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Resistance Welder MULTISPOT MI-90 T

Troubleshooting

35

7 Troubleshooting

7.1 Health and safety during troubleshooting

WARNING
People with insufficient skills may suffer injuries.

If you carry out troubleshooting and repairs yourself, you may encounter certain risks and
hazards that may entail severe injuries.
Therefore:
– Do not open the welder. Do not modify the welder. Do not try to carry out repairs yourself.
– For any and all troubleshooting measures not explicitly mentioned and/or described in this

manual, you should call service personnel and/or contact the manufacturer.

–  Be sure to adhere strictly to the hierarchy of responsibilities defined in the table.
–  When you're in doubt: do contact service personnel / manufacturer.
–  If a damage does occur: minimise, contain and avert consequential damage.

NOTE

In the event that problems occur more frequently due to above-average 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

Fig. 35: LED display

1

LED display green:

mains OK

LED display green/yellow: mains drop within tolerance range
LED display yellow:

considerable mains drop

LED display red:

mains drop out of tolerance range

5

LED display red:

thermal overload (see next page)

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Summary of Contents for MULTISPOT MI-90 T

Page 1: ...ULTISPOT MI 90 T Resistance welder Item no 327527 Revision 3 0 Translation Version 9th December 2008 Be sure you have read and understood this operating manual before you carry out any works on and or with this equipment ...

Page 2: ...EKTRON BREMEN Elektrotechnik GmbH Am Hohentorshafen 17 19 28197 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 ELEKTRON BREMEN ...

Page 3: ...nd wear parts 14 2 9 Waste management and environmental protection 14 3 Transport packaging storage 15 3 1 Safety during transport 15 3 2 Symbols on packaging 15 3 3 Unpacking 15 3 4 Acceptance after shipping 16 3 5 Handling 16 3 5 1 Forklift 16 3 5 2 Moving equipment to the site 16 3 6 In case of return of goods further transport needs 17 3 7 Storage 17 4 Design and functionality 18 4 1 Overview ...

Page 4: ... safety during troubleshooting 29 7 2 Error messages and troubleshooting tables 29 7 2 1 Problems displayed on the control panel 29 7 2 2 Possible causes and remedies in case of unsatisfactory welding results 29 8 Maintenance 29 8 1 Maintenance schedule 29 8 2 Carrying out maintenance jobs 29 8 2 1 Cleaning 29 8 2 2 Maintaining the pneumatic unit 29 8 2 3 Replacing water filter 29 9 Specifications...

Page 5: ...d or its contents may not be relinquished to third parties and or communicated processed used and or reproduced in any way or form whatsoever not even in excerpts and or for internal purposes without the prior written consent of the manufacturer Contravention shall entail damage claims All other rights reserved 1 3 Symbols Safety information This manual uses symbols to highlight important safety i...

Page 6: ...tions your equipment is a special design and or technical progress facilitates improvements Shall apply any and all obligations and stipulations of the Delivery Contract the General Terms of Business and Terms of Supply and Delivery of the manufacturer as well as any and all legal stipulations and regulations in force on the day the Contract was concluded We constantly strive to further develop an...

Page 7: ...ipulate etc this equipment The manufacturer shall not be held liable for any and all damage due to misuse of this equipment 2 2 Responsibilities of the operating company 2 2 1 General responsibilities This equipment has been designed for professional use The owner operator or operating company therefore being a businessman or commercial company they are subject to any and all legal obligations con...

Page 8: ...risks due to the influence of electromagnetic fields must not approach this equipment Electromagnetic fields hazard to persons with magnetisable implants Persons who may suffer health risks due to the influence of electromagnetic fields must not approach this equipment Symbols the operating company must install in the immediate vicinity of the equipment Symbol Meaning Electromagnetic fields hazard...

Page 9: ...se 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 injuries Defective safety clothing may not constitute a proper protection against injuries Therefore Be sure to check PPE for integrity and good working condition before you start any works Replace defe...

Page 10: ...t cables Make sure protective ground conductors have been connected properly After disconnecting the welder from the mains the welder still contains residual current for approx 15 minutes Electromagnetic fields DANGER Electromagnetic fields pose a potentially fatal hazard to people with pacemakers or other magnetisable implants Electromagnetic fields affect the functionality of pacemakers and othe...

Page 11: ...s centigrade 212 F right after welding So there is an acute risk of burning yourself Therefore Never work without proper safety clothes and gloves near hot components Let freshly welded parts cool down to ambient temperature before you go on to work with them 2 3 2 Dangers due to the work environment Vapours WARNING Vapours may constitute a danger to your health Stock that has not been properly gr...

Page 12: ...ping and toppling hazard On the other side though this detail causes 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 2 4 Correct behaviour in accidents and dangerous situations Preventive measures Be prepared to confront accidents and fires Be sure to have first aid equipment ki...

Page 13: ...ectromagnetic 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 Electromagnetic fields pose a mortal danger to persons with pacemakers Electromagnetic fields affect the functionality of pacemakers and other magnetisable implants Electromagnetic fields can ir...

Page 14: ...ling may constitute an environmental hazard Inexpert handling of environmentally harmful substances especially wrong disposal may constitute a hazard to the environment Therefore Be sure to take appropriate measures whenever harmful substances get or threaten to get into the environment In case of doubt inform competent local authorities about the hazard or damage Local authorities and specialised...

Page 15: ...ot stack Do not stack Fragile goods Do not stack goods otherwise the contents of the packing unit could be damaged 3 3 Unpacking 1 Do not remove packaging until immediately before installation During unpacking do not use pointed tools 2 Keep the original pallet Fig 6 in case of any further transport needs return of goods further transport 3 Recycle packing materials What to do with packing materia...

Page 16: ...f gravity Make absolutely sure they cannot tip over NOTE Keep the original pallet in case of any further transport needs return of goods further transport 3 5 2 Moving equipment to the site There is a danger of tipping and toppling of the device because of its centre of gravity CAUTION Tipping and toppling may cause damage to property This equipment s centre of gravity is relatively high In the ev...

Page 17: ...coolant tank may cause damage during transport Therefore Be sure to completely drain coolant tank before transport Use packaging of appropriate size and quality 3 7 Storage Storage conditions Do not store packing units outdoors Provide for dry and dust free storage Protect against aggressive media Protect against direct sun exposure Protect against mechanical shocks and vibrations Storage temperat...

Page 18: ...g pliers support 7 Welding pliers Fig 7 Overview Multispot System Standard 4 2 Description The MULTISPOT MI 90 T resistance welder has been designed and built with the special requirements of body makers and maintenance in mind The inverter which provides the power for welding is controlled by a microprocessor That way weld current and weld time will be adjusted automatically on the basis of the s...

Page 19: ...Touch key for selecting welding jobs from top to bottom high strength steel HSS 3 layer sheets galvanised sheets 3 Touch key for power selection 4 Touch key for selecting sheet gauges 5 LED display Malfunction 3 2 4 5 1 Fig 8 Control panel 4 3 2 On the back Fig 9 Power switch in OFF position The power switch Fig 9 is for switching the power supply on and off ...

Page 20: ...front side 1 Connection for sensors 2 Central connection for weld current 3 Air supply for pliers 1 2 3 Fig 10 Connections on the front side 4 4 2 Connections on the backside 1 Compressed air filter unit 2 Pressure gauge 3 Air supply for pump 4 mains supply 5 Power switch Fig 11 Connections on the backside ...

Page 21: ...ign and functionality 21 4 4 3 Connections cooling water tank 1 Cooling water tank cap 2 Coolant return 3 Coolant outlet 4 Fastening screw 5 Pump 6 Air supply for pump Fig 12 Connections cooling water tank 4 5 Accessories see Accessory List ...

Page 22: ... 1 Twist off cap 2 Fill about 15 litres 4 gal of cold clean drinking water into the tank 3 Add chlorine free disinfectant to prevent growth of algae and bacteria 4 Replace cap properly Check for tightness 5 Check water level before each use 6 Fill up when necessary Keep water level close underneath the tank cap 5 2 Electrical connections Fig 14 Power grid specifications CAUTION Insufficient conduc...

Page 23: ...e of the electrodes of 3 5 kN 787 lb f approx To adjust the contact force of the electrodes proceed as described below Fig 17 Pressure gauge and pressure regulator 3 Check the pressure supplied at the pressure gauge Fig 17 2 If necessary use the pressure regulator Fig 17 1 to set the pressure as required depending on welding program and manufacturer s specs Turn the regulator in the direction to i...

Page 24: ...ly 4 Coolant outlet 5 Coolant return 1 2 Fig 19 Connecting the pliers 1 Push the main plug of the welding pliers into the main socket of the equipment Fig 19 1 2 Push down the clamps Fig 19 2 to lock the connection Fig 20 Connecting air supply of the pliers 3 Connect the air supply system of the pliers Push the hose into the connection until it locks ...

Page 25: ...Fig 21 Connecting sensors of the pliers 4 Connect the sensors of the pliers 1 2 Fig 22 Connecting water supply 1 Connect the coolant return of the pliers to the cooling tank Fig 22 1 2 Connect the coolant outlet of the pliers to the cooling tank Fig 22 2 ...

Page 26: ...TISPOT MI 90 T Installation 26 5 5 Connecting air supply of the cooling water tank 1 Fig 23 Connecting air supply 1 Connect the air supply of the cooling tank Fig 23 1 to the connection on the back side of the unit Fig 23 2 ...

Page 27: ...ing 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 will not be possible to apply clean spot welds 6 1 2 Preparing welding pliers WARNING Unintentional startup of welder may constitute a hazard of injuries If the new tool is switched on during retooling the weld current and or unintentional movem...

Page 28: ...nt tool Fig 26 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 results Electrode caps must be milled or replaced after 50 welding jobs especially when working with super speed and or galvanised steel Deploying the electrode arm Fig 27 Unlocking the arm 1 Switc...

Page 29: ...hers Inexpert operation 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 equipment is put to use by skilled welding operators with sufficient training and experience in spot welding exclusively Before operation consult the manual and make sure any and all precon...

Page 30: ...instructions you may switch it on by turning the power switch Fig 32 6 3 Basic settings 6 3 1 Keyboard operation 1 LED display Mains voltage drop 2 Touch key for selecting welding jobs from top to bottom high strength steel HSS 3 layer sheets galvanised sheets 3 Touch key for power selection 4 Touch key for selecting sheet gauges 5 LED display Malfunction 3 2 4 5 1 Fig 33 Control panel ...

Page 31: ...tions Welding job Ratio of sheets Sheet gauges up to about Set value Selection 0 8 0 8 0 8 1 0 1 0 1 0 1 5 1 5 1 5 d1 d2 d3 2 0 2 0 2 0 2 0 0 8 0 8 0 8 1 0 1 0 0 8 1 5 1 5 0 8 2 0 2 0 d2 d3 0 8 3 0 3 0 d1 d2 d3 d1 d2 d3 3 Select next higher set value optionally ON or OFF 3 sheets OFF ...

Page 32: ...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 sure access and escape routes are not blocked During any and all welding jobs be sure to be wearing a face screen non inflammable safety clothing and welder s gloves Do not carry easily inflammable objects in ...

Page 33: ... 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 equipment PPE Non inflammable safety clothing is a tight fitting sort of special clothing that is not inflammable covers arms and legs completely and tears easily instead of getting pulled in Its main purpose is to protect again...

Page 34: ...rty When using the electrode arm configuration shown to the left 12 mm electrodes will slightly bend if the contact 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 here make sure the contact force does not exceed 1 8 kN 405 lb f 6 bar 87 Psi Lifetimes...

Page 35: ...d or contact the manufacturer Be sure to adhere strictly to the hierarchy of responsibilities defined in the table When you re in doubt do contact service personnel manufacturer If a damage does occur minimise contain and avert consequential damage NOTE In the event that problems occur more frequently due to above average workloads you must adapt the inspection and maintenance intervals accordingl...

Page 36: ... off again Do not switch off the unit and cooling during the cooling down phase to prevent any heat congestion Operator 7 2 2 Possible causes and remedies in case of unsatisfactory welding results Symptom Possible cause Remedy WHO should do it Weld current too weak Weld spot too small Weld time too short Adapt welding parameters Operator Weld current too high Welding spot burns up excessive spatte...

Page 37: ...ry out jobs as required Visually check the water filter Replace if necessary whenever necessary Empty cooling water tank Refill Operator 8 2 Carrying out maintenance jobs Personnel The maintenance jobs described here may be carried out by operators if not explicitly stated otherwise Have works on electrical equipment carried out by skilled electricians exclusively 8 2 1 Cleaning CAUTION Failure to...

Page 38: ...Visually check the compressed air filter Fig 36 Replace when you see any accumulation of dirt 2 Visually check the water separator under the compressed air filter for residues of water If you find any accumulations of water pull of the cap in the direction indicated by the arrow and empty water from the separator ...

Page 39: ...itch off the welder Wait until the pump stops pumping 5 Separate the cooling water supply from the pump 6 Pull the water filter unit from the hoses to the left and right However do not loosen the hose clips 7 Replace the old filter with a new one and insert the new water filter between the hoses 8 Re connect the cooling water supply to the pump 8 3 Measures to be taken after maintenance When you f...

Page 40: ...Rated output at 50 duty cycle 30 kVA No load voltage max 16 V AC weld current regulated 13000 A DC Enclosure IP21 Compressed air supply Item Value Unit Operating pressure min max 6 10 87 145 Bar Psi Quality clean dry free of oil 9 3 Supplies Item Value Unit Cooling water tank capacity 15 4 l gal approx Chlorine free disinfectant accor dosing instructions 9 4 Working conditions Ambient conditions I...

Page 41: ...ency in Hz 6 Power consumption in kVA 7 Enclosure 8 Production no 9 Duty cycle in 10 Max current in A 11 Output voltage in VDC 12 Appeal Read operating manual Comply with operating manual Fig 40 Type plate on water cooling unit 1 Manufacturer 2 Designation 3 Type 4 Item no 5 Production no 6 Flow rate in l h 1 7 Rated pressure in bar 8 Operating pressure in bar 9 Volume in l ...

Page 42: ...eds 17 G Guarantee 6 H Handling 16 I Intended purpose 7 Intended use 7 Inverter control unit 19 L Liability 6 M Maintaining the pneumatic unit 38 Maintenance schedule 37 Misuse 7 O Operating company 7 Overview 18 P Personnel 8 maintenance 37 Power requirements 40 Power supply 40 Power switch 13 PPE 9 33 Preparing the sheets 27 Preparing welding pliers 27 Problems not displayed on the control panel...

Page 43: ...Resistance Welder MULTISPOT MI 90 T Appendix 43 Appendix Training Report NOTE Master copy Do not fill in Make copies Date Name Type of training Trainer Signature ...

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