7
Operating Manual
MULTISPOT MI-100-3
Resistance Welder
Item no.
328 008
Revision:
1.0 - Translation
Version:
29
th
, March 2014
Be sure you have read and understood this operating manual before you carry out any works on and/or with this equipment.
Page 1: ...LTISPOT MI 100 3 Resistance Welder Item no 328 008 Revision 1 0 Translation Version 29 th March 2014 Be sure you have read and understood this operating manual before you carry out any works on and or...
Page 2: ...otary GmbH Branch Bremen Hinterm Sielhof 22 28277 Bremen Germany Phone 49 0 54 90 6 906 Fax 49 0 54 90 6 19 Email vertrieb elektron bremen de Web www elektron bremen de Release BlitzRotary GmbH Branch...
Page 3: ...equipment 13 2 7 1 On the flap cover 13 2 7 2 Signs on the backside 14 2 7 3 On the balancer 14 2 8 Spare and wear parts 14 2 9 Waste management and environmental protection 15 3 Transport packaging...
Page 4: ...38 6 5 7 Welding on T pins 40 6 5 8 Fixing sheet metal parts tacking 41 6 5 9 Water cooled spot welding gun special accessory 41 6 5 10 Connection of Airpuller Dentpuller 41 7 Troubleshooting 42 7 1...
Page 5: ...t It may be used for internal purposes exclusively The manual and or its contents may not be relinquished to third parties and or communicated processed used and or reproduced in any way or form whats...
Page 6: ...presentations in this manual if and when you ordered special options your equipment is a special design and or technical progress facilitates improvements Shall apply any and all obligations and stipu...
Page 7: ...misuse this equipment for heating thawing or perhaps even igniting objects Do not use this equipment in explosive atmospheres Do not open alter modify and or manipulate etc this equipment The manufact...
Page 8: ...the operating company must install on access ways and doors Symbol Meaning Electromagnetic fields hazard to persons with pacemakers Persons who may suffer health risks due to the influence of electrom...
Page 9: ...e protection of the operating company s power grid must be adapted to the special requirements of resistance welding 2 2 3 Personal protective equipment PPE CAUTION Insufficient protection against inj...
Page 10: ...fatal hazard to people with pacemakers or other magnetisable implants Electromagnetic fields affect the functionality of pacemakers and other magnetisable implants Electromagnetic fields can irritate...
Page 11: ...ng welding Therefore Before you tackle any welding jobs make sure the sheets you want to weld have been properly ground and cleaned and are free of residues Be sure to be wearing a face screen Respira...
Page 12: ...fore Never put objects on the accessory box beneath the control panel Proceed with care when closing the flap cover with integrated control panel 2 4 Correct behaviour in accidents and dangerous situa...
Page 13: ...tic fields pose a potentially fatal hazard to people with pacemakers or other magnetisable implants Electromagnetic fields also affect magnetisable objects like e g watches smart cards etc DANGER Elec...
Page 14: ...ver CAUTION Tipping and toppling may cause damage to property This equipment s centre of gravity is relatively high In the event the wheels jam and or block due to an obstacle or transverse pull for i...
Page 15: ...of doubt inform competent local authorities about the hazard or damage Local authorities and specialised waste management companies will be happy to advise you with your disposal issues Please also co...
Page 16: ...diately before installation During unpacking do not use pointed tools 2 Keep the original pallet Fig 7 in case of any further transport needs return of goods further transport 3 Recycle packing materi...
Page 17: ...of the packing unit at hand The operator must have a licence to drive forklift trucks Packing units may have very high centres of gravity Make absolutely sure they cannot tip over NOTE Keep the origi...
Page 18: ...s equipment 3 6 In case of return of goods further transport needs 1 Drain cooling water tank completely See 8 2 4 2 Use original transport pallet See Fig 7 3 Use packing materials that correspond to...
Page 19: ...8 7 6 5 3 1 2 4 9 Fig 10 Multispot system standard 4 2 Description The MULTISPOT MI 100 3 resistance welding unit is designed for special requirements for the repair and production of motor vehicle bo...
Page 20: ...selection 1 2 3 4 5 Fig 11 Display and control panel 4 3 2 On the inverter control unit Fig 12 Power switch in OFF position The power switch Fig 12 is for switching the power supply on and off 4 4 Co...
Page 21: ...oolant outlet towards pump 6 Coolant return 7 Water filter 8 Cooling tank cap 9 Cooling tank 10 Water pump Fig 14 Connections on the backside 4 5 Accessories 4 5 1 Optional accessories See catalogue f...
Page 22: ...g order Do wear safety shoes 5 2 Filling up cooling water tank Fig 16 Filling up the cooling water tank 1 Remove the cover on the rear side the coolant outlet and coolants return 2 Remove cooling wate...
Page 23: ...pipe Replacement carabine hook Four M8 bolts with two nuts and washers each Mounting instructions Fig 18 Vertical pipe 3 Mount the vertical pipe using four M8 bolts Fig 18 see separate operating and m...
Page 24: ...of cable length Before you connect the welder to the mains make sure the grid is properly protected by fuses at 32 A Fig 21 Connecting welder to power supply 1 Take the power cord from its support 2...
Page 25: ...the pressure as required depending on welding program and manufacturer s specs Turn the regulator in the direction to increase the input pressure Max admissible 10 bar 145 Psi Turn the regulator in t...
Page 26: ...Fig 24 Connecting the pliers 1 Push the main plug of the welding pliers into the main socket of the equipment Fig 24 1 2 Turn the retainer nut clockwise Fig 24 2 to lock the connection Fig 25 Water c...
Page 27: ...ounding cable to a bare point on the bodywork to be welded Use lever clamp provided or a mole wrench Before using the lever clamp you have to weld on two 8 mm washers as close to the point of weld as...
Page 28: ...serve any manuals etc that come with the grinding tools Galvanised sheets should not be damaged if possible Make sure the sheets are always stacked with their faces parallel to each other Otherwise it...
Page 29: ...l Fig 30 2 Turn clockwise otherwise the cone comes loose 3 Put the new caps on the electrode head and press in position NOTE The perfectly sound condition of the caps is essential for good welding res...
Page 30: ...tion constitutes a hazard of injuries Inexpert and or negligent handling of this equipment and or ignorance of hazards and dangers may entail the most severe injuries Therefore Make sure this equipmen...
Page 31: ...ared according to instructions you may switch it on by turning the power switch Fig 35 6 3 Keyboard operation 1 LED malfunction see also 7 2 1 2 Touch key for selecting welding tool 3 Touch key for se...
Page 32: ...area Do not carry out welding jobs in the vicinity of pressure vessels tanks oil barrels paint cans and or in a work area with an explosive atmosphere Have fire extinguishing gear ready at hand Make s...
Page 33: ...uses and increases the danger the equipment rolls away Therefore Be sure to operate this equipment only on a flat and even floor Proceed with care when moving this equipment Personal protective equipm...
Page 34: ...force is set higher than 1 8 kN 405 lb f Therefore Ask yourself whether the job at hand could be handled just as well with a different configuration When you have to use the configuration as shown her...
Page 35: ...not be selected 1 2 Fig 39 welding gun contact piece 1 release button 2 6 Press the welding gun to the welding point with a pressure of approx 8 12 kgs Fig 40 Pressure on welding point NOTE Excessive...
Page 36: ...4 Position welding gun with washer in the area of the dent 5 Press release button of the gun 6 Hook pulling tool into the washer Fig 42 and carefully beat out the dent 7 Remove washer by twisting Only...
Page 37: ...the gun and weld on welding tip 6 Beat out the dent 7 Twist the high speed planishing hammer SAH off the sheet steel Select the weld time as short as possible 8 From time to time dress the weld on ti...
Page 38: ...2 Insert carbon electrode Fig 45 into contact piece of the welding gun 3 Select anneal shrink on display time controller is now inoperative 4 Locate the damaged area by finger pressure 5 Position car...
Page 39: ...step for studs of 4 mm 5 Increase power by one step for studs of 6 mm 6 Position welding gun with the stud at the welding point and press slightly 7 Press and keep hold of release button of the gun un...
Page 40: ...ting piece 1 Contact piece TST 3 Art Nr 407 227 2 T pin 3 x 4 5 Art Nr 408 597 3 Fitting piece Golf 2 Art Nr 313 451 Special accessory 4 Fitting piece Passat B 3 Art Nr 315 671 Special accessory 5 Fit...
Page 41: ...ral socket of the welder unit Unit changes over automatically to the right gun symbol 2 Connect the cooling water feed pipe and return pipe to the corresponding connections of the welder unit 3 Clamp...
Page 42: ...age workloads you must adapt the inspection and maintenance intervals accordingly 7 2 Error messages and troubleshooting tables 7 2 1 Problems displayed on the control panel Error Possible cause Remed...
Page 43: ...ace if and as soon as necessary Every 6 months Check purity and quality of operating company s compressed air supply Operator Check the work environment Does it still fulfil all the operating requirem...
Page 44: ...regular schedule especially around air vents Adequate dissipation of heat must be ensured Clean the welder with a dry lint free cloth For persistent dirt use a textile cloth that has been slightly dam...
Page 45: ...ly Slip hazard DANGER Slip hazard due to water coming out While pulling out the cooling water hoses water may come out Therefore Remove water from the floor Fig 51 Water filter 1 Visually check the wa...
Page 46: ...emove rear cover pull out forward and return hose from the cooling water tank 2 Cooling water tank carefully pull out straighten up and turn off cooling water tank cap 3 Cooling water tank emptying ob...
Page 47: ...g 1 Re establish any and all connections you loosened and or removed before Check for tight fit 2 Make sure any and all safety devices covers etc you may have removed are properly back in place 3 Make...
Page 48: ...AWG 6 mm 2 10 m 33 ft 6 AWG 10 mm 2 10 m 33 ft Mains fuse min 32 A slow 63 A slow 32 A slow Installed power 42 kVA 42 kVA 42 kVA Rated output at 50 duty cycle 60 kVA 60 kVA 60 kVA No load voltage max...
Page 49: ...s opening Safe compliance with distances 7 cm to welding cable 9 6 Type plate 13 14 Fig 53 Type plate on the backside 1 Manufacturer 2 Inverter type 3 Item no 4 Input voltage in VAC 5 Frequency in Hz...
Page 50: ...ts 20 E Electromagnetic fields 10 32 Empty cooling water tank 46 Environmental protection 15 Error messages 42 F Filling up cooling water tank 22 Further transport needs 18 G Guarantee 6 H Handling 17...
Page 51: ...ing balancer 23 Storage 18 Supplies 48 Switching on 31 Symbols on equipment 13 to be installed by operating company 8 Symbols on packaging 16 Symbols used in the operating manual 5 T tacking 41 thread...
Page 52: ...Resistance Welder MULTISPOT MI 100 3 Appendix 11 Appendix Training Report NOTE Master copy Do not fill in Make copies Date Name Type of training Trainer Signature...
