GYS 230 Arc Welding Battery Chargers and Body Repair Instruction Manual

Arc Welding Battery Chargers and Body Repair
Instruction Manual

G-SPOT EXPERT
200 / 230 / 400

GENERAL INSTRUCTIONS

Read and understand the following safety instructions before use.
Any modification or maintenance not specified in the instructions manual should not be undertaken.
The manufacturer is not liable for any injury or damage due to non-compliance with the instructions featured in this manual. In the event of problems or uncertainties, please consult a qualified person to handle the installation properly.
These instructions cover the material in the condition it was delivered. It is the responsibility of the user to carry a risk analysis in case the instructions are not followed.

ENVIRONMENT

This equipment must only be used for welding operations in accordance with the limits indicated on the descriptive panel and/or in the user manual. Safety instructions must be followed. In case of improper or unsafe use, the manufacturer cannot be held liable.
This equipment must be used and stored in a room free from dust, acid, flammable gas or any other corrosive agent. The same rules apply for storage. Operate the machine in an open, or well-ventilated area.

Operating temperature:
Use between -10 and +40°C (+14 and +104°F).
Storage between -20 and +55°C (-4 and 131°F).
Air humidity:
Lower or equal to 50% at 40°C (104°F).
Lower or equal to 90% at 20°C (68°F).
Altitude:
Up to 1000 meters above sea level (3280 feet).

PROTECTION OF THE INDIVIDUALS

Resistance welding can be dangerous and cause serious injuries or even death. It needs to be used by a qualified technician with training relevant to the machine.
Welding exposes the user to dangerous heat, arc rays, electromagnetic fields, the risk of electric shock, noise, and gas fumes. People wearing pacemakers are advised to consult a doctor before using the welding machine.
To protect oneself as well as others, ensure the following safety precautions are taken:

| In order to protect you from burns and radiation, wear clothing without turn-ups or cuffs. These clothes must be insulating, dry, fireproof, in good condition, and cover the whole body.
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| Wear protective gloves which guarantee electrical and thermal insulation.
| Use sufficient welding protective gear for the whole body: hood, gloves, jacket, trousers… (varies depending on the application/operation). Protect the eyes during cleaning operations. Contact lenses are prohibited during use.
It may be necessary to install fireproof welding curtains to protect others against arc rays, weld spatters, and sparks.
Ask people around the working area to look away from the arc or the molten metal, and to wear protective clothing.
| Ensure ear protection is worn by the operator if the work exceeds the authorized noise limit (the same applies to any
person in the welding area).
Stay away from moving parts (e.g. engine, fan…) with hands, hair, clothes, etc…
****| Parts that have previously been welded will be hot and may cause burns if manipulated. During maintenance work on the torch or the electrode holder, you should make sure it’s cold enough and wait at least 10 minutes before any intervention. When using a water-cooled torch, make sure that the cooling unit is switched on to avoid any burns caused by the liquid.
It is important to secure the working area before leaving to ensure the protection of property and the safety of others.

WELDING FUMES AND GAS

| Fumes, gas and dust produced during welding are hazardous to health. It is mandatory to ensure adequate ventilation and/or extraction to keep fumes and gas away from the work area. Using an air-fed welding helmet is recommended in case of insufficient ventilation in the workplace.
Check that the air supply is effective by referring to the recommended safety regulations.
Precautions must be taken when welding in small areas, and the operator will need supervision from a safe distance. In addition, the
welding of certain materials containing lead, cadmium, zinc, mercury or beryllium may be particularly harmful.
Also, remove any grease on the metal pieces before welding. Do not weld in areas where grease or paint is stored.
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FIRE AND EXPLOSION RISKS

Protect the entire welding area. Flammable materials must be moved to a minimum safe distance of 11 meters.  A fire extinguisher must be readily available near the welding operations. Be careful of spatter and sparks, even through cracks. It can be the source of fire or explosion. Keep people, flammable materials/objects, and containers that are under pressure at a safe distance.

Welding in closed containers or pipes should be avoided and, if they are opened, they must be emptied of any flammable or explosive material (oil, fuel, gas …).
Grinding operations should not be carried out close to the power supply or any flammable materials.

ELECTRICAL SAFETY

The electrical mains used must have an earth terminal. An electric shock could cause serious injuries or potentially even deadly accidents.

Never make contact with live parts inside or outside the current source (cables, electrodes, arms, guns…) as they are connected to the welding circuit.
Before opening the device, it is imperative to disconnect it from the mains and wait 2 minutes, so that all the capacitors are discharged. Damaged cables and torches must be changed by a qualified and skilled professional. Make sure that the cable cross-section is adequate with the usage (extensions and welding cables). Always wear dry clothes which
are in good condition in order to be isolated from the welding circuit. Wear insulating shoes, regardless of the workplace/environment in which you work in.

EMC CLASSIFICATION

| This Class A machine is not intended to be used on a residential site where the electric current is supplied by the domestic low-voltage power grid. There may be potential difficulties in ensuring electromagnetic compatibility at these sites, due to conducted interferences as well as radiation.
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| This equipment does not comply with IEC 61000-3-12 and is intended to be connected to domestic low-voltage systems interfacing with the public supply only at the medium- or high-voltage level. If it is connected to a public low- voltage power grid, the installer or user of the machine has to ensure, by checking with the network operator, that the device can be connected.
GYSPOT EXPERT 200| This equipment complies with IEC 61000-3-11 if the power supply network’s impedance at the electrical installation’s connection point is inferior to the network’s maximum admissible impedance Zmax = 0,153 Ohms.
GYSPOT EXPERT 230| This equipment complies with IEC 61000-3-11 if the power supply network’s impedance at the electrical installation’s connection point is inferior to the network’s maximum admissible impedance Zmax = 0,130 Ohms.
GYSPOT EXPERT 400| This equipment complies with the IEC 61000-3-11 standard.

ELECTROMAGNETIC INTERFERENCES

The electric currents flowing through a conductor cause electrical and magnetic fields (EMF). The welding current generates an EMF around the welding circuit and the welding equipment.
The EMF electromagnetic fields can interfere with certain medical implants, such as pacemakers. Protection measures must be taken for people having medical implants. For example, access restrictions for passers-by or an individual risk evaluation for the welders.

Each welder must follow the procedures below in order to minimize exposure to electromagnetic generated by the welding circuit:

• position the welding cables together – strap them if possible;
• keep your head and top half of the body as far from the welding circuit as possible;
• never enroll the cables around your body;
• never position your body between the welding cables. Hold both welding cables on the same side of your body;
• connect the earth clamp as close as possible to the area being welded;
• do not work too close to, do not lean, and do not sit on the welding machine
• do not weld when you’re carrying the welding machine or its wire feeder.

**** People wearing pacemakers are advised to consult their doctor before using this device.
Exposure to electromagnetic fields while welding may have other health effects which are not yet identified.

RECOMMENDATIONS FOR EVALUATING THE WELDING AREA AND INSTALLATION
Miscellaneous
The user is responsible for the correct installation and usage of the welding material based on the instructions supplied by the manufacturer. If electromagnetic disturbances are detected, it is the user’s responsibility to resolve the situation with the manufacturer’s technical assistance. In some cases, this corrective action may be as simple as earthing the welding circuit. In other cases, it may be necessary to construct an electromagnetic shield around the welding power source and around the entire piece by fitting input filters.
In all cases, electromagnetic interferences must be reduced until they are no longer inconvenient.

Welding area assessment
Before installing the machine, the user must evaluate the possible electromagnetic problems that may arise in the area where the installation is planned. The following must be taken into account:
a) the presence (above, below, and next to the arc welding machine) of other power cables, remote cables and telephone cables;
b) television transmitters and receivers;
c) computers and other hardware;
d) critical safety equipment such as industrial machine protections;
e) the health and safety of the people in the area such as people with pacemakers or hearing aids;
f) calibration and measuring equipment;
g) the isolation of other pieces of equipment which are in the same area.
The user has to ensure that the devices and pieces of equipment used in the same area are compatible with each other. This may require extra precautions;
h) the time of day during the welding or other activities that have to be performed.

The surface of the area to be considered around the device depends on the building’s structure and other activities that take place there. The area taken into consideration can be larger than the limits of the installations.
Review of the welding installation
Reviewing the welding installations can be useful to determine and resolve any case of electrical disturbances. The assessment of emissions must include in situ measurements as specified in Article 10 of CISPR 11. In situ measurements can also be used to confirm the effectiveness of mitigation measures.

RECOMMENDATION ON METHODS OF ELECTROMAGNETIC EMISSIONS REDUCTION
a. National power grid: The arc welding machine must be connected to the national power grid in accordance with the manufacturer’s recommendation. In case of interferences, it may be necessary to take additional precautions such as the filtering of the power supply network. Consideration should be given to shielding the power supply cable in a metal conduit or equivalent of permanently installed arc welding equipment. It is necessary to ensure the electrical continuity of the shielding along its entire length. The shielding should be connected to the welding current’s source to ensure good electrical contact between the conduct and the casing of the welding current source.
b. Maintenance of the arc welding equipment: The arc welding machine should be subject to a routine maintenance check according to the recommendations of the manufacturer. All accesses, service doors, and covers should be closed and properly locked when the arc welding equipment is on. The arc welding equipment must not be modified in any way, except for the changes and settings outlined in the manufacturer’s instructions.
c. Welding cables: Cables must be as short as possible, close to each other, and close to the ground, if not on the ground.
d. Equipotential bonding: consideration should be given to bonding all metal objects in the surrounding area. However, metal objects connected to the workpiece increase the risk of electric shock if the operator touches both these metal elements and the electrode. It is necessary to insulate the operator from such metal objects.
e. Earthing of the welded part: When the part is not earthed – due to electrical safety reasons or because of its size and its location (which is the case with ship hulls or metallic building structures), the earthing of the part can, in some cases but not systematically, reduce emissions It is preferable to avoid the earthing of parts that could increase the risk of injury to the users or damage other electrical equipment. If necessary, it is appropriate that the earthing of the part is done directly, but in some countries that do not allow such a direct connection, it is appropriate that the connection is made with a capacitor selected according to national regulations.
f. Protection and shielding: The selective protection and shielding of other cables and devices in the area can reduce perturbation issues. The protection of the entire welding area can be considered for specific situations.

TRANSPORT AND TRANSIT OF THE WELDING MACHINE

The welding source is fitted with a handle or strap to make it transportable by hand. Be careful not to underestimate the weight of the machine. The handle or strap is not designed to be used to hang the machine to something else.
Do not use cables or torches to move the machine.
Do not place/carry the unit over people or objects.

EQUIPMENT INSTALLATION

• Provide an adequate area to ventilate the machine and access the controls.
• Do not use in an area with conductive metal dust.
  • Power cables, extension leads, and welding cables must be fully uncoiled to prevent overheating.

The manufacturer does not accept any liability in relation to damages caused to objects or harm caused to persons as the result of incorrect and/or dangerous use of the machine.

MAINTENANCE

• The operators must have received suitable training in order to use the machine at its maximum potential and weld correctly.
• Check which welding process is authorized by the manufacturer before attempting any vehicle repair.
• The maintenance and the repair of the. Any work undertaken by a third party on the generator will invalidate the warranty. The manufacturer will not accept liability in the event of an incident that would occur after this work was undertaken.
• Ensure the machine is unplugged from the mains, and wait for two minutes before carrying out maintenance work. Inside, voltages and currents are high and dangerous.
• All the welding tools will wear off with use. Ensure that these tools are clean to get the best results.
• Prior to using the gun, check the condition of the different tools (star, single-sided electrode, carbon electrode…) and clean or replace them if required.
• Remove regularly the casing and any excess dust. Take this opportunity to have the electrical connections checked by a qualified person, with an insulated tool.
• Regularly review the condition of the power cable and welding connection cables. In case of visible signs of damage, organize for them to be replaced by the manufacturer or a qualified technician.
• Ensure the vents of the device are not blocked to allow adequate air circulation.

INSTALLATION – PRODUCT OPERATION

PRODUCT IDENTIFICATION

At the back of the product, there is an identification plate on which the CE marking is affixed as well as the following instructions:

• Name and address of the manufacturer
• Date of manufacture
• Model
• Product Type
• Operating Voltage

This information must be specified for each maintenance intervention, or if spare parts are requested.

GENERAL DESCRIPTION

The GYSPOT EXPERT has been designed to undertake the following car body operations :
– Dent pulling,
– Welding of nails, rivets, rings, and pins,
– removal of bumps and dents,
– sheet stretching.
It is not designed for the assembly of metal parts. This device is delivered with :
– an earth clamp,
– two guns (1 with trigger, 1 without trigger) with cable and a quarter turn connector,
– a consumables and accessories box,
– a mains cable.

POWER SUPPLY (I P.51)
G-SPOT EXPERT 230
This equipment is supplied with a 16 A CEE7/7 type socket and must only be used on a single-phase 230 V (50-60 Hz) 3-wire electrical installation with an earthed neutral.
G-SPOT EXPERT 200
Supplied without a plug. Single phase power supply 200V to 240V, 50-60Hz. Use of PH (1), NEUTRAL (2), and EARTH (PE). Circuit breaker 30A delayed D curve.
G-SPOT EXPERT 400
400 V two-phase power supply 50-60 Hz. Use of PH (1), PH 2 (2), and EARTH (PE). Circuit breaker 16A delayed D curve or 16A fuses type aM.
NB: If the product trips the circuit breaker, please check that the correct fuse and an adequate circuit breaker are being used.

PRODUCT SPECIFICATIONS

THERMAL SPECIFICATIONS

OPERATING AND SETTINGS (III P.51)

1. Connect the machine to an appropriate power supply.

2. Connect the gun (or the guns) with the connectors.
   The trigger gun has, in addition to the power connector, a trigger control connector. Connect the latter to initiate using the trigger

3. Turn the breaker (1) to ON. (ON switch on the front panel on the EXPERT 230)

4. For the first use :
   • The indicators switch on for a few seconds then the machine automatically switches to SYNERGIC mode (8) It indicates :
   – the tool (2): set on 1 by default (star welding or use the hollow pulling clamp).
   – the power level (3): set on 2 by default (setting adapted for 0.8mm steel sheets).
   • To use the MANUAL mode (9), press the button (10).
   The SYNERGIC mode gives the user recommended factory settings for each tool used on a given sheet thickness.
   The MANUAL mode allows the user to choose his own types of settings, without the tool connected being taken into account, by selecting the desired power and point time.

5. Depending on the mode is chosen, SYNERGIC or MANUAL, change the settings as follows :
   – To change the tool, press on the arrows (5). – (Accessible in SYNERGIC mode only).
   1 Dent pulling work using the inertia hammer, sparks, or hollow pulling clamp.
   2 Crimped welding wire or rings for straightening works.
   3 Impacts beating with a specific copper nozzle.
   4 Carbon shrinking electrode.
   5 Welding rivets for side rods.
   6 Welding rings to connect the earth.
   7 Welding studs to connect the earth connection cables
   – To change the power level, press on the arrows (6). The power levels available allow the straightening of sheets of varying thicknesses.Power level| L| 1| 2| 3| 4| 5| 6| 7| 8| 9| H
   ---|---|---|---|---|---|---|---|---|---|---|---
   Metal sheet thickness (mm)| 0,6| 0,7| 0,8| 0,9| 1,0| 1,1| 1,2| 1,3| 1,4| 1,5| 1,6

– To change the point time, press on the narrow (7). – (Accessible in MANUAL mode only).

6. By using the button (13), select the type of ignition (cf. ignition part) :
   – indicator 11 ( ) indicate the use of a trigger gun.
   – indicator 12 ( ) indicates the use of an automatic trigger.

7. Follow the instructions to perform the welding point(s).

8. After the first use, the GYSPOT EXPERT will light up each time the machine starts on the previous settings. It also records the setting of the last weld point made for each tool and gun.

USE INSTRUCTIONS (III P.51)

Operation
Follow the process:

1. Connect the earth clamp of the generator to the sheet metal to be straightened and follow the instructions below:
   • Connect it as close as possible to the place to be welded.
   • Do not connect it to a different part of the car body (example: Do not connect it on the door when working on the wing).
   • Ensure the metal has been properly stripped at the connection point.

2. Strip clean the area where the work is to be performed.

3. Attach the required tool to the end of the gun, tightening the nut firmly.

4. Select the tool and the power (cf. startup part).

5. Create contact between the gun tool and the metal (cf. ignition part).

6. Perform your welding spot.

Ignition
The GYSPOT EXPERT 200 / 230 / 400 is supplied with 2 ignition systems:
Manual mode (using the trigger)

1. Plug the power connector and the command connector connected,
2. Press the ignition select button (13) until to turn the LED on (11- ).

The automatic mode does not work anymore, only one pressure on the trigger allows the welding point.

Automatic mode

1. Plug the power connector,
2. Press the ignition select button (13) until to turn the LED on (12 – ).

The machine is able to create the welding arc automatically.
The generator automatically detects the electrical contact and creates the welding arc in less than 1 second. To create a new arc, stop the contact with the gun tip for at least ½ second and establish contact again to form another arc.

For optimum operation, it is recommended to use the earth cable and guns originally supplied.

THERMAL PROTECTION

The machine is provided with an automatic thermal protection system. This system will stop the machine to prevent it from overheating. The thermal fault indicator will light up if this is the case(fig.3 – 14).

WARRANTY

The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labour).
The warranty does not cover:

• Transit damage.
• Normal wear of parts (eg. : cables, clamps, etc..).
• Damages due to misuse (power supply error, dropping off equipment, disassembling).
• Environment-related failures (pollution, rust, dust).
  In case of failure, return the unit to your distributor together with:
  – The proof of purchase (receipt etc …)
  – A description of the fault reported

GYSPOT EXPERT 200 / 230 / 400

SPARE PARTS

Automatic Quick gun (réf. 059207)

N°| |
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1| Holding screw| 41031
2|  Hose plate| 98920
3| Wire guide hole| 56145
4| Gun casing| 56144
5|  Texas connector| 51460
6| Hose clamp for Quick Gun| 51199ST
7| Quick Gun with a hose clamp| 57531

Manual Quick gun (réf. 057524)

N°| |
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1| Holding screw| 41031
2|  Hose plate| 98920
3|  Wire guide hole| 56027
4|  Gun casing| 77049
5| Trigger| 56029
6| TEXAS plug| 51460
7| Connector| 51137
8| Hose clamp for Quick Gun| 51199ST
9| Quick Gun with a hose clamp| 57531

SYMBOLS

| Warning! Read the user manual before use
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| Alternating welding current
**A**| Amperes
**V**| Volt
**Hz**| Hertz
|  Rated power supply voltage
| Permanent power (at a 100% duty cycle)
| Alternative no-load voltage
| The maximal current of a second short circuit
|   Permanent current to secondary
**M**| Mass of the machine
| / Product in compliance with European directives, The EU declaration of conformity is available on our website (see cover page).
| – Equipment in conformity with Moroccan standards. The declaration Cم (CMIM) of conformity is available
on our website (see cover page).
ISO 669:2016| ISO 669.
| Ne pas jeter dans une poubelle domestique !
| This product should be recycled appropriately
| EAEC Conformity marking (Eurasian
Economic Community).
| – Equipment in compliance with British requirements. The British Declaration of Conformity is available on
our website (see home page).
| Information zur Temperatur (Thermoschutz)
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CIRCUIT DIAGRAM

GYSPOT EXPERT 200

GYSPOT EXPERT 400

GYSPOT EXPERT 230

GYS SAS
1, rue de la Croix des Landes
CS 54159
53941 SAINT-BERTHEVIN Cedex

Documents / Resources

| GYS 230 Arc Welding Battery Chargers and Body Repair [pdf] Instruction Manual
230, 400, 200, Arc Welding Battery Chargers and Body Repair, 230 Arc Welding Battery Chargers and Body Repair, Welding Battery Chargers and Body Repair, Battery Chargers and Body Repair, Body Repair
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