GYSPACK PRO 800 Arc Welding Battery Chargers & Body Repair User Manual

** GYSPACK PRO 800
C73585 V7
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www.gys.fr
**

SAFETY INSTRUCTIONS

This manual contains safety and operating instructions, to be followed for your safety. Please read it carefully before using the device for the first time and keep it for future reference. Read and understand the following safety instructions before use. Any modification or updates that are not specified in the instruction’s 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.
If you have any problems or uncertainties, please consult a qualified person to handle the equipment correctly. This machine should only be used for starting and / or power supply operations comprised within the limits indicated on the machine and in the instruction manual. The operator must observe the safety precautions. In case of improper or unsafe use, the manufacturer cannot be held liable.
The device is destined to be used indoors. Must not be exposed to the rain.
This unit can be used by children aged 8 or over and by people with reduced physical, sensory or mental capabilities or lack of experience or knowledge, if they are properly monitored or if instructions for using the equipment have safely been read and risks made aware of. 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.
Never use on a frozen or damaged battery.
Do not cover the device.
Do not place the unit near a heat source/direct sunlight and durably high temperatures (above 50 ° C)
Risk of explosion or acid splash if the clamps are short-circuited or if the 12 V booster is connected to a 24 V vehicle.
Fire and explosion risks!
A charging battery can emit explosive gases.

• During the charge, the battery must be placed in a well ventilated area.

• Protect the battery’s electrical contact surfaces against shortcircuits

• Do not leave a battery being charged unattended for long periods of time.

• Never start a vehicle without a battery.
  Risk of acid dispersion!****

• Wear protective goggles and gloves.

• In case of contact with the eyes or the skin, rinse with water immediately and seek medical attention 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 starting, disconnect the booster from the power supply, then remove the frame connection and finally the battery connection, in the order shown.
  Connection:

• Class II device (for the charger).

• Class III device (for the GYSPACK 800).

• This device is equipped with a fuse protection

• The connection to the power supply must be carried out in compliance with national standards.
  Maintenance:

• If the power supply cable is damaged, it must only be replaced by a cable specified or supplied by the manufacturer or its aftersales service.

• Maintenance should only be carried out by a qualified person.

• Warning! Always disconnect from the mains before performing maintenance on the device.

• Do not use solvents or any agressive cleaning products.

• Clean the device’s surfaces with a dry cloth.
  Regulations:

• **** Equipment complies with European directives

• The compliance declaration is available on our website.

• EAEC Conformity marking (Eurasian Economic Community).

• **** Material complies with British requirements. The UK Declaration of Conformity is available on our website (see cover page).

• Device consistent with Moroccan standards.

• The Cم (CMIM) declaration of conformity is available on our website.
  Waste management::

• This product should be disposed of in an appropriate recycling facility. Do not throw away in a household bin.

• This device’s battery is recyclable. Please comply with the the applicable waste management laws.

GENERAL DESCRIPTION

Thanks to its integrated high-performance battery, the GYSPACK PRO 800 provides 3 functions:
– Battery test
– Instant start for vehicles equipped with a 12 V lead-acid or GEL battery (6-cell 2 V).
– 12 V DC power supply for spotlight, TV, tools, etc.
INTERNAL BATTERY CHARGING
Before handling, set the switch to “OFF”.
Charge the device immediately upon purchase and after each use via the external charger.
Do not use an external charger other than the one supplied with the product.
These devices are supplied with an external charger, double insulation, equipped with a floating system which maintains the internal battery fully charged without the need for monitoring.
Therefore, in order to maintain the charge level, the charging is automatically stopped and resumed and the charger can remain permanently connected to the mains.
To charge it up:

• Place the unit upright during charging to avoid the risk of acid leaks and destruction of the internal battery.
• Connect the charger to the 230 V mains, the LED on the block lights up green and the LED on the cigarette lighter lights up red
• Plug the cigarette lighter socket into the receptacle on the side of the unit.
• The LED on the block turns red when the cigarette lighter socket is properly connected and charging is in progress.
• The device is charged when this light turns green again.

USE IN STARTER MODE

Do not disconnect the battery fom the vehicle. Connecting the battery can lead to the vehicle’s memory loss and a potential impossibility to restart it.
The booster must be stored in a vertical position. Any other storage position should only be temporary.
To use the GYSPACK PRO 800 in start-up mode, the following cycle must be observed:

• Disconnect the GYSPACK PRO 800 from the mains. Turn the vehicle’s ignition key to “OFF”.

• Set the switch to OFF.

• In the event that the negative terminal is plugged onto the car’s chassis :
  – Connect the red clamp to the battery’s positive terminal.
  – Connect the black clamp to the vehicle’s chassis so that it is away from the fuel lines and battery.

• Some vehicles have the positive terminal plugged onto the car chassis, in this event :
  – Connect the black clamp to the battery’s negative terminal.
  – Connect the red clamp to the vehicle’s chassis, make sure it is a safe distance from the battery and the fuel/exhaust pipe.
  Warning: the cables must not be kinked or in contact with hot or sharp surfaces. .

• Set the switch to “ON” according to the vehicle to be started.

• Go to the vehicle control station and turn the ignition key (6 sec max). If the engine does not start, wait 3 minutes between each start attempt.
  – If the recommended time between each test is not observed (3 min) or if the test duration is too long (>6 seconds) the chances of starting are reduced (risk of power loss).
  – Risk of battery acid leaks or damage if the recommended periods are not observed.
  – If the vehicle does not start, there may be a problem other than a bad battery: alternator, glow plug…
  – Risk of explosion or acid splash when connecting the 12 V booster to a 24 V vehicle.
  – Danger if clamps are short-circuited.

• Position the switch «OFF».

• After use, if the negative pole of the battery is connected to the chassis:
  – Turn the switch to OFF and disconnect the black clamp and then the red clamp.

• In the event that the negative terminal is plugged onto the car’s chassis:
  – Turn the switch to OFF, disconnect the red clamp and then the black clamp.

• Recharge the GYSPACK PRO 800 after use (see charging section).

IN THE EVENT OF A PROBLEM

Some more modern vehicles, equipped with highly sensitive ECUs, will not start when using this product. The voltage drop caused by the starting current can potentially trigger ECU safety devices, and prevent the vehicle from starting.
USE AS A 12 V DC POWER SUPPLY
The cigarette lighter plug is protected by an integrated 10 A circuit breaker. In the event of an overheating due to an overcharge, the circuit breaker will stop the power supply.
This unit can be used as a 12 V DC power source for your electrical appliances such as radios, fans, power tools, cam- corders, etc.

• Set the switch to “OFF”.
• Insert the cigarette lighter cable from your electrical device into the receptacle (cable not supplied).

The output is protected by a 10 A thermal circuit breaker.
BATTERY TESTER
This device contains a built-in battery tester to view the charge status of both internal batteries. Use the test button located on the control panel. The result is displayed on the screen: if it is between 0 and 12 V, the battery is in critical condition. Above 12 V the battery is in a good state of charge.
PROTECTIONS
Your device has been designed with maximum protection:

• ON/OFF battery breaker protection against overvoltage when charger is connected to the mains.
• An audible alarm warns of polarity reversal in the event of an operating error.Sound alarm to alert the user in case of polarity reversal.
• The starter is equipped with 2 x 1.80 m copper cables, ø 25 mm² with insulated 600 A clamps.
• The GYSPACK PRO 800 is equipped with two 200 A fuses.
• The fuses can be replaced by removing this protective cover.

TROUBLESHOOTING

battery.
Polarity reversal.| Check the battery polarity.
The unit can not start the vehicle.| The switch is in the OFF position.| Set the switch to the ON position.
The unit can not start the vehicle. The internal battery voltage is lower than 12V.| The internal battery is discharged.| Charge the unit, and try again after the charge is complete.
Several jump start attempts without pause between each.| Wait 3 minutes between 2 starts. A start must not last more than 6 seconds.
The battery voltage is incorrect..| Check that the battery voltage of the vehicle is 12V.
The device can not start the vehicle anymore and the voltage battery is less than 8V or the display doesn’t work.| The voltage of the internal batteries is very low. It may be that the internal batteries are damaged.| Put the device on charge in order to attempt to recover the battery.
The internal battery is damaged and it cannot be recharged.| Contact the GYS after sale service to replace the battery.
The charge of the internal batteries does not start (the charge LED re- mains green when first connected to the mains).| The cigarette lighter plug is not correctly plugged to the socket of the machine.| Check the cigarette lighter connection.
The fuse of the cigarette lighter sock- et has melted.| Replace the fuse of the cigarette light-er socket by unscrewing its end.
The charger red LED flashes during the charge.| The internal battery is damaged and it cannot be recharged.| Contact the GYS after sale service to replace the battery.
After a day of charge, the end of charge indicator does not activate.| The internal batteries are damaged and cannot be recharged.| Contact the GYS after sale service to organise a replacement of the batteries.
In external 12V power source mode, the booster no longer delivers power.| The internal thermal protection cir- cult-breaker has cut the circuit.| Disconnect the external device connected to the machine and wait for the circuit-breaker to reset itself automatically.
The voltage display does not switch on.| The internal battery is discharged.| Charge the unit, and try again after
the charge is complete.

NO WARRANTY ON THE BATTERY

The battery is an operating element and its life depends on its maintenance. After each use of this start booster, it is imperative to charge the internal battery. Storage in places with high temperatures considerably reduces the life of the battery. In case of prolonged non-use, it is strongly recommended to recharge the battery before use. As a general rule, we recommend leaving the product connected at all times to keep the battery at peak performance.
This product is equipped with a high performance battery which, if not maintained properly, can deteriorate irreversibly over time.
As its preservation depends on its use, the battery of the GYSPACK PRO 800 is excluded from the warranty.

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 of 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

BATTERY REPLACEMENT:

Product| Battery| Type| Voltage (V)| Capacity (Ah)| Dimensions (cm)| Battery ref
---|---|---|---|---|---|---
GYSPACK PRO 800| 6-SPB-25| Lead acid battery| 12| 28| 20 x 14 x 16| 53140

To replace the battery :

• The booster must be disconnected form the power supply.

• Unscrew the back panel (10 screws) and remove it.

• Once the back panel is removed, the battery front appears (illustration). Remove the positioning belt 1

• The battery is connected to the GYSPACK at two points: at the + and – terminals. 2 3 To remove the battery, remove the 2 screws that enable the connection between the battery and the GYSPACK at the terminals + and -.
  When handing over a new battery, make sure that the polarity of the battery and the GYSPACK are matched.
  Terminal – on the left, terminal + on the right (illustration). Put the 2 screws and washers back on, tighten the nuts (recommended tightening torque of 4 Nm).

• Place the booster’s back panel screws back on.

SPARE PARTS

Brass terminal (x2)
SN > 23.02.)30DXICJO000a| 31348

CIRCUIT DIAGRAM

TECHNICAL SPECIFICATIONS

SYMBOLS

|  Keep away from flames and sparks. Do not smoke.
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| Warning, Danger of electric shock
| Do not let children handle the battery.
| This product should be recycled appropriately
< 50 dB| Noise level
| Charger connection plug

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

Documents / Resources

| GYS GYSPACK PRO 800 Arc Welding Battery Chargers & Body Repair [pdf] User Manual
GYSPACK PRO 800 Arc Welding Battery Chargers Body Repair, GYSPACK PRO 800, Arc Welding Battery Chargers Body Repair, Welding Battery Chargers Body Repair, Battery Chargers Body Repair, Chargers Body Repair, Body Repair, Repair
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