GYS PTI-s7 User Manual
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GYS PTI-s7 User Manual

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GYSPOT INVERTER EVOLUTION PTI-s7 - 220V
1- PRESENTATION, SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS ........................................................ 2
2- DESCRIPTION OF THE MACHINE ........................................................................................................................... 3-4
3- INSTALLATION OF THE MACHINE ......................................................................................................................... 5-6
4- PRODUCT OPERATION ......................................................................................................................................... 7
Key definition ................................................................................................................................................ 7
Recommendations on the use of welding modes ............................................................................................. 8
Using pneumatic clamps C ............................................................................................................................. 9-12
Use a gun ..................................................................................................................................................... 12
Error management ........................................................................................................................................ 13
Welding spot counter .................................................................................................................................... 14
Recording features (report - user identification mode - user programs) ........................................................... 14-17
SD memory card ........................................................................................................................................... 17
GYSPOT Software.......................................................................................................................................... 18-21
5- USE AND MAINTENANCE PRECAUTIONS ................................................................................................................ 22
User training ................................................................................................................................................. 22
Preparation of the work-piece ........................................................................................................................ 22
Single sided gun welding ............................................................................................................................... 22
Cooling liquid level and efficiency ................................................................................................................... 22
Cleaning the pneumatic filter ......................................................................................................................... 22
Generator maintenance ................................................................................................................................. 22
Cleaning / replacement of welding tools and other items ................................................................................. 22
Installation and use of the gun....................................................................................................................... 23
Replacement of C arms ................................................................................................................................. 24
Adjustment of C arms .................................................................................................................................... 25-27
6 - SYMPTOMS / REASONS / SOLUTIONS .................................................................................................................. 28
7 - DECLARATION OF CONFORMITY ......................................................................................................................... 29
8 - WARRANTY ........................................................................................................................................................ 29
9 - CIRCUIT DIAGRAM ............................................................................................................................................. 30
10 - COOLING LIQUID CIRCUIT ................................................................................................................................ 31
11 - CLAMP CABLE BEAM CONNECTORS ................................................................................................................... 31
12 - TECHNICAL SPECIFICATIONS ............................................................................................................................ 32
13 - ICONS .............................................................................................................................................................. 32
10/03/2016-V2
USER MANUAL

Table of Contents

V2
Autres langues disponibles sur la carte SD.
Other languages are available on the SD card.
Weitere auf SD-Karte verfügbare Sprachen.

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  • Page 1: Table Of Contents

    GYSPOT INVERTER EVOLUTION PTI-s7 - 220V USER MANUAL Table of Contents 1- PRESENTATION, SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS ............2 2- DESCRIPTION OF THE MACHINE ........................... 3-4 3- INSTALLATION OF THE MACHINE ......................... 5-6 4- PRODUCT OPERATION ............................7 Key definition ..............................7 Recommendations on the use of welding modes .....................

  • Page 2: 1- Presentation, Safety Recommendations And General Precautions

    Thank you for choosing this GYS product! Please read the instructions carefully before installing, using the product, or before maintenance in order to avoid accidents, and keep the manual in a safe place for future reference. GYS cannot be held responsible for damage to persons or items, as a result of using the machine in the following circumstances:...

  • Page 3: 2- Description Of The Machine

    2. DESCRIPTION DE LA MACHINE Front panel SD card reader Display panel Rear panel 40A D-Curve Switch Pneumatic filter, 30 mA differential Pneumatic network air connector C clamp Button (B) : remote Button (A) : Open / Close control of welding the clamp.
  • Page 4 a X4 PTI Stand assembly b X4 d x4 a X2 b X2 60mm 1 mm M8 x 12 70mm 2 mm 80mm M5 x 10 M8 x 16...

  • Page 5: 3- Installation Of The Machine

    3. INSTALLATION OF THE MACHINE Before use Several checks are necessary before using the unit to ensure good performance of the machine: Check the electrical line voltage: it should be between 200V and 240V, 3 phases, with a 40A delayed circuit breaker, curve D (or aM type fuse).
  • Page 6 Filling the cooling tank GYS recommends that you use CORAGARD CS330 (or equivalent) cooling liquid in this cooling tank, for more information, visit the website: http://www.aqua-concept-gmbh.eu The use of other cooling liquids, and in particular standard cooling liquids, can lead to the accumulation of solid substances inside the cooling system (due to electrolysis), this will negatively impact the cooling efficiency, and possibly cause total obstruction of the system.

  • Page 7: 4- Product Operation

    4- PRODUCT OPERATION Key definition        allow modification of each parameter. sich die Werte ① key ändern oder auswählen; die + und – Tasten erhöhen bzw. _ This key is used to select the tool required: Clamp, verringern den ausgewählten Wert.

  • Page 8: Recommendations On The Use Of Welding Modes

    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 C

    Using the C pneumatic clamp - Tighten the C-clamp using the locking lever and check that the screw between the arm and the clamp is correctly tightened. - The clamping force is calculated by the machine, considering the force setting or the thickness of the sheets selected. CLAMP SETTING MODE key is used to enter the clamp adjustment mode.
  • Page 10 Before the weld: If the input air pressure is too low to reach the required electrode force, a warning will sound, and the machine will display the error message “Pressure too low”. Pressing the button for a second time will force the execution of the welding spot with the available air pressure.
  • Page 11 User programmed welding spots can be recalled by selecting USER in the list of car manufacturers. The welding spots can be programmed using the welding spot programming module in the GYSPOT software. AUTO Mode : The AUTO mode is optional and is configurable in the setup menu that is activated by pressing the mode key for 2 seconds (AUTO MODE : ON / OFF).

  • Page 12: Use A Gun

    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 and ENERGY modes can be also be disabled in this menu.

  • Page 13: Error Management

    Press for 2 seconds to revert back to standard mode. When highlighted, a parameter can be adjusted using the + and – keys. The  and  keys allow movement from one parameter to the next. Error Management Different events might cause the appearance of error messages. They can be classified in three categories: - General Warnings: i.e overheating, lack of electrode force or welding current, etc…...

  • Page 14: Welding Spot Counter

    Saving a report allows spot welding data to be stored on a memory card, in order to retrieve it at a later date e.g. on a computer. GYS supplies software called GYSPOT to read the SD card and the user manual.
  • Page 15 To erase the content of a report , it has to be To erase the report shown, press and the on screen by pressing "view" following message will be on the screen: When the warning image is displayed, press again and the report content will be erased. The warning image will disappear after 3 seconds.
  • Page 16 ♦ The page number is indicated top left. ♦ All the repair orders are saved in the file catalog.GYS. ♦ This file contains the total number of repair orders, the name of each repair order and the name of each user. There are a maximum of 100 repair orders.

  • Page 17: Sd Memory Card

    A program can be linked to a clamp and gun. The button will save the settings in the manual mode (intensity, time and pressure). The 20 memory slots are indicated by their identifier (when in use) or by the symbol « --- ». To enter an identifier, use the 4 buttons +,-, up and down arrow keys.

  • Page 18: Gyspot Software

    GYSPOT Software The software allows the user to edit and save the weld reports made by a GYSPOT equipped with a SD drive. The GYSPOT software can be installed from files present on the SD card. In the \GYSPOT V X.XX directory, double click on the INSTALL.EXE file, and follow the instructions to install the software on your PC.
  • Page 19 The other files are restricted to Car Manufacturer defined welding spots. It is possible to import downloaded Car manufacturer files from the GYS website (http://www.gys.fr). It is not possible to add, edit or delete a welding spot saved in a Car Manufacturer file.
  • Page 20 4.1/ Import a Car Manufacturer welding spot file Double click in the first column and highlight a car manufacturer name. 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.
  • Page 21 4.3/ Edit a welding spot programmed in the USER file In order to edit the parameters of a programmed welding spot, select a welding spot in the list and then edit the welding parameters. To validated the modifications, click on the button 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...

  • Page 22: 5- Use And Maintenance Precautions

    Generator maintenance The maintenance and repair of the generator should only be carried out by a GYS technician. Any repair/maintenance made to the generator by unauthorized personnel will invalidate the machine's warranty - GYS will not take responsibility for any incident or accident under these circumstances.

  • Page 23: Installation And Use Of The Gun

    Installation and use of the gun The gun and the earth clamp are optional. Ref: 051010 - Select the clamp adjustment mode in the menus, in order to stop the pump and the flow of cooling liquid. - Fix the earth cable on the removable electrode; put the clamp and tighten the lever. - Remove the arm from the top and put the gun cable instead of that one.

  • Page 24: Replacement Of C Arms

    Replacement of C arms Please read the following instructions carefully. Incorrectly tightening or setting the C clamp arms can lead to the arm and clamp overheating and causing damage. Damage caused by incorrect assembly are not covered under the warranty ...

  • Page 25: Adjustment Of C Arms

    Adjustment of 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. Ⓔ - Tighten the lever manually and check it is not end up against the joint stop (see diagram below). Ⓓ.
  • Page 26 C clamp overhaul: The tightening of the following screws need to be inspected every month: Screw between the arm and the clamp: These 4 screws fix the arm to the clamp. They need to be tightened to have a good transmission of the current.
  • Page 27 Arm types for the C clamp: Spot control Consumables...

  • Page 28: Symptoms / Reasons / Solutions

    6. SYMPTOMS / REASONS / SOLUTIONS SYMPTOMS REASONS SOLUTIONS The caps used are worn Replace the caps out/faulty Insufficient grinding / Sand and clean the metal The Spot weld doesn’t hold / preparation of the workpiece sheet again is not good The arm selected doesn’t Check the arm with the match the one installed...

  • Page 29: Declaration Of Conformity

    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...

  • Page 30: Circuit Diagram

    9 - CIRCUIT DIAGRAM...

  • Page 31: Cooling Liquid Circuit

    10 – COOLING LIQUID CIRCUIT 11 – CLAMP CABLE BEAM CONNECTIONS...

  • Page 32: Technical Specifications

    12 – Technical specifications ELECTRICAL CHARACTERISTICS Nominal input voltage : U1N 3~200V 3~208V 3~230V 3~240V Frequency 50/60 Hz Permanent input current : I1N 40 A Power at 50 % duty cycle : S50 20 kVA Permanent input power : Sp 14 kVA Maximum welding input power : Smax 80 kVA...

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