Elektron MULTISPOT M20 Operating Instructions Manual

Operating instructions

MULTISPOT M20

ELEKTRON Bremen GmbH Hinterm Sielhof 22 D-28277 Bremen
Fon +49/(0)421/54906-906 Fax [phone] [e-mail] www.elektron-bremen.de

- 1 -

Contents page

1.0 Warning notes – explanation of symbols 3

2.0 Description of equipment and overview 5

3.0 Start-up 6

3.1 Connection to power supply 6

3.2 Mains power supply connection 6

4.0 Applications 7

5.0 Technical data 7

6.0 Operating the welding gun 9

6.1 Pulling-out dents with washer 11

6.2 High-speed planishing hammer "SAH" (special accessory) 13

6.3 Pushing-in dents 15

6.4 Shrinking sheet metal 15

6.5 Welding-on threaded studs 17

6.6 Welding-on T-pins 19

6.7 Positioning/fixing sheet metal (tacking) 21

7.0 Appendix/self-test and troubleshooting 22

7.1 Self-test 22

7.2 Checking the LED displays 22

7.3 Mains-supply test and troubleshooting 23

7.4 Manual tool selection 24

7.5 Operating panel malfunction 24

- 2 -

1.0 Warning notes – explanation of symbols

Caution!

The power supply unit and leads of the welding gun
and other tools generate a powerful electromagnetic
field when in use. This can cause malfunctions in heart
pacemakers, quartz watches and other electronic devi­ces. Electromagnetic storage devices, e.g. on credit
cards, may be erased.

Caution! Danger!

Ignoring this warning may result in injury!

Observe the notes!

This is the only way to achieve satisfactory welding re-



sults.

Work on the power supply unit may ONLY be per­formed by qualified electricians.

Wear protective goggles and gloves!

- 3 -

Tool selecting keys (manual) see Ap­pendix
CD Gun functions selecting keys
GH Fine adjustment keys time +/–
Tools
1 Gun
2 Special (e.g. AIRPULLER)
Working with gun
3 Welding of corrugated wire
4 Stud welding/Copper shrinking
5 Beat-out with washers, T-pins,
Special
6 High-speed planishing hammer
7 Anneal/shrink
8 Fine adjustment +/–
9 Mains plug symbols with
LED "control mains voltage drop"
(15, 16, 17)
10 LED malfunction
11 Mains plug
12 Mains cable
15
16 Indicator

18 19 20

M20 – front

11

12

17 “control mains voltage drop“
18 Ground cable
19 Flange socket
20 Welding socket

- 4 -

M20 – back

2.0 Description of equipment and overview

The MULTISPOT M20 resistance welding unit is designed for the
special requirements of motor vehicle body repair.
The power source is controlled by a micro-processor. After selec­ting the operating mode, the current and weld time will be as­signed automatically.
An audible alarm is performed, if the welding current is too low.

Further functions:

– Automatic tool recognition
– Integrated mains monitor recognises undervoltage
– Automatic current rise, welding and current recognition
– Easy and distinct operation by means of foil keyboard

- 5 -

3.0 Start-up

3.1 Compressed air connection 8 bar

The compressed air connection (8 bar) is located on the back of
the power supply unit. The compressed air supply is necessary for
operating special tools (e.g. Airpuller) and cooling the welding gun.

3.2 Connection to power supply

230 V (205 - 250 V) 50/60 Hz or 400V 50/60Hz

Connection to a 16 A socket 16A-CEE-socket
Fuse: 16 A slow fuse
or

16 A automatic circuit-breaker

3.3 Checking the mains voltage drop during welding

If the full performance of the MULTISPOT M20 is to be obtained,
the mains voltage drop during welding must be kept as small as
possible. The full test is described on page 20 Chapter 8.3:

 Information about the mains drop during welding
 Display with 3 LEDs (15, 16, 17) under the mains plug

symbol:
Green = mains OK
Green/yellow = mains drop within tolerance range.
Only yellow = considerable mains drop – welding
performance impaired

If necessary, check mains cord, extension cables etc. or use
thicker cables.

Red LED and = large mains drop with high loss in performance
warning tone: Welding is not possible. Welding current too
low.

If necessary, check mains cord, extension cables etc. or use
thicker cables.

– After 2 seconds, the display automatically reverts to green.
– After each welding operation, any mains voltage drop is
displayed for 2 seconds.

- 6 -

4.0 Applications

Programme switch Material Max. sheet
Function thickness
in mm

Dent-pulling
with washer sheet steel 1.0
T-pins 3 mm Ø sheet steel 1.0
Dent-pulling with other tools sheet steel 1.0
(e.g. Airpuller)
Dent-pulling with
high-speed
planishing hammer sheet steel 1.0
Shrinking sheet steel 0.6 - 1.0
Stud welding Steel bolts Ø 4 - 5 mm
on sheet steel 2.0 mm
Corrugated wire on sheet steel 1.0
Copper shrinking sheet steel 1.0

5.0 Technical data

Power supply unit 230 V (205 - 250 V) 400V

Supply voltage 1x230 V (1~) 400V (2~)
Slow fuse 16 A 16A

Mains frequency 50/60 Hz 50/60 Hz
Power supply cord 3.3 kVA 3.3 kVA
Max. welding capacity 11 kVA 11 kVA
Open-circuit voltage 8 V AC 8 V AC
Welding current max. 3000 A 3000 A
Ambient temperature 40 °C 40 °C
Type of protection IP21 IP21

Power supply unit with Dinse-plug
Dimensions H/W/D in mm 285/220/340
Weight 21 kg

(standard version)

- 7 -

33 Welding gun
34 Button of welding gun
35 Grounding cable
36 Copper shoe
37 Lever clamp
38 Connection piece

A B

- 8 -