Elektron MULTISPOT MI-100 Operating Manual Download

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Operating Manual

MULTISPOT MI-100

Resistance Welder

Item no.

327519

Revision:

3.0 - Translation

Version: 24

, March 2009

Be sure you have read and understood
this operating manual before you carry
out any works on and/or with this
equipment.

Summary of Contents for MULTISPOT MI-100

Page 1: ... MULTISPOT MI 100 Resistance Welder Item no 327519 Revision 3 0 Translation Version 24th March 2009 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: ...Textmarke nicht definiert 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 storage 16 3 1 Safety during transport 16 3 2 Symbols on packaging 16 3 3 Unpacking 16 3 4 Acceptance after shipping 16 3 5 Handling 17 3 5 1 Forklift truck 17 3 5 2 Transport with belt...

Page 4: ...ing on threaded studs 40 6 5 7 Welding on T pins 41 6 5 8 Fixing sheet metal parts tacking 42 6 5 9 Water cooled spot welding gun special accessory 42 6 5 10 Connection of Airpuller Dentpuller 42 7 Troubleshooting 43 7 1 Health and safety during troubleshooting 43 7 2 Error messages and troubleshooting tables 43 7 2 1 Problems displayed on the control panel 43 7 2 2 Possible causes and remedies in...

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 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 info...

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 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 Co...

Page 7: ...isuse 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 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 pr...

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 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 m...

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 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 defec...

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 human sense organs nerve and muscle cells Therefore Persons with pacemakers or other magnetisable implants must not approach the work area Be sure to put up suitable warning signs Be sure to put warni...

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 Respiratory equipment may be recommendable in case of doubt Stumbling hazards WARNING Possibility of injuries due to stumbling and falling The work environment may pose stumbling risks Stumbling and falling ...

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 situations Preventive measures Be prepared to confront accidents and fires Be sure to have first aid equipment kits blankets etc and fire extinguishers ready at hand All personnel must know about accident ...

Page 13: ...lds Electromagnetic 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 ...

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 instance there is a danger the equipment tips over Therefore Move this equipment always using the handles Keep potential obstacles out of the work area Install cables and supply lines in such a way tha...

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 consider the following information Electronic components Electronic components and scrap are subject to hazardous waste management and must be collected by authorised companies Other components Unless y...

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 materials What to do with packing materials CAUTION Improper waste disposal may cause environmental hazards Packing materials are valuable raw materials In many cases they can be recycled i e used again for...

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 original pallet in case of any further transport needs return of goods further transport 3 5 2 Transport with belts Fig 8 Transport with belts To unload and transport use suitable device and belts The belt...

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 original packing materials 4 Mark packing materials with symbols as shown in 3 2 CAUTION Improper transport conditions may cause damage to property Packaging with inappropriate dimensions quality or w...

Page 19: ... 8 7 6 5 3 1 2 4 9 Fig 10 Multispot system standard 4 2 Description The MULTISPOT MI 100 resistance welding unit is designed for special requirements for the repair and production of motor vehicle bodies The inverter power source is controlled by a micro processor After selecting the operating mode the sheet steel thickness and the welding task the current and weld time will be assigned automatica...

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 Connections 4 4 1 Connections on the front side Fig 13 Connections on the front side 1 Pressure gauge displays input pressure 2 Pressure reducer continuous adjustment of input pressure 3 Central connect...

Page 21: ...tions on the backside 1 Compressed air filter unit 2 Coolant pump air supply 3 Power cord 4 Power switch 5 Coolant outlet towards pump 6 Coolant return 2 1 4 3 6 5 Fig 14 Connections on the backside 7 Water filter 8 Cooling water tank cap 8 7 Fig 15 Connections on the backside ...

Page 22: ...er for dressing electrodes and Allan key for taking off electrode arms hoops C pliers complete with set of electrodes and arms or X pliers complete with set of electrodes and arms Welding gun 4 5 2 Optional accessories See catalogue for accessories 4 5 3 Tools required Fig 17 Key for electrode caps Key for electrode caps Fig 17 NOTE Find our complete range of products and order information at www ...

Page 23: ...e of clutter and offers enough room to move Make sure your tools are complete and in good working order Do wear safety shoes 5 2 Filling up cooling water tank 33 l Fig 18 Filling opening 1 Twist off cap 2 Fill about 33 litres 9 gallons 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 Bef...

Page 24: ...pipe Replacement carabine hook Four M8 bolts with two nuts and washers each Mounting instructions Fig 20 Vertical pipe 3 Mount the vertical pipe using four M8 bolts Fig 20 see separate operating and mounting instructions Fig 21 Crossbar pipe 4 Mount the crossbar Fig 21 see separate mounting instructions Proceed as follows Mount and screw down stopper Fig 21 1 Insert crossbar pipe into guiding elem...

Page 25: ... of cable length Before you connect the welder to the mains make sure the grid is properly protected by fuses at 32 A Fig 23 Connecting welder to power supply 1 Take the power cord from its support 2 Run the power cord along a safe route WARNING Stumbling hazards Power cords may constitute a stumbling hazard when improperly laid or installed and may cause people to fall and hurt themselves In this...

Page 26: ... 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 the direction to decrease the input pressure Min admissible 6 bar 87 Psi 4 When decreasing the input pressure actuate the pliers from time to time to let the air escape CAUTION Improper pressure of com...

Page 27: ... Fig 26 Connecting the pliers 1 Push the main plug of the welding pliers into the main socket of the equipment Fig 26 1 2 Turn the retainer nut clockwise Fig 26 2 to lock the connection Fig 27 Water cooling system for the pliers 3 Connect the water cooling system of the pliers ...

Page 28: ...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 possible see Fig 29 and section 6 5 2 In this case press the copper shoe of the grounding cable firmly onto the metal sheet This is the only way to obtain a good current transfer Attention The copper ...

Page 29: ...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 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 retooli...

Page 30: ...l Fig 32 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 maximum 50 welding jobs especially when working with high strength and or galvanised steel Deploying the electrode arm Fig 33 Unlocking the arm 1 S...

Page 31: ...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 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 preconditions are fulfill...

Page 32: ...ed according to instructions you may switch it on by turning the power switch Fig 37 6 3 Bedienung über Tastatur 1 LED malfunction see also 7 2 1 2 Touch key for selecting welding tool 3 Touch key for selecting welding gun functions 4 Touch key for selecting sheet gauges 5 Touch key for power selection 1 2 3 4 5 Fig 38 Control panel ...

Page 33: ...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 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 obj...

Page 34: ...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 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 purpo...

Page 35: ...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 Distances between welding spots Fig 40 Distances should not be too short Don t keep the distances between welding spots too s...

Page 36: ...not be selected 1 2 Fig 41 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 42 Pressure on welding point NOTE Excessive contact pressure will lead to poor welding results when the distance to the ground connection is too great Inadequate contact pressure air gap or paint grease between the steel sheets will result in t...

Page 37: ...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 44 and carefully beat out the dent 7 Remove washer by twisting Only twist the washer off otherwise holes in the sheet steel could result Fig 43 contact piece UB Fig 44 Pulling tool Note 8 mm Washer Always beat out major dents from the outside working inwards Use brig...

Page 38: ... 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 tip with a file Fig 45 High speed planishing hammer SAH special accessory NOTE Repeat the procedure until the damaged area is entirely repaired CAUTION Heavy dents only remove with extractor tool and 8m...

Page 39: ... until the welding time has expired 6 5 5 Shrinking sheet 1 Grind damaged area to a bright metal finish 2 Insert carbon electrode Fig 47 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 carbon electrode 39 in the centre of the damaged area 6 Press and keep hold of release button of the...

Page 40: ...ce until limit stop 3 Select weld on studs mode and sheet thickness on display 4 Decrease power by one step for studs of 4 mm Ø 5 Increase power by one step for studs of 6 mm Ø 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 until welding program has ended Fig 48 Contact piece threaded stud Threaded studs without colla...

Page 41: ...ing 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 Fitting piece Porsche Art Nr 314 465 Special accessory 6 Fitting piece Golf 3 Vento Art Nr 317 962 Special accessory 7 Contact piece TST 5 Art Nr 408 540 Special accessory 8 T pin 5 x 10 Art Nr 408 571 Sp...

Page 42: ...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 the copper ground lug to the body Caution ensure there is good current conduction 4 Proceed with spot welding as described in 6 5 1 5 Instead of the ground lug a second gun can be connected switch wel...

Page 43: ...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 Remedy WHO should do it Power cord not plugged in Plug in power cord Welder does not switch on If the power cord is indeed connected a mains fuse may have been triggered Reset fuse Operator Tool error Let ...

Page 44: ...essary Operator Check purity and quality of operating company s compressed air supply Check the work environment Does it still fulfil all the operating requirements See 9Fehler Verweisquelle konnte nicht gefunden werden Operator Every 6 months Check actual input current and voltage Take your own measurements Skilled electrician Visually check the water separator and air filter of the pneumatic uni...

Page 45: ...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 damped with a mild detergent As for the display just dust Be careful not to scratch the display 8 2 2 Maintaining the pneumatic unit Fig 52 Pneumatic unit 1 Visually check the compressed air filter Fig 5...

Page 46: ...fore Remove water from the floor Fig 53 Water filter 1 Visually check the water filter Fig 53 Fig 54 Unlocking supply Fig 55 Unlocking supply If you detect clear signs of dirt 2 Switch off the welder Wait until the pump stops pumping 3 Separate the cooling water supply from the pump Fig 54 Fig 55 Fig 56 4 Pull the water filter unit from the hoses to the left and right However do not loosen the hos...

Page 47: ...buckets ready at hand to catch the cooling water 3 Do one weld without sheet by pushing the trigger of the welding pliers once Cooling water will be drained 4 Turn off the power switch to turn off the pump 8 3 Measures to be taken after maintenance When you finish maintenance and before you switch the welder back on carry out the following 1 Re establish any and all connections you loosened and or...

Page 48: ...10 m 33 ft 16 AWG 6 mm2 10 m 33 ft Mains fuse min 32 A träge 63 A träge Installed power 42 kVA 42 kVA Rated output at 50 duty cycle 60 kVA 60 kVA No load voltage max 23 V DC 23 V DC weld current regulated 12000 A DC 12000 A DC Enclosure IP21 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 w...

Page 49: ...anufacturer 2 Inverter type 3 Item no 4 Input voltage in VAC 5 Frequency 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 13 Sign of confirmity 14 Block circuit diagram Fig 59 Type plate on water cooling unit 1 Manufacturer 2 Designation 3 Type 4 Item no 5 Productio...

Page 50: ...nvironmental protection 15 Error messages 43 F Filling up cooling water tank 23 Further transport needs 18 G Guarantee 6 H Handling 17 I Intended purpose 7 Intended use 7 Inverter control unit 20 L Liability 6 M Maintaining the pneumatic unit 45 Maintenance schedule 44 Messages displayed on the control panel 43 Misuse 7 O Overview 19 P Personnel 8 maintenance 44 Power supply 48 Power switch 13 PPE...

Page 51: ...s on equipment 13 to be installed by operating company 8 Symbols on packaging 16 Symbols used in the operating manual 5 T tacking 42 threaded studs 40 T pins 41 Training Report 52 Troubleshooting 43 Type plates 49 W washer 37 Waste management 15 Working conditions 48 ...

Page 52: ...Resistance Welder MULTISPOT MI 100 Appendix 52 11 Appendix Training Report NOTE Master copy Do not fill in Make copies Date Name Type of training Trainer Signature ...

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