GYSFLASH 8.12 PL Arc Welding Battery Chargers and Body Repair Instructions

: June 14, 2024
: GYS

Table of Contents

SAFETY INSTRUCTIONS
GENERAL DESCRIPTION
START UP
CHARGE MODES
DEFECTS: CAUSES & SOLUTIONS
WARRANTY CONDITIONS
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

GYSFLASH 8.12 PL Arc Welding Battery Chargers and Body Repair Instructions

SAFETY INSTRUCTIONS

This user’s manual includes operation instructions, and the safety precautions to be followed by the user. Please read it carefully before first use and keep it for future reference. This machine should only be used for charging within the specifications indicated on the machine and in the instruction manual. The safety instructions must be followed. The manufacturer cannot be held responsible in the event of improper or dangerous use.

This unit can be used by children aged eight or over, by people with reduced physical, sensory or mental capabilities as well as by those with a lack of experience or knowledge. However, these aforementioned persons must be properly supervised and they must have read and understood the user instructions, alongside having been made aware of the risks. Children must not play with the product. Cleaning and maintenance should not be performed by an unsupervised child.

Do not use to charge domestic batteries or non rechargeable batteries.

Do not use the charger if the mains cable or plug is damaged.

In order to avoid short-circuiting the battery, do not use the appliance if the charging cable is damaged or has an assembly defect.

Never charge a frozen or damaged battery.

Do not cover the device.

The automatic operating mode and the relevant usage restrictions are explained later in this manual.

Fire and explosion risks!

A charging battery can emit explosive gases.

During the charge, the battery must be placed in a well ventilated area.
Avoid flames and sparks. Do not smoke near the device.
Protect the electrical contact surfaces of the battery against short circuits.

Do not leave a charging battery unattended for a long time

Risk of acid dispersion!

Wear protective goggles and gloves.
In case of contact with the eyes or the skin, rinse with water abundantly and see a medical doctor as soon as possible.

Connection / disconnection :

Disconnect the power supply before plugging or unplugging the connections to/from the battery.
Always ensure the Red clamp is connected to the «+» battery terminal first. If it is necessary to connect the black clamp to the vehicle chassis, make sure it is a safe distance from the battery and the fuel/exhaust pipe. The charger must be connected to the power supply.
After charging, disconnect the charger from the mains, then disconnect the negative clamp from the car body and then disconnect the positive clamp from the battery, in this order.

Power supply:

Class II equipment
This equipment complies with standard IEC 61000-3-12.
This equipment complies with standard IEC 61000-3-11.

Maintenance:

If the power cable is damaged, it must be replaced by the manufacturer, its after-sales service, or an equally qualified person to prevent possible danger.
Maintenance should only be carried out by a qualified person.
Warning!
Always disconnect from the mains before carrying out maintenance on this machine.
If the internal fuse has blown, it must be replaced by the manufacturer, the service department or a similarly qualified person in order to avoid a safety hazard.
Do not use solvents or any aggressive cleaning products.
Clean the surfaces of the unit with a dry cloth.

Regulations:

Equipment complies with European directives
The Declaration of Conformity is available on our website.
The Eurasian Economic Community (EAEC) mark of conformity.
This equipment conforms to UK requirements. The UK Declaration of Conformity is available on our we- bsite (see cover page).
This device complies with Moroccan standards.
The Cم) CMIM) declaration of conformity is available on our website.

Disposal:

This machine is subject to selective collection. Do not dispose of in domestic waste.

GENERAL DESCRIPTION

The GYSFLASH 8.12 PL is ideal for recharging most lead-acid (Gel, AGM, Liquid, …) and Lithium Iron Phosphate (LFP / LiFePO4) batteries, commonly used for motorbikes, cars, utility vehicles and small agricultural machines..

This charger is ideally suited for:

Charging of 12 V lead-acid batteries (6*2 V cells in series) from 15 Ah to 160 Ah, and up to 240 Ah for float charging.
Recharging of 12V Lithium Iron Phosphate batteries (4*3V cells in series) from 1.2 Ah to 160 Ah, and up to 240 Ah for float charging.

START UP

Connect the charger to the battery using the proper accessory (clamps, lugs, etc…).
Plug the charger to the mains (single phase 220-240Vac 50-60Hz).
Charger operation:

Button	Action	Selection	LED

| long press (3 s)| Change mode.| Lead-acid| Pb
Lithium| Lithium
short press| Change the charging current and access|
the AGM option in Lead mode.
In Lead-acid mode:| 1 A| 1A
| +| Pb
8 A| 8A
| |
| +| Pb
1A – AGM| 1A
| +| Pb
8A – AGM| 8A
| |
| +| Pb
In Lithium mode:| 4 A| 4A
| +| Lithium
8 A| 8A
| +| Lithium

After about five seconds without pressing the button, charging starts automatically.
During the charge, the device indicates the charge progress. When the light flashes, the battery is ready to start the engine. Once the indicator stays on, the battery is completely charged.
Charging can be stopped at any time by unplugging the mains plug or by pressing the button .
After the charge is complete, disconnect the charger from the mains, then disconnect the clamps from the battery.

CHARGE MODES

Description of Modes and Options:

CHARGE mode Lead (14.4V / 1A – 8A) :
Mode designed for lead-acid batteries, 12V from 15Ah to 160Ah and up to 240Ah for floating charge.
Automatic seven step charge cycle.

COLD/AGM Option (14.7 V) :
Modifies the charging voltage at 14.7V to charge the battery during cold weather (Less than 5°C) or for some AGM batteries or batteries with caps.

Charge mode Lithium (14.4V / 4A – 8A) :
Mode designed for 12V Lithium batteries, from 1.2Ah to 160Ah and up to 240Ah for floating charge. Automatic charging cycle in eight steps.

Some Lithium batteries incorporate a UVP protection (Under Voltage Protection) which disconnects the battery in case of deep discharge. This protection prevents the charger from detecting the battery. In order for the Gysflash 8.12 PL to be able to charge the battery, the UVP protection must be deactivated. To do this, set the charger to Lithium charging mode and then unplug it. Press the button while plugging the Gysflash back in and hold it down for 5 seconds after the charger is turned on. The charger will then deactivate the UVP protection and automatically start charging

Charging current:

1A 4A 8A: Selection designed to choose the most suited charging current based on the type and size of the battery (lead-acid or lithium).

Charging current		1 A	4 A	8 A
Battery capacity	Pb	15 50Ah	–	50 160Ah
LFP	–	1.2 20Ah(36 60Ah EqPb*)	20 160Ah(60 480Ah EqPb*)

*Lead-acid battery equivalent : Lithium batteries have better starting performance (CCA) than lead-acid batteries. This is why some lithium battery manufacturers indicate the lead battery equivalent (EqPb) corresponding to the capacity of a lead-acid battery with the same starting performance. For instance, a 10Ah LFP battery will have approximately the same starting performance as a 30 Ah lead-acid battery.

Lead-acid charge curve:
The Gysflash 8.12 PL uses an advanced 7-step lead-acid charging curve that ensures optimal performance of your lead-acid battery.

Step 1 : Analysis
Analysis of the battery status (level of charge, reverse polarity, incorrect battery connected…)
Step 5 : Charge (1A – 8A)
Fast charge at maximum current to reach 80% charge level.
Step 2 : Recovery (0.5A – 3A)
Recovering damaged elements following a prolonged deep discharge.
Step 6 : Absorption (14.4V or 14.7V with AGM option)
Constant voltage load to bring the charge level to 100%.
Step 3 : Test
Sulfated battery test
Step 7 : Maintenance charge (13.6 V)
Maintaining the battery charge level at maximum.
Step 4 : Desulphation (15.8V)
Battery desulphation process.

Lithium charging curve:
The Gysflash 8.12 PL uses an advanced 8-stage Lithium charging curve that ensures optimal performance of your LFP battery

Step 1 : Analysis
Analysis of the battery status (level of charge, reverse polarity, incorrect battery connected…)
Step 5 : Test
Charge retention test
Step 2 : Recovery (0.2A – 1A)
Recovery process after deep discharge.
Step 6 : Completion
Reduced current charging to reach 100% level of charge.
Step 3 : Charge (4A – 8A)
Fast charge at maximum current to reach 90% charge level.
Step 7 : Equalization / balancing (14.4V)
Balancing the battery cells
Step 4 : Absorption (13.8V)
Constant voltage load to bring the charge level to 98%.
Step 8 : Maintenance charge (13.8V)
Maintain the battery charge level at its maximum with maintenance charging every 10 days.

Estimated charge time

| Lead-acid| Lithium
---|---|---
Battery capacity| 2Ah| 5Ah| 50 Ah| 100 Ah| 120 Ah| 160 Ah| 2Ah(6Ah EqPb)| 15 Ah(45Ah EqPb)| 50 Ah(150Ah EqPb)| 70 Ah(210Ah EqPb)| 125 Ah(375Ah EqPb)| 160 Ah(480Ah EqPb)
Charge time 0% >> 90%| 2 h| 3 h| 5 h| 9 h| 11 h| 14 h| 1 h| 3 h| 5 h| 6 h| 11 h| 14 h

Lead acid battery equivalent: Lithium batteries have better starting performance (CCA) than lead-acid batteries. This is why some
lithium battery manufacturers indicate the lead battery equivalent (EqPb) corresponding to the capacity of a lead-acid battery with
the same starting performance. For instance, a 10Ah LFP battery will have approximately the same starting performance as a 30
Ah lead-acid battery.

If the motorcycle is equipped with a 12V socket, the GYSFLASH 8.12 PL is able to charge the battery via this socket with the CAN-BUS system, without having to switch on the dashboard. In this setup, connect the cigratte lighter adapter (ref. 077331) on the charger and the 12 V socket of the motorcycle and then follow the «Start-up» procedure detailed above. In some cases, charging may not start until 2 minutes after the connections have been made.

Protections :

The GYSFLASH 8.12 PL has comprehensive safety features to protect it against short-circuits and polarity reversals. It has an anti-spark feature which prevents sparks whilst connecting the device to the battery. This charger has double insulation and is safe to use with the battery in situ as it will protect the vehicle’s on-board electronics.

The GYSFLASH 8.12 PL is fitted with an integrated temperature sensor that ensures that the charging current is adapted to the ambient temperature to prevent internal the electronics from overheating.

DEFECTS: CAUSES & SOLUTIONS

| Troubleshooting| Causes| Solutions
---|---|---|---
**** 1| The indicator blinks rapidly.|

Polarity reversal
Battery voltage too high
Short-circuited clamps

|

Check that the clamps are properly connected.
Check that it is a 12V battery.

WARRANTY CONDITIONS

The warranty covers any defects or manufacturing faults for two years from the date of purchase (parts and labour).
The warranty does not cover:

Any other damage caused by transport.
The general wear and tear of parts (i.e. : clamps, etc.).
Incidents caused by misuse (incorrect power supply, dropping or dismantling).
Environment-related faults (such as pollution, rust and dust).
In the event of a breakdown, please return the appliance to your distributor, along with:
- a dated proof of purchase (receipt or invoice etc.). a note explaining the malfunction.

GYS France
Siège social / Headquarter
1, rue de la Croix des Landes – CS 54159
53941 Saint-berthevin Cedex
France
www.gys.fr
+33 2 43 01 23 60
service.client@gys.fr
GYS UK
Filiale / Subsidiary
Unit 3
Great Central Way
CV21 3XH – Rugby – Warwickshire
United Kingdom
www.gys-welding.com
+44 1926 338 609
uk@gys.fr
GYS GmbH
Filiale / Niederlassung
Professor-Wieler-Straße 11
52070 Aachen
Deutschland
www.gys-schweissen.com
+49 241 / 189-23-710
aachen@gys.fr
GYS Italia
Filiale / Filiale
Vega – Parco Scientifico Tecnologico di
Venezia
Via delle Industrie, 25/4
30175 Marghera – VE
Italia
www.gys-welding.com
+39 041 53 21 565
italia@gys.fr
GYS China
Filiale / 子公司
6666 Songze Road,
Qingpu District
201706 Shanghai
China
www.gys-china.com.cn
+86 6221 4461
contact@gys-china.com.cn
GYS Iberica
Filiale / Filial
Avenida Pirineos 31, local 9
28703 San Sebastian de los reyes
España
www.gys-welding.com
+34 917.409.790
iberica@gys.fr