GYS Gyspot Inverter PTI 400V
Instruction Manual
Product Overview
The GYS Gyspot Inverter PTI 400V is a professional-grade resistance spot welding machine designed for automotive body repair. It utilizes inverter technology for precise control and efficient welding of various sheet metals. The unit is equipped with advanced features for ease of use, safety, and optimal performance in demanding workshop environments.
Important Safety Instructions
General Precautions: Read and understand all instructions before use. Do not modify the device or perform maintenance not specified in the manual. Keep the manual for future reference. The manufacturer is not liable for injury or damage due to non-compliance with instructions. Consult a qualified person for any issues.
Environmental Conditions: Use only for welding operations within specified limits. Install in a dust-free, acid-free, gas-free environment. Ensure good air circulation. Operating temperature: -10 to +40°C. Storage temperature: -20 to +55°C. Humidity: ≤50% at 40°C, ≤90% at 20°C. Altitude: Up to 1000m.
Personal and Collective Protection: Welding can be dangerous. Use by qualified personnel only. Protect yourself and others from heat, sparks, electromagnetic fields (especially for pacemaker wearers), electric shock, noise, and fumes. Wear appropriate protective clothing (non-flammable, dry, insulating), gloves, and a welding mask/shield with adequate protection. Protect eyes during cleaning. Contact lenses are prohibited. Use fire-resistant curtains to protect surrounding areas.
Noise Protection: Use hearing protection if welding noise exceeds authorized limits.
Moving Parts: Keep hands, hair, and clothing away from moving parts (fan, electrodes).
Hot Surfaces: Welded parts are hot and can cause burns. Allow parts and equipment to cool before handling. In case of burns, rinse with water and seek medical attention.
Fumes and Gas: Welding fumes and gases are hazardous. Ensure adequate ventilation or fume extraction. Be cautious when welding small parts. Degrease parts before welding, especially those containing lead, cadmium, zinc, mercury, or beryllium. Store gas cylinders upright and secured.
Fire and Explosion Risk: Protect the welding area. Keep flammable materials at least 11 meters away. Have fire protection equipment nearby. Be aware of hot material or sparks that can cause fires. Remove flammable objects and pressurized containers. Cutting closed containers is prohibited; ensure they are clean of flammable residue. Grinding operations should not be performed near welding power sources or flammable substances.
Electrical Safety: The electrical network must be grounded. Never touch live parts. Disconnect from the mains and wait 2 minutes before opening the power source to allow capacitors to discharge. Replace cables and electrodes only with qualified personnel. Ensure cable cross-sections are adequate. Wear dry, insulating clothing and safety footwear.
EMC Classification: This equipment is Class A (industrial use) and not intended for domestic use on low-voltage public networks due to potential electromagnetic interference. It is not compliant with IEC 61000-3-12 and is intended for connection to private low-voltage networks or public networks at medium/high voltage levels. Users must ensure compatibility with the public network operator.
Electromagnetic Emissions: Welding currents produce electric and magnetic fields (EMF) which can interfere with medical devices like pacemakers. Pacemaker wearers must consult a doctor and take extra precautions. Minimize exposure by positioning cables together, keeping the body away from the welding circuit, not wrapping cables around the body, and connecting the return cable close to the weld area.
Installation and Usage
Installation must be performed by authorized personnel. Ensure the generator is disconnected from the mains during installation. The unit requires a 400V three-phase power supply with grounding and a 20A delayed circuit breaker or fuse (type aM). Use a dedicated power outlet and appropriate extension cords if necessary. The machine requires a compressed air supply of 8 bar (116 Psi) for operation. Avoid connecting to generators due to potential overvoltages.
The equipment is designed for specific welding operations including spot welding of sheets, nail/rivet/washer welding, and dent removal.
Operating Modes
The Gyspot Inverter PTI offers several operating modes:
- AUTO: Automatically determines welding parameters. Requires initial calibration.
- NORMAL: Parameters set based on sheet thickness and steel type.
- MANUAL: Allows manual setting of current, time, and clamping force.
- MULTI: Precise adjustment for thickness and type of 2 or 3 sheets.
- GYSTEEL: Similar to NORMAL, but allows input of material yield strength (Re).
- PRODUCATOR (Manufacturer): Access pre-registered welding points based on manufacturer specifications.
- ENERGY: Controls energy transmitted during welding, used for testing by manufacturers or inspection bodies.
The machine features an intuitive Human-Machine Interface (HMI) for parameter adjustment and mode selection. The welding gun/clamp can also be used for remote parameter adjustment.
Maintenance and Recommendations
Regular maintenance is crucial for optimal performance and longevity. Key maintenance points include:
- Ensure users are adequately trained.
- Verify manufacturer authorization for specific welding procedures on vehicles.
- Disconnect power and wait 2 minutes before any internal intervention.
- Regularly empty the dehumidifier filter.
- Check and maintain cooling liquid levels; replace every 2 years.
- Inspect and clean/replace electrodes and caps regularly (e.g., replace caps every ~200 points).
- Clean the device casing to remove dust and check electrical connections.
- Inspect power and welding circuit cables for damage.
- Ensure all air vents are clear for proper cooling.
- Periodically check and tighten critical screws, especially those securing the arm support to the clamp body.
The device includes a balancer for clamp handling; avoid letting the clamp hang for extended periods or drop repeatedly.
Technical Specifications
| Characteristic | Symbol | Value |
|---|---|---|
| Electrical Characteristics | ||
| Nominal Supply Voltage | U1N | 400 V 3~ |
| Mains Frequency | F | 50 / 60 Hz |
| Continuous Supply Current | ILP | 19 A |
| Power at 50% Duty Cycle | S50 | 13.2 kVA |
| Permanent Power | Sp | 19 kVA |
| Maximum Instantaneous Power | Smax | 110 kVA |
| Secondary Voltage | U2d | 7.3 V |
| Primary Max Short Circuit Current | ILCC | 159 A |
| Secondary Short Circuit Current | I2cc | 14 500 A |
| Continuous Secondary Current | I2P | 1 750 A |
| Circuit Breaker or Fuse (aM) | 20 A (Type D) | |
| Differential | 30 mA | |
| Duty Cycle | 1.45 % | |
| Fuse F1/F2/F3 (ref. 051363) | 5x20 mm T4A - 250 VAC | |
| Fuse F4 (ref. 051409) | 5x20 mm T5A - 450 VDC | |
| Thermal Characteristics | ||
| Operating Temperature | @ 40°C (104°F) | 5°C to 40°C (+41°F to +104°F) |
| Storage Temperature | @ 20°C (68°F) | -25°C to +55°C (-13°F to +131°F) |
| Air Humidity | < 50% @ 40°C, < 90% @ 20°C | |
| Altitude | 1 000 m (3800 ft) | |
| Thermal Protection | Thermistor on diode bridge at 70°C (158°F) | |
| Mechanical Characteristics | ||
| Protection Rating | IP20 | |
| Dimensions (LxWxH) | 65 x 80 x 230 cm | |
| Weight | 92 kg | |
| Mains Cable Length | 8 m (26 ft) | |
| Clamp Cable Length | 4 m / 6 m (13 ft / 20 ft) | |
| Arm Spacing Range | > 450 mm (1.6 to 18 inch) | |
| Arm Length Range | > 600 mm (0.8 to 24 inch) | |
| Pneumatic Characteristics | ||
| Max Pressure | P1 max | 10 bar (145 Psi) |
| Min Pressure | P1 min | 8 bar (116 Psi) |
| Cooling Liquid Flow Rate | Q p | 1 l/min (0.26 US gpm) |
| Cooling Liquid Pressure Loss | F1min | 3 bar (44 Psi) |
| Min Welding Force | Fmax | 100 daN (225 Lbf) |
| Max Regulated Force with C Clamp | 550 daN (1236 Lbf) |
Parts and Accessories
The document details various spare parts, accessories, and optional equipment, including different types of welding arms (C1-C14), consumables like electrodes and caps, cooling liquid, protective covers, and software. A comprehensive list is provided within the original document for reference.
PC Software
GYS offers PC software (GYSPOT) for managing welding reports, updating parameters, and configuring welding points. This software can be installed from the SD card provided with the unit and allows for data retrieval, editing, and archiving of welding activities.
Assembly and Arm Changes
Detailed instructions and diagrams are provided for the assembly and changing of welding arms. Proper tightening and adjustment are critical to prevent overheating and damage. Specific instructions are given for different arm types and extensions. Users are advised to follow these procedures carefully to ensure correct operation and warranty validity.
Troubleshooting
The manual includes a troubleshooting section addressing common anomalies such as poor weld quality, machine overheating, insufficient power, or incorrect arm usage. It lists potential causes and recommended solutions.
