LX and BP.LCX) Assemble the clamp handle on the left or right side of the clamp, depending on the preferred choice. X clamp bracket Cables bracket (BP) C clamp bracket Gun bracket (BP) Earth cable ( BP.LX / BP.LC / BP.LCX) Assemble the copper plate on the extremity of the earth cable This earth cable has to be used with the gun.
PAGE 5
3- INSTALLATION OF THE MACHINE Before use - - Several verifications are necessary before using the unit to ensure good performance of the machine : Check the electrical line voltage: it should be 400V, 3 phases, with a 32 A delayed circuit breaker, curve D (or fuse of aM type). Check the cross section of the cable going from the main electrical board to the socket where the machine will be plugged : it should be 4x6 mm2. If this cable is longer than 10m, use a conductor size of 10mm².
PAGE 6
Safety recommendations regarding cooling liquid : - In case of contact with the eyes, rinse thoroughly with plenty of water immediately after contact (remove contact lenses first if worn). Seek medical help if necessary. - In case of contact with the skin, wash thoroughly with soap and plenty of water. Remove any contaminated clothing, and if skin irritation occurs (redness etc…) consult doctor.
PAGE 7
4- PRODUCT OPERATION Key definition         . ① Key _Pressing the key allow to select the clamp mode, gun mode or clamp adjustment. - Pressing this key 2 seconds allows to come back to normal mode from the other modes. - Pressing this key 2 seconds brings the spot counter to zero, when it is displayed. - Pressing briefly twice this key erases the report that is displayed on the screen, when in the visualisation mode.
PAGE 8
Recommendations on the use of welding modes : Only qualified and specially trained personnel are permitted to use of the spot-welder. Please observe repair manuals of respective car- manufacturers before carrying out any welds. The correct application of instructions specified in the user manual and commitment to the indications of the manufacturer as well as the necessary preparations, implementations and tests of welding jobs lies within the responsibility of the user.
PAGE 9
Using pneumatic clamps When using the pneumatic clamp, always disconnect the copper plate used in single sided gun welding. For the GYSPOT BP.LCX, select the type of clamp to be used with the ! key on the front panel.
PAGE 10
MANUAL mode This mode allows the user to manually select the welding parameters, for example when following instructions from a manufacturer. The default settings in manual mode correspond to the settings automatically selected in standard mode (thickness and type of sheet, electrode force, arm). The parameters can be adjusted using the + and – keys (Key Definition diagram, (3) ).
PAGE 11
CAR MANUFACTURER Mode : The CAR MANUFACTURER mode is optional and is configurable in the setup menu that is activated by pressing the mode key for 2 seconds (CAR MANUFACTURER : ON / OFF). This mode allows calling, in a nominative manner, a pre-recorded welding spot according to a car manufacturer repair specification. Select the CAR MANUFACTURER in the left column, then by pressing the (+) key the spots list is displayed on the right column.
PAGE 12
The user can then change the welding current, the energy, and the impedance. The machine will weld during the time necessary to reach the requested energy. If the welding is too long, the machine will display an error message « Timeout (ms) » X clamp  Line up the electrodes so they face each other, then set and tighten the clamp arms (couple: 15 Nm).  Enter « clamp adjustment » mode to check the alignment of the electrodes.
PAGE 13
Multi-sheet mode This mode allows the user specify the thickness and type of each sheet in an assembly of 2 or 3 sheets. The first piece (Thickness of the metal sheet 1) is selected. The up and down button allows the selection of the parameters for each sheet. When the parameters for a sheet are highlighted, the sheet thickness and type of steel can be adjusted using the + and – keys. The parameters to set in that mode are:  Thickness of the metal sheet 1: from 0.60mm up to 3.00mm by steps of 0.05mm.
PAGE 14
SETTINGS MODE : The SETTINGS mode can be accessed by pressing the MODE key during more than 2 seconds. The language of the menus can be selected on line 1. The date and time can be entered on line 2. The GYSTEEL, CAR MANUFACTURER, AUTO, ENERGY, STANDARD and MULTITOLE modes can be also be disabled in this menu. GLUE MODE : In the SETTINGS menu shown above, a specific mode can be selected in case there is glue in between the steel sheets to be welded.
PAGE 15
When highlighted, a parameter can be adjusted using the + and – keys. The and keys allow movement from one parameter to the next. ATTENTION : The clamps and gun are connected to the same power supply, therefore when one is in use, current will be delivered to all tools. It is necessary that the tools which are not used are placed on their respective supports.
PAGE 16
Insufficient air pressure : Before the welding spot: If the input air pressure is too low to reach the required electrode force, the machine will beep and display the following error message “Insufficient Pressure”. Pressing the button allows the user to force the execution of the welding spot, which will be performed with the air pressure available. If the actual measured clamping force is too low, then the machine will display the following message “Low Pressure”.
PAGE 17
The View button allows the user to retrieve a previously saved report and view it on the screen. To view a report, stop any current recording by pressing To erase the content of a report , it has to be displayed on screen by pressing "view" . . Use the « mode » button to exit the report displayed. To erase the report shown, press and the following message will be on the screen: When the warning image is displayed, press again and the report content will be erased.
PAGE 18
Screen: « Registration number » (optional) Screen: « Vehicle make » (optional) Screen: « Vehicle model » (optional) Screen: Chassis number (optional) Catalogue The View button , allows you to view all repair orders on the screen - "CATALOGUE": The number of pages is displayed (max 13) at the top The left and right arrow keys scroll through the pages. The up and down arrow keys scroll through the list of Repair Orders. Press the Mode button to display the repair order selected.
PAGE 19
The « recall » button allows access to previously saved settings. Pressing will erase the selected program from the saved program list. The « mode » button exits the program selection mode, the machine will then enter manual mode with the parameters and the tool saved in the program. To deactivate a program simply change the parameter value in one of the 3 modes manual, normal or multi metal sheet, or change the tool (clamp or gun) by using the The view .
PAGE 20
3.2/ Consult archived spot reports To consult the report archives, click on the tab “Archives”. The files are grouped by year and month. To view the spot information, select a report and they will appear in the table. For archived reports, it is possible to search, edit or to erase a report. Attention! When a report is archived or erased, the SD card must then be formatted to prevent the report from being imported again.
PAGE 21
Then, double click in the second column to select a Car Manufacturer file previously downloaded from our website. The list of welding spots defined by the Car Manufacturer are displayed in the second table below. Select a programmed welding spot in order to display the welding spot profile on the screen. 4.2/ Add a programmed welding spot in the USER file In order to add a welding spot in the USER file, select the USER file in the list of files and then click on the button the right of the table below.
PAGE 22
To cancel the modifications, click on the button . 4.4/ Delete a welding spot programmed in the USER file Select a welding spot programmed in the list, then click on the button Example of report : 22 on the right of the list.
PAGE 23
5- USE AND MAINTENANCE PRECAUTIONS User training Any operator of this machine should receive training adapted to its use in order to gain maximum performance from the unit (e.g.: car body repair training). Adjust the balancer’s spring tension Adjust the balancer’s spring tension with the Allen key equipped. Do not leave the clamp hanging for a long time on the balancer, as it would induce early wear out of this part.
PAGE 24
Replacement of the arms : ATTENTION : The clamps and gun are connected to the same power supply, therefore when one is in use, current will be delivered to all tools It is necessary that the tools which are not used are placed on their respective supports. Failure to follow this precaution may result in serious damage to the user, the generator and its tools, and there is a high risk of sparks and metal spatter. Replacement of the C arms : ! Please read the following instructions carefully.
PAGE 25
Adjustment of the C arms :  Ⓓ  Position screw  to fix the arm on the  clamp. Tighten it in manually - do not overtighten.  Tighten ring  manually, then the tighten  using the Allen key.  Serrer Ⓔ  Tighten the lever manually and check it is not end up against the joint stop (see diagram below). If it is the case go back to stepⒹ. max i OK NO Warning: Clamp and arm may be damaged if the lever is not tightened properly. Ⓕ  Check the cooling liquid level.
PAGE 26
Arms types for the C clamp: Spot control Consumables Spotter consumable box Spanner for cap removal Contact Grease Replacement of the X arms : follow carefully the instructions below.  Turn the machine off, or place machine in « clamp setting » mode.  Place the clamp somewhere above the level of the cooling liquid tank to drain water from the arms.  Wait at least one minute to lower the pressure in the arms.  Unscrew the tightening screws of the circular arm joints.
PAGE 27
 Check the cooling liquid level.  Switch on the unit. ! ATTENTION: If the circular joints are not securely tightened as the liquid circulates, the arms could be ejected and cause severe damage or injury. ATTENTION : The warranty does not cover defects or damage caused by incorrect assembly or incorrect tightening of the X-Clamp.
PAGE 28
6-SYMPTOMS / REASONS / SOLUTIONS SYMPTOMS REASONS The Spot weld doesn’t hold / is not good The caps used are worn out/faulty Insufficient preparation of the work-piece Sand and clean the metal sheet again The arm selected doesn’t match the one installed Check the arm with the software The caps used are worn out/faulty Replace the caps Not enough pressure Check the compressed air network (min.
PAGE 29
7 – DECLARATION OF CONFORMITY GYS confirm that the product described within this manual conforms to the following directives: - Low Voltage Directive 2006/95/CE in respect of the harmonized norm EN 62135-1 - Electromagnetic Compatibility Directive EMC 2004/108/CE in respect of the harmonized norm EN62135-2 - Machine Directive 2006/42/EC in respect of the harmonized norm EN 60204-1 - Electromagnetic Field - exposure of workers Directive 2004/40/CE of the 29thof April 2004 in respect of the harmonized norm EN
PAGE 30
9 – CIRCUIT DIAGRAM 30
PAGE 31
PAGE 32
PAGE 33
10 - TECHNICAL SPECIFICATIONS ELECTRICAL CHARACTERISTICS Nominal input voltage : U1N Permanent input current : I1N Power at 50 % duty cycle : S50 Permanent input power : Sp Maximum welding input power : Smax Secondary voltage : U2d Maximum short-circuit output current : I2cc Maximum permanent output current : I2P Maximum regulated welding current Circuit breaker Duty cycle THERMAL CHARACTERISTICS Ambient temperature range Transport and storage temperature range Thermal protection by thermistor on the diode
PAGE 34
ICÔNES / SYMBOLS / SYMBOLE / ICONOS / ZEICHENERKLÄRUNG / СИМВОЛЫ - Appareil(s) conforme(s) aux directives européennes. La déclaration de conformité est disponible sur notre site internet. - Machine(s) compliant with European directives The declaration of conformity is available on our website. - Die Anlage entspricht den folgenden europäischen Bestimmungen: Niederspannungsrichtlinie 2014/35/EU und EMV-2014/30/EU. Dieses Gerät entspricht den harmonisierten Normen EN60974-1, EN60974-10 und EMV-2014/30/EU.