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Operating Manual

MULTISPOT MI-100control

Resistance welder

Item no.:

328 010

Revision: 0.9 – Translation
Version:

31. July 2013

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

Содержание MULTISPOT MI-100control

Страница 1: ...anual MULTISPOT MI 100control Resistance welder Item no 328 010 Revision 0 9 Translation Version 31 July 2013 Be sure you have read and understood this operating manual before you carry out any works on and or with this equipment ...

Страница 2: ...mbH Branch Bremen Hinterm Sielhof 22 D 28277 Bremen Germany Phone 49 0 421 54 90 6 906 Fax 49 0 421 54 90 6 19 E Mail vertrieb elektron bremen de Internet www elektron bremen de Release BlitzRotary GmbH Branch Bremen ...

Страница 3: ...idents and dangerous situations 17 2 5 Measures to be taken in case of work at the device 17 2 6 Safety devices 18 2 7 Safety labels and markings on this equipment 19 2 7 1 On the flap cover 19 2 7 2 Signs on the backside 19 2 7 3 On the balancer 20 2 7 4 On the control board 20 2 8 Spare and wear parts 20 2 9 Waste management and environmental protection 21 3 Transport packaging storage 22 3 1 Sa...

Страница 4: ...settings 43 6 3 1 Set languages 43 6 3 2 Register welder 44 6 4 Recurring settings 45 6 4 1 Maintaining electrode caps 45 6 4 2 Selecting control mode 45 6 4 2 1 Keyboard operation 46 6 4 2 2 Setting welder in mode Keyboard operation 47 6 4 2 3 OEM programs 48 6 4 2 4 Free mode 49 6 4 3 Electrode recognition 51 6 4 4 Manual tool selection 52 6 4 5 Switching off the cooling water pump 53 6 5 Import...

Страница 5: ... sheet metal parts tacking 73 6 9 9 Water cooled spot welding gun special accessory 73 6 9 10 Connection of Airpuller Dentpuller 73 7 Troubleshooting 74 7 1 Health and safety during troubleshooting 74 7 2 Error messages and troubleshooting tables 74 7 2 1 Problems displayed on the control panel 74 7 2 2 Problems NOT displayed on the control panel 78 7 2 3 Possible causes and remedies in case of un...

Страница 6: ...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 Disclaimer Any and all information contained in this operating manual has been written on the basis of pertinent standards and regulations the state of the art an...

Страница 7: ... and prevented WARNING indicates a situation that may become dangerous and may entail the death of people and severe injuries unless it is properly avoided and prevented CAUTION indicates a situation that may become dangerous and may entail medium and small injuries unless it is properly avoided and prevented CAUTION indicates a situation that may become critical and may entail damage to property ...

Страница 8: ...h this equipment Electromagnetic fields Hazard to magnetisable objects Magnetisable data carriers and similar objects that may suffer from magnetism must not be brought close to this equipment Mandatorys 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 aga...

Страница 9: ...ll be as stipulated in the General Terms of Business of the manufacturer 1 6 Customer service Our customer service will be happy to provide technical support For contact information see page 2 of this manual or the service menu on the control panel Please note Our staff is always eager to learn about new information insights and or experience our customers may derive from the work with our product...

Страница 10: ... its specs and limits of use see Specifications Be sure to use this equipment for welding sheet metal up to 3 mm galvanised stock and sheets made of super speed steel HSS exclusively Do not 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 manufacturer shall...

Страница 11: ...e appropriate and suitable fire protection measures and make available fire extinguishers and first aid kits The operating company is responsible that the equipment is in proper working order at all times Therefore The operating company must make sure that any and all maintenance jobs described in this manual are really carried out The operating company must have any and all safety labels markings...

Страница 12: ...finishing jobs The welder operator has been coached trained by employees of ELEKTRON and or an authorised representative dealer of ELEKTRON concerning his tasks and duties and possible hazards in connection with inappropriate behaviour and confirms this with his signature see draft of training report form Appendix Service personnel refer to manufacturer s own service personnel and or that of his r...

Страница 13: ... concerning PPE that may be installed at the workplace When working always wear 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 against burns Safety shoes protect the wearer s feet against falling objects slippery surfaces and being run over by vehicles I...

Страница 14: ... on the plug Do not use the cable to trail or drag equipment over the floor Always grab equipment by the handles provided for that purpose Use strain relief clamps to protect 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 Electroma...

Страница 15: ...ked 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 your pockets matches lighters etc Hot surfaces CAUTION Hot surfaces pose a risk of burns Electrodes may heat up to 80 degrees centigrade approx Stock may have up to 100 degrees right after welding So there is an acute risk of burning...

Страница 16: ...hat they do not constitute a stumbling trap When welding assume a safe and stable working position 2 3 3 Dangers to this equipment and other property Tipping and toppling hazards due to high centre of gravity and obstacles during travel 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 ...

Страница 17: ...asures 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 signalling systems first aid rescue and escape equipment Keep access ways for ambulances clear and open Measures to be taken in case of accidents Actuate emergency stop see 2 6 Initiate first aid Evacuate people from da...

Страница 18: ...gain Fig 2 Power switch on the backside Power switch Turning the power switch to position 0 will disconnect the power supply immediately which basically has the same effect as an emergency stop WARNING Danger of life and limb Equipment may still be under voltage The emergency stop will shut down the equipment but will not disconnect the power supply To accomplish that push the power switch on the ...

Страница 19: ...mplants Electromagnetic fields can irritate human sense organs nerve and muscle cells Therefore Persons with pacemakers or other magnetisable implants must not approach the working area Be sure to put up suitable warning signs Be sure to put warning signs on access ways and doors leading to the work area Do not guide welding cables along people s heads or spines Keep a distance of at least 2 cm 2 ...

Страница 20: ...is equipment always using the handles Keep potential obstacles out of the work area Install cables and supply lines in such a way that they do not constitute a stumbling trap 2 7 4 On the control board Fig 6 Warning sign on the control board Meaning Do not pull compact flash card unless equipment has been properly switched off Compact flash card might be destroyed otherwise 2 8 Spare and wear part...

Страница 21: ...and specialised waste management companies will be happy to advise you with your disposal issues Please also consider the following information Batteries Batteries contain toxic heavy metals Batteries are subject to hazardous waste management and must be collected by specialised companies or taken to special collection centres Electronic components Electronic components and scrap are subject to ha...

Страница 22: ...8 Do not stack Do not stack Fragile goods Do not stack 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 9 in case of any further transport needs return of goods further transport 3 Recycle packing materials What to do with packing materia...

Страница 23: ...as soon as a defect has been detected Claims for damages may be brought forward only within the deadlines set for complaints 3 5 Handling 3 5 1 Forklift truck Fig 9 Using a forklift truck Packing units on pallets may be handled with a forklift truck as long as the following conditions are fulfilled The forklift truck must be certified for the weight of the packing unit at hand The operator must ha...

Страница 24: ...s a danger the equipment tips over Therefore Move this equipment always using the handles Keep potential obstacles out of the work area Securely stow cables and wires There is a danger the equipment rolls away because the wheels must not be blocked due to the tipping and toppling hazard CAUTION Equipment rolling away may cause damage to property The wheels of the equipment must not be blocked beca...

Страница 25: ...ater left in 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 Sto...

Страница 26: ...andard 4 2 Description The MULTISPOT MI 100control 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 selected operating mode sheet gauge and welding job The automat...

Страница 27: ... control panel 1 Tools detected automatically 2 Electrode caps required for welding program 3 No of pulses 1 36 4 Weld current set 5 Weld time set Total of all current times 6 Contact pressure set 7 Program name 8 Operating mode 9 Projection of electrodes i e actual length minus engaging area Fig 13 Detail from Fig 12 Fig 14 Detail from Fig 12 1 LED Malfunction see 7 2 2 work cannot continue as lo...

Страница 28: ... 4 4 Connections 4 4 1 Connections on the front side Fig 16 Connections on the front side 1 Pressure gauge displays input pressure 2 Pressure reducer continuous adjustment of input pressure 3 Central connection point for weld current compressed air and control voltage of the welding pliers 4 Coolant outlet 5 Coolant return 6 Connection for sensors 7 Emergency stop pushbutton shuts down equipment i...

Страница 29: ...ty 29 4 4 2 Connections 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 7 Water filter 8 Cooling water tank cap 9 Cooling water tank Fig 17 Connections on the backside ...

Страница 30: ... accessories Fig 18 Optional cooler Additional cooler Fig 18 to increase service life of welder Electrode arms hoops Electrode caps 4 5 2 Tools required Fig 19 Key for electrode caps Key for electrode caps Fig 19 NOTE Find our complete range of products and order information at www elektron bremen de ...

Страница 31: ...orking order Do wear safety shoes 5 2 Filling up cooling water tank Fig 20 Filling up the cooling water tank 1 Remove the cover on the rear side the coolant outlet and coolants return 2 Remove cooling water tank raise and turn off cooling water tank cap 3 Fill about 30 litres 7 9 gallons of cold clean drinking water into the tank 4 Add chlorine free disinfectant to prevent growth of algae and bact...

Страница 32: ...ling of the coolant tank the cooling circuit must be vented 1 Press service button on the control panel once This will call up the Service menu page 1 2 Use the control knob to select Empty cooling liquid tank Press to confirm Fig 21 Draining the cooling system 3 To vent select ON and confirm To stop select OFF and confirm To go back to the menu select Cancel and confirm 4 To vent the cooling wate...

Страница 33: ...ar pipe Replacement carabine hook Four M8 bolts with two nuts and washers each Mounting instructions Fig 23 Vertical pipe 3 Mount the vertical pipe using four M8 bolts Fig 23 see separate operating and mounting instructions Fig 24 Crossbar pipe 4 Mount the crossbar Fig 24 see separate mounting instructions Proceed as follows Mount and screw down stopper Fig 24 1 Insert crossbar pipe into guiding e...

Страница 34: ...3 ft of cable length Before you connect the welder to the mains make sure the grid is properly protected by fuses at 32 A Fig 26 Connecting welder to power supply 1 Take the power cord from its support 2 Run the power cord along a safe route 3 Connect the power cord to the mains 4 Use strain relief clamps to protect cables WARNING Stumbling hazards Power cords may constitute a stumbling hazard whe...

Страница 35: ...set 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 5 Push in the regulator to se...

Страница 36: ... the main plug of the welding pliers into the main socket of the equipment Fig 29 1 2 Turn the retainer nut clockwise Fig 29 2 to lock the connection Fig 30 Water cooling system for the pliers 3 Connect the water cooling system of the pliers Fig 31 Connecting sensors of the pliers 4 Connect the sensors of the pliers 2 1 ...

Страница 37: ...e of the grounding 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 6 9 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 shoe mus...

Страница 38: ...rve 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 start up of welder may constitute a hazard of injuries If the new tool is switched on during retoolin...

Страница 39: ...rm and bolt down Exchanging electrode caps Fig 36 Exchanging electrode caps 1 To loosen the electrode caps use the special key provided for that purpose or some equivalent tool Fig 36 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 ...

Страница 40: ...ig 38 Locking the arm hoop 2 Push the electrode arm hoop without much force into the locking device until you feel and hear it engage Fig 38 Adjusting the distance between electrodes Fig 39 Adjusting the distance between electrodes Make sure the distance between the electrodes is 6 to 8 mm Carry out the first welds and then check the distance again Re adjust if necessary Use an Allen key SW 5 as g...

Страница 41: ...ed welding operators with sufficient training and experience in spot welding exclusively Before operation consult the manual and make sure any and all preconditions are fulfilled any and all checks and preliminary works etc have been carried out Work place must be clean and tidy no clutter Make sure you have enough room to move Be sure to be wearing adequate PPE see 2 2 3 Check any and all connect...

Страница 42: ... Clean mill and or replace the electrode caps as required Fig 44 Control knob 3 Turn the control knob Fig 44 clockwise cw to position OK Confirm by pressing The display shows S12 Calibrate tool Please weld without sheets 4 Press the welding button on the welding pliers If calibration was successful the display will show S13 Calibration successful OK 5 Acknowledge by pressing the control knob If ca...

Страница 43: ...ding pliers 3 Switch on again The display will show message F35 4 Acknowledge by pressing the control knob 5 Press the service button wrench icon Fig 45 Service menu page 1 6 Use the control knob to select menu item Set languages Fig 45 Confirm Fig 46 Languages menu Next the display will show a list of languages from which to choose Fig 46 7 Use the control knob to select a language Confirm ...

Страница 44: ...ipment info Fig 48 2 Write down equipment ID and software version 3 Go to the ELEKTRON website www elektron bremen de Call up the Product registration page Enter your data 4 Fill in all the information in the online form in order to obtain the best possible service As soon as we have received your registration data we send you an email with your registration number 5 Enter the registration no in m...

Страница 45: ...lure to properly set the risk of faulty welds Therefore Welding parameters in the Free mode must be set by skilled welding operators exclusively Fig 50 Main menu 1 Press the control knob twice quickly 2 Use the control knob to select one of the three following control modes Keyboard operation For the welding job at hand the following parameters may be set manually see 6 4 2 2 OEM programs To selec...

Страница 46: ...on Weld current 1 Selecting welding gun active only if a welding gun has been installed 2 Selecting sheet gauge weld current and time will be calculated and displayed 3 Selecting material combination weld current and time will be calculated and displayed 4 Manual selection of weld current If weld current is changed manually the weld time will be adjusted automatically Fig 52 Touch keys on control ...

Страница 47: ...mine the pertinent gauges for the job using the following table 4 Using the following table determine the set value required Use the touch keys Fig 53 to enter the set value Welding job Ratio of sheets Sheet gauges up to about Set value Selection d1 d2 d3 0 8 0 8 0 8 1 0 1 0 1 0 1 5 1 5 1 5 2 0 2 0 2 0 d2 d3 2 0 0 8 0 8 0 8 1 0 1 0 0 8 1 5 1 5 0 8 2 0 2 0 0 8 3 0 3 0 d1 d2 d3 d1 d2 d3 3 Select nex...

Страница 48: ... show a list of available welding programs Fig 55 2 Use the control knob to select a program Confirm Next you will see the parameters of the program selected Fig 56 1 Tools required 2 Electrode caps required for welding program 3 No of pulses 1 36 4 Weld current required 5 Weld time required Total of all current times 6 Contact force required 7 Program name or 8 Control mode depending on selection...

Страница 49: ...8 Prompting for password The display shows a prompt requiring a password Fig 58 2 Use the control knob to select OK Confirm NOTE It is incumbent upon the operating company to decide whether passwords should be used and who should have a password or not Make passwords inaccessible to strangers Fig 59 Dialogue box You will see the following prompt Fig 59 Take over current parameters or load program ...

Страница 50: ...ng time ms Fig 62 Parameters 1 Press control knob 2 Use the control knob to select ms Confirm The time value ms will be highlighted in black 3 Use the control knob to adjust the welding time value ms Turn clockwise to increase the value Turn counter clockwise to decrease the value 4 Press control knob to confirm 5 Press Esc to cancel and go back to the main menu Storing own programs generated in F...

Страница 51: ...tored in the folder Individual programs Fig 66 Main menu 6 To continue press the control knob The display takes you back to the main menu 6 4 3 Electrode recognition Fig 67 No electrode recognition The MULTISPOT MI 100control and the electrode arms are equipped with an automatic electrode recognition system Electrodes are being identified automatically and the length is shown on the display If the...

Страница 52: ...on Fig 70 Control knob In case of emergency and or for service purposes it is possible to switch off the automatic tool recognition system and select the tool installed manually on the control panel Proceed as follows 1 Switch off the welder 2 Install the tool on the welder 3 When you switch on the welder again press the start button of the tool The tool box of the display will contain a question ...

Страница 53: ...least 10 mins After you have finished a job 6 5 Important information concerning welding 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 other magnetisable implants Electromagnetic fields can irritate human sense organs nerve and muscle cel...

Страница 54: ...th residues of glues paints undercoating products etc that may generate harmful or even toxic vapours during 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 Hot surfaces CAUTION Hot surfaces pose a ...

Страница 55: ...ng that is not inflammable covers arms and legs completely and tears easily instead of getting pulled in Its main purpose is to protect against burns Safety shoes protect the wearer s feet against falling objects slippery surfaces and being run over by vehicles For special works wear Face screen protects the face and eyes against splashes flying sparks and other hot particles Welder s gloves prote...

Страница 56: ...e contact force is set higher than 240 daN 540 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 240 daN 540 lb f 4 6 bar 67 Psi Distances between welding spots Fig 73 Distances should not be too short Don t keep the distances between weldi...

Страница 57: ...ton twice Fig 75 Displaying all parameters This will call up all the welding parameters Fig 75 6 7 Settings in the service menu NOTE The access and edit rights of some of the menus depend on the settings defined in ELEKTRON s key file If you should have any questions or need additional rights please contact us NOTE Any service settings not described in this manual must be handled by skilled servic...

Страница 58: ...ess to confirm Fig 76 Categories of information Vehicle number User ID Vehicle licence number Type of vehicle Order number If the control does not detect activities over 60 mins the data must be either 75 confirmed or modified 6 7 1 2 Concluding an order Menu item Quit order is for concluding an order Use the control knob to select Quit order Press to confirm Fig 77 Concluding an order As soon as ...

Страница 59: ...l programs for future transfer Deleting individual programs Activating special welding programs Deactivating special welding programs 6 7 1 4 Emptying cooling system see 8 2 3 6 7 1 5 Registering welder see 6 3 2 6 7 1 6 Activating fuse protection Menu item Fuse protection is for calling up a time delay after welding in order to protect the fuses against overheating Fuse protection is off by defau...

Страница 60: ...nd date 2 Use the control button to set the date and or time Press to confirm 6 7 2 Service menu settings page 2 Press service button on the control panel twice This will call up the Service menu page 2 6 7 2 1 Calling up electrode cap service mode Use the menu item Cap service mode to manually call up electrode cap cleaning In this mode the power supply is cut off Only the electrode clamp system ...

Страница 61: ...hts In addition you need an Expert CF memory card Fig 82 Changing the configuration If no Expert CF memory card has been slotted you will see the message shown here on the left 6 7 2 3 Loading most recent configuration With the menu item Load last configuration you can restore the most recent configuration used If the new configuration fails the system will automatically revert to the previous ver...

Страница 62: ...n here on the left 6 7 2 4 Storing all welding jobs Use the menu item Save data on compact flash to store data on the internal CF memory card The data can be later read and printed with special software traceability program Use the control knob to select Save data on compact flash Press to confirm Fig 84 Storing all welding jobs You will see the message shown here on the left ...

Страница 63: ...ct Switch off weld rules Press to confirm Fig 85 Switching off weld rules Depending on your access rights you may receive for instance the status message shown on the left 6 7 2 6 Calling up status and error messages Use the menu item Status error messages to display the current software version s installed on the welder Use the control knob to select Status error messages Press to confirm Fig 86 ...

Страница 64: ... and spare parts Use the control knob to select Software version Press to confirm Fig 87 Software version You will see the message shown here on the left 6 7 2 8 Calling up current and voltage values Use the menu item Measure mains supply to display the voltage drop You need the data for troubleshooting Use the control knob to select Measure mains supply Press to confirm Fig 88 Current and voltage...

Страница 65: ...card CF memory card or Update by email You will need a compact flash memory card reader Option CD ROM CF card The CD ROM contains the documentation explaining the use of the OEM weld programs The documentation refers only to OEM weld programs and contains information on programs to be used electrode arms welding positions and number of spots to be applied on certain bodies Depends on OEM and may v...

Страница 66: ...new or updated CF memory card into the card reader slot 6 Close the control unit and turn the knob on the left clockwise 7 Switch the welder back on The welder will boot up and automatically download the update data to the control unit 8 You can simply acknowledge the next message by setting the control knob to OK You can now call up the programs using the menu Program selection NOTE Please check ...

Страница 67: ...ness on display Thickness of more than 1 5 mm cannot be selected Press the welding gun to the welding point with a pressure of approx 0 78 0 12 daN Fig 93 Pressure on welding point NOTE Excessive contact pressure will lead to poor welding results when the distance to the ground connection is too great CAUTION Inadequate contact pressure air gap or paint grease between the steel sheets will result ...

Страница 68: ...djust 5 Position welding gun with washer in the area of the dent 6 Press release button of the gun Fig 94 Contact piece U B 7 Hook pulling tool Fig 95 into the washer and carefully beat out the dent 8 Remove washer by twisting Only twist the washer off otherwise holes in the sheet steel could result Fig 95 Pulling tool NOTE 8 mm Washer Always beat out major dents from the outside working inwards U...

Страница 69: ... of the gun and weld on welding tip 7 Beat out the dent 8 Twist the high speed planishing hammer SAH off the sheet steel Select the weld time as short as possible 9 From time to time dress the weld on tip with a file Fig 96 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...

Страница 70: ...lding gun until the welding time has expired 6 9 5 Shrinking sheet 1 Grind damaged area to a bright metal finish 2 Insert carbon electrode Fig 98 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 in the centre of the damaged area 6 Press and keep hold of release button ...

Страница 71: ...ct piece 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 99 Contact piece SB threaded stud Threaded studs with...

Страница 72: ...l limit stop into welding gun 3 Select T pin mode and sheet thickness on display 4 Insert head of T pin into tip of contact piece 5 Select welding position and press on welding gun 6 Press and keep hold of release button of gun until end of welding program Fig 100 Contact piece TST Fig 101 Fitting piece 1 Contact piece TST 3 Item no 407 227 2 T pin 3 x 4 5 Item no 408 597 3 Fitting piece Golf 2 It...

Страница 73: ...he 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 9 1 5 Instead of the ground lug a second gun can be connected switch welder unit off first and wait until cooling pump switches off automa...

Страница 74: ...st adapt the inspection and maintenance intervals accordingly 7 2 Error messages and troubleshooting tables 7 2 1 Problems displayed on the control panel Message What s the problem What should be done Who should do it F01 Welding job has been successfully re adjusted There has been some problem and the welder has re adjusted the weld parameters accordingly Nothing the control unit has solved the p...

Страница 75: ...rrent welding job Let the pump run Operator Central connection is not tight Re tighten The plug of the temperature sensor has gone loose Re tighten F35 No tool recognised Please insert a tool A tool has not been connected Connect a tool Operator Otherwise the tool must be defective Replace the tool F36 Wrong tool for selected program Please connect tool as per indication The tool connected is not ...

Страница 76: ...as detected an error in the software Carry out an update with elk files 6 8 Operator F46 Days until registration of the control becomes necessary This shows the number of days until menu item Program selection will be blocked If the display runs down to zero days you can only use the keyboard programs However the welder can be released at any time 6 3 2 Operator F47 Invalid release key expired or ...

Страница 77: ... deactivated safety routines One or several safety rules have been switched off If a problem should occur during welding the system cannot adjust You must determine yourself whether the results will be satisfactory or not If yes confirm Operator F62 Internal flash error The internal memory is damaged and or does not contain any data Service personnel only Service An error occurred while trying to ...

Страница 78: ... Operator Power cord not plugged in Plug in power cord If the power cord is indeed connected a mains fuse may have been triggered Reset fuse Display freezes LEDs not plausible System error Reboot Operator The red LED to the left of the control knob lights up Thermal overload Let the welder cool off Let the cooling system run at least 10 mins After you finish Operator Tool error Let the tool cool o...

Страница 79: ...Operator Welding spot burns up excessive spattering sheets not strong enough Weld current too high Adapt welding parameters If that doesn t do it fall back on pre defined programs and or keyboard mode Operator Weld time too long Wrong welding program Select correct welding program If in doubt talk to the manufacturer and or OEM Operator Welding job flawed Welding parameters not set correctly accor...

Страница 80: ...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 requirements see 9 4 Check actual input current and voltage Take your own measurements Skilled electrician Whenever necessary Use the CF memory card to make data backups Store externally Operator Visually check the water separator...

Страница 81: ...titute a hazard Wrong and or defective spare and wear parts may constitute a safety hazard and may entail errors damage and even total destruction Therefore Always use genuine spare and wear parts made by the manufacturer 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 no...

Страница 82: ...ully 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 104 Water filter 1 Visually check the water filter Fig 104 If you detect clear signs of dirt 2 Switch off the welder Wait until the pump stops pumping 3 Pull the water filter unit from the hoses to the top and bottom 4 Replace the old fi...

Страница 83: ... 1 Remove 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 observing disposal regulations 4 Fill about 30 litres 7 9 gallons of cold clean drinking water into the tank 5 Add chlorine free disinfectant to prevent growth of algae and bacteria 6 Cooling water ...

Страница 84: ...wing 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 sure you have properly removed and taken away from the work area any and all tools materials etc you may have used 4 Clean the work area If there have been any leaks spills etc clean up ...

Страница 85: ...Ph Hz Admissible voltage range 440 500 380 415 208 240 V AC Power cord 6 AWG 10 6 AWG 10 16 AWG 6 mm 2 10 m 33 ft Mains fuse min 32 32 63 A slow blow Installed power 42 42 42 kVA Rated output at 50 duty cycle 60 60 60 kVA No load voltage max 23 23 23 V DC weld current regulated max 12000 12000 12000 A DC Enclosure IP21 Compressed air supply Item Value Unit Operating pressure min max 6 10 87 145 ba...

Страница 86: ...it values Welding pliers Item Compliance Exposure limit values accor EU directive 2004 40 EG Safe compliance with distances 15 cm perpendicular to pliers opening Safe compliance with distances 7 cm to welding cable 9 6 Type plates Fig 106 Type plate on the backside 1 Manufacturer 2 Inverter type 3 Item no 4 Input voltage in VAC 5 Frequency in Hz 6 Power consumption in kVA 7 Enclosure 8 Production ...

Страница 87: ... 45 Control panel 27 Copyright 6 Customer service 9 D Dentpuller 73 Description 19 Dimensions 85 Disinfection 31 83 Display and control elements 27 E Electricity 14 Electrode recognition 51 Electromagnetic fields 14 53 Emergency stop button 18 Empty cooling water tank 83 Environmental protection 21 Error messages 74 Exposure limit values 86 F Filling up cooling water tank 31 Flying sparks 15 Furth...

Страница 88: ... 2 60 Settings Contact force 56 Electrode recognition 51 Language 43 Time and date 60 Tool selection 52 Shrinking sheet 70 Slip hazard 15 Spare and wear parts 20 Specifications 85 Splashes 15 Spring balancer 33 Storage 25 Stumbling hazards 16 Supplies 85 Switching off the cooling water pump 53 Switching off weld rules 63 Switching on 42 Symbols on equipment 19 on packaging 22 to be installed by op...

Страница 89: ...Resistance welder MULTISPOT MI 100control Appendix 89 11 Appendix 11 1 Training Report NOTE Master copy Do not fill in Make copies Date Name Type of training Trainer Signature ...

Страница 90: ...BlitzRotary Gm bH Branch Brem en Hinterm Sielhof 22 D 28277 Brem en Phone 49 0 421 54 90 6 906 Fax 49 0 421 54 90 6 19 vertrieb elektron bremen de www elektron bremen de ...

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