GYS V5 Plastic Welding Station Instruction Manual

GYS V5 Plastic Welding Station

Product Specifications :

• Electrical Power: 320 W
• Power Supply Voltage: 50 V
• Air Pump Capacity: 24 L/min

Product Usage Instructions

• Safety Instructions:
  When working with the plastic welding station, ensure to use protective clothing as plastic work can generate harmful dust or smoke. It is recommended to wear respiratory protection or ensure proper ventilation. Adequate air supply might be necessary in some cases.

• Maintenance:
  For maintenance, clean and degrease the damaged area before lightly sanding the plastic on a strip of 15 to 20 mm on each side of the tear to remove any paint or impurities.

Caution and Application:
The plastic welding station allows heating of plastics using a hot air flow. Follow these steps for application:

1. Power Supply: Connect the power cord to the station and plug it into an electrical outlet. Once connected, switch on the device.
2. Technical Features:
   • Electrical Power: 320 W
   • Power Supply Voltage: 50 V
   • Air Pump Capacity: 24 L/min
3. Repair: Clean and sand the area, identify the type of plastic, define heating temperature, and ensure a good connection between rod and support for effective welding.

Additional Tips:
After welding, remove the unit while the air is still hot. Cut the rod close to the welded part once it has cooled down. Allow the weld to cool to room temperature after completion. For restoring impact resistance, weld V-shaped or flat rods transversely to the crack.

Handle with Care:
During and after use, handle the welding gun with care to avoid severe burns.

FAQ :

• Q: How should I choose the heating temperature for different types of plastics?
  A: Identify the type of plastic, which is often engraved on the parts. Define the heating temperature according to the filler plastic and support material.

• Q: What should I do if new cracks appear during welding?
  A: Treat and weld the new cracks like any other. Ensure a good connection between the rod and support for effective welding.

PLASTIC WELDING STATION

SAFETY INSTRUCTIONS

• These instructions must be read and understood before any operation, and any modifications or maintenance not specified in the manual must not be carried out.
  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.

• 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 potential risks understood. Children must not play with the product. Cleaning and maintenance should not be performed by an unsupervised child.

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

Fire and explosion risks!

• Use caution when using the appliance in areas where combustible materials are present;
• Do not apply for a long time in the same place
• Do not use in the presence of an explosive atmosphere;
• Be aware that heat can be directed onto combustible materials that are out of sight;
• Place the unit on its stand after use and allow it to cool before storage;
• Do not leave the appliance unattended

Protections :

• To protect yourself and others, follow these safety instructions: Use eye protection
• Use gloves that guarantee thermal insulation.
• Use protective clothing
• Working on plastic can create dust or smoke that is dangerous to health. It is recommended to wear respiratory protection or to have adequate ventilation, air supply is sometimes necessary.
• Keep your body in balance and firmly on your feet. Repetitive work movements, unusual positions and exposure to vibration can be harmful to your hands and arms. In case of numbness, tingling, pain or pallor, stop using the tool and consult a doctor.

Connection :

• This unit must be connected to a socket outlet of current connected to the ground.
• This device is equipped with a fuse protection

Maintenance:

• If the power supply cable is damaged, it must be replaced by a cable or a special set, available from the manufacturer or its after sales team.
• 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 other aggressive cleaning products under any circumstances
• Clean the surfaces of the unit with a dry cloth.

Regulations :

• Device compliant with European directives.

Disposal :

• ****This product should be disposed of at an appropriate recycling facility. Do not throw away in a household bin.
• Equipment complying with Chinese requirements on the restricted use of hazardous substances in electrical and electronic products.

CAUTION
Ensure that you have removed the 4 transit screws under the unit before using it, otherwise the machine may be seriously damaged.

• This tool must be placed on a stable support when not in use.
• Using this unit recklessly might cause a fire.
• Use caution when using the unit in areas with combustible materials;
• Do not heat in the same place for a long time;
• Do not use in the presence of an explosive atmosphere;
• Heat can be transferred to combustible materials out of sight;
• Place the unit on a stable surface after use and allow it to cool before storage;
• Do not leave the unit unattended while it is on.

APPLICATION

This tool allows the heating of plastics via a hot air flow.

POWER SUPPLY

1. Connection
   Connect the power cord to the station and plug the other end into an electrical outlet.
   Once the connection is established, the device can be switched on.

2. Power supply switch
   The power switch is used to switch the plastic welding station on and off. The air control switch turns the LCD screen and the air flow rate on and off (there is a one-minute delay before it stops).

   • Turn the air control switch to ON before use. Turn on the unit by pressing ON (POWER switch).
   • The user can adjust the air flow and temperature.

3.  Air flow and temperature adjustment
   After adjusting the air flow and temperature control knob, wait for the temperature to stabilise for a short period of time. To adjust the temperature, refer to the table «Welding temperature».

4. Air flow
   Set the knob according to the surface to be heated. When the working temperature is above 450°C, the air flow control knob must be set on a higher setting than 4 or the machine might be damaged.

5. System de refroidissement automatique

   • When the work is finished, the user can do the following operations :
   • Set the temperature to 160°C, then set the air control switch to OFF; the display turns off. The delayed cooling function of the air pump continues to provide cooling for 1 minute. Set the knob to the OFF position.
   • Set the temperature to 160°C. Allow the air pump to run for 1 minute. Set the button to OFF.

6. Turn off the power switch
   If the unit is not used for a long period of time, unplug the unit.

Electrical power (W)| Power supply voltage (V)| Frequency (Hz)| Air pump| Capacity (L/min)| Hot air temperature
---|---|---|---|---|---
320 W| 220 – 240 VAC| 50| Diaphragm pump| 24 L/min| 160 – 480°C

REPAIR

1. Clean and degrease the damaged area, then lightly sand the plastic on a 15 to 20 mm strip on either side of the tear to remove paint and other impurities.
2.  Remove any risk of subsequent extension of the tears by drilling a Ø 3 mm hole at each end.
3.  A 90° angle «V» groove must be milled on the tear to a depth of 2/3 to 3/4 of the material thickness. Start milling the groove about 10 mm before the start of the tear and on a gentle slope so that the correct depth is reached at the beginning of the tear. Remove plastic peelings and sanding/milling residue from the groove with a sharp object (e. g. a cutter) and blow the surface to ensure a clean surface.
4.  Identify the type of plastic of the support (often engraved on the parts). Define the heating temperature according to the filler plastic and the support.
5. For a good start and a progressive filling of the chamfer, cut the bevel of the filler rod (in the shape of a «V»). Flat filler rods do not require any preparation. They will mainly be used for filling operations and reinforcement.
6. Heat the area of the support to be repaired with the gun previously assembled to temperature. As soon as its surface becomes «plastic» (slightly shiny, pasty, soft, never liquid). Bring the filler rod in contact with the support slightly before the chamfer. For a homogeneous weld, apply a constant vertical pressure of about 2-3 kg during melting.
7.  When the welding is finished, immediately remove the unit while air is hot. As soon as the rod has cooled down, cut the rod as close as possible to the welded part. A good connection between rod and support is obtained if a small and regular bead can be seen all along the weld on each side. New cracks, which were invisible on the surface, may appear during welding. They must be treated and welded like any other.
8.  Once the operation is complete, allow the weld to cool to room temperature. To restore the part’s original impact resistance, weld V-shaped rods (if a chamfer is milled as before) or flat rods approximately every 30 mm transversely to the crack.

During operation and after switching off the machine, the gun must be handled with care at the risk of severe burns.

ADVICE & CHARACTERISTICS OF PLASTICS

• It is essential to weld similar plastics. (PP, PP EPDM, ABS…) The versatility of PP and PP EPDM plastics also allows them to be used on PE plastic.
• The welding speed is controlled by the thickness of the materials (support and filler rods) and the temperature set.
• For a good fusion the support and the rod must be in the same state (pasty) at the time of welding.
• A successful weld has a slight flat and regular bead on both sides along its length.

Plastic recognition
The following experiment allows experienced welders to identify most plastics by their surface hardness. For others, and in the absence of a code engraved on the element, there is a safe and simple method of identification known as a «flame test». Light a chip of the material in question using a match or lighter, observe the flame and smell the smoke.

a candle and diffuses a waxy smell”

Polyamide| No smoke, stretchable into filaments, smells like burnt

horn.

Polycarbonate| Yellowish smoke with soot production, sweet smell.
ABS| Blackish smoke with soot flakes, sweet smell.

Welding temperature

PRECAUTIONS

Nozzle fitting

Do not press the nozzle and do not pull the edge of the nozzle with pliers. Do not overtighten the screw as this may deform the nozzle.
Thermal protector :

• For safety reasons, the power supply is automatically switched off if the unit exceeds a certain temperature.
• Once the temperature has dropped to a safe level, the power supply automatically resumes.
• Turn off the switch and cool the gun down. Then reduce the temperature setting or increase the air flow rate.
• Caution – high temperature operation :
• Do not use the appliance near gas, paper or other flammable materials.
• The air coming out of the gun is extremely hot, and can cause painful burns.
• Do not touch the heating pipe and do not allow the heated air to blow against the skin.
• Never drop or shake the unit abruptly.
• Warning ! The pipe contains quartz glass that can break if the device falls or is shaken violently.
• Do not disassemble the pump

TEMPERATURE DISPLAY

Change the temperature setting

1| Shows the actual temperature of air. Short press the “UP” / “DOWN” button to adjust the temperature by ±1℃. Long-

press the button to adjust it quickly.

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2| Symbol for airflow display.
3| Press the ℃/℉ button to change the temperature unit between ℃ and ℉.
4| When the actual temperature of the nozzle is lower than the setting, «HEAT ON» will display.
5| When the difference is more than ±10℃ between the actual and setting temperatures, «WAIT» will display. Wait until it

has disappeared.

6| When “ERROR” displays, there may be some problem with the system. Or the hot air gun is not correctly connected.
7| The airflow display bar shows the air volume, with air volume increasing from left to right. LO represents low airflow, and HI represents high airflow. The air control knob can adjust the air volume.

MAINTENANCE
After each welding operation, clean the nozzle using a wire brush. A resistant residue will easily be removed by increasing the heating to the maximum.

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

SYMBOLS

|

Warning! Read the user manual before use

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|  This machine is fuse-protected

| Protected against access to dangerous parts of solid bodies with a diameter of >12.5mm

|  Product in compliance with Europeans directives, The EU declaration of conformity is available on our website (see cover page).
|  CMIM : Moroccan Certification

|  Equipment in compliance with British requirements. The British Declaration of Conformity is available on our website (see home page).
| This product should be recycled appropriately

| / Für die Entsorgung Ihres Gerätes gelten besondere Bestimmungen
(sondermüll) gemäß europäische Bestimmung 2012/19/EU. Es darf nicht mit dem Hausmüll entsorgt
werden! / Dit materiaal moet gescheiden ingezameld worden, volgens de Europese richtlijn 2012/19/UE

| **** Equipment complying with Chinese requirements

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