Elektron MULTISPOT MI-100control Operating Manual
Version:
Made in G e r many
Operating Manual
MULTISPOT MI-100control
Resistance welder
Item no.: 328 010
Revision: 0.9 – Translation
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.
© BlitzRotary GmbH
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
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Resistance welder MULTISPOT MI-100control
Table of contents
1
General Information .............................................................................................. 6
1.1 Information concerning the operating manual .......................................................................... 6
1.2 Copyright ................................................................................................................................... 6
1.3 Disclaimer ................................................................................................................................. 6
1.4 Symbols .................................................................................................................................... 7
1.5 Warranty and guarantee ........................................................................................................... 9
1.6 Customer service ...................................................................................................................... 9
2
Health and safety ................................................................................................ 10
2.1 Intended purpose .................................................................................................................... 10
2.2 Responsibilities of the operating company ............................................................................. 10
2.2.1
2.2.2
2.2.3
2.3 Particular dangers ................................................................................................................... 14
2.3.1
2.3.2
2.3.3
2.4 Correct behaviour in accidents 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
2.7.2
2.7.3
2.7.4
2.8 Spare and wear parts.............................................................................................................. 20
2.9 Waste management and environmental protection ................................................................ 21
General responsibilities ........................................................................................... 10
Requirements to personnel ..................................................................................... 12
Personal protective equipment (PPE) ..................................................................... 13
Dangers due to the equipment ................................................................................ 14
Dangers due to the work environment .................................................................... 16
Dangers to this equipment and other property ........................................................ 16
On the flap cover ..................................................................................................... 19
Signs on the backside ............................................................................................. 19
On the balancer ....................................................................................................... 20
On the control board ................................................................................................ 20
Table of contents
3
Transport, packaging, storage ........................................................................... 22
3.1 Safety during transport............................................................................................................ 22
3.2 Symbols on packaging ............................................................................................................ 22
3.3 Unpacking ............................................................................................................................... 22
3.4 Acceptance after shipping ...................................................................................................... 23
3.5 Handling .................................................................................................................................. 23
3.5.1
Forklift truck ............................................................................................................. 23
3.5.2
Moving equipment to the site .................................................................................. 24
3.6 In case of return of goods / further transport needs ............................................................... 25
3.7 Storage ................................................................................................................................... 25
4
Design and functionality .................................................................................... 26
4.1 Overview ................................................................................................................................. 26
4.2 Description .............................................................................................................................. 26
4.3 Display and control elements .................................................................................................. 27
4.3.1
On the display and control panel ............................................................................. 27
4.3.2
On the inverter control unit ...................................................................................... 28
4.4 Connections ............................................................................................................................ 28
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Resistance welder MULTISPOT MI-100control
Table of contents
4.4.1
Connections on the front side .................................................................................. 28
4.4.2
Connections on the backside .................................................................................. 29
4.5 Accessories ............................................................................................................................. 30
4.5.1
Optional accessories ............................................................................................... 30
4.5.2
Tools required .......................................................................................................... 30
5
Installation ........................................................................................................... 31
5.1 Before installation ................................................................................................................... 31
5.1.1
Preliminary works .................................................................................................... 31
5.2 Filling up cooling water tank.................................................................................................... 31
5.3 Ventin coolant circuit ............................................................................................................... 32
5.4 Assembling the balancer ......................................................................................................... 33
5.5 Electrical connections ............................................................................................................. 34
5.6 Connecting the pneumatics .................................................................................................... 35
5.7 Connecting the pliers .............................................................................................................. 36
5.8 Connecting the welding gun .................................................................................................... 37
6
Operation ............................................................................................................. 38
6.1 Preliminary works before welding ........................................................................................... 38
6.1.1
Preparing the sheets ............................................................................................... 38
6.1.2
Preparing welding pliers .......................................................................................... 38
6.1.3
Checks before switching on ..................................................................................... 41
6.2 Switching on ............................................................................................................................ 42
6.3 Basic 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 Important information concerning welding .............................................................................. 53
6.6 Calling up welding parameters................................................................................................ 57
6.7 Settings in the service menu ................................................................................................... 57
6.7.1
Service menu settings (page 1) ............................................................................... 58
6.7.1.1 Enter order data ....................................................................................... 58
6.7.1.2 Concluding an order ................................................................................. 58
6.7.1.3 Administering programs ........................................................................... 59
6.7.1.4 Emptying cooling system ......................................................................... 59
6.7.1.5 Registering welder ................................................................................... 59
6.7.1.6 Activating fuse protection ......................................................................... 59
6.7.1.7 Setting languages .................................................................................... 60
6.7.1.8 Setting time and date ............................................................................... 60
6.7.2
Service menu: settings (page 2) .............................................................................. 60
6.7.2.1 Calling up electrode-cap service mode .................................................... 60
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Resistance welder MULTISPOT MI-100control
6.7.2.2 Changing configuration ............................................................................ 61
6.7.2.3 Loading most recent configuration ........................................................... 61
6.7.2.4 Storing all welding jobs ............................................................................ 62
6.7.2.5 Switching off weld rules ........................................................................... 63
6.7.2.6 Calling up status and error messages ..................................................... 63
6.7.2.7 Calling up the software version ................................................................ 64
6.7.2.8 Calling up current and voltage values ...................................................... 64
6.7.2.9 Modifying service address ....................................................................... 65
6.8 Updating software ................................................................................................................... 65
6.9 Operating the welding gun ...................................................................................................... 67
6.9.1
Push spot welding ................................................................................................... 67
6.9.2
Pulling-out dents with washer .................................................................................. 68
6.9.3
High-speed planishing hammer “SAH” (special accessory) .................................... 69
6.9.4
Pushing-in dents ...................................................................................................... 70
6.9.5
Shrinking sheet ........................................................................................................ 70
6.9.6
Welding-on threaded studs ..................................................................................... 71
6.9.7
Welding-on T-pins ................................................................................................... 72
6.9.8
Fixing sheet metal parts (tacking) ........................................................................... 73
6.9.9
Water-cooled spot welding gun (special accessory) ............................................... 73
6.9.10 Connection of Airpuller/ Dentpuller .......................................................................... 73
Table of contents
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 unsatisfactory welding results ............... 79
8
Maintenance ........................................................................................................ 80
8.1 Maintenance schedule ............................................................................................................ 80
8.2 Carrying out maintenance jobs ............................................................................................... 80
8.2.1
Cleaning .................................................................................................................. 81
8.2.2
Maintaining the pneumatic unit ................................................................................ 81
8.2.3
Replacing water filter ............................................................................................... 82
8.2.4
Empty cooling water tank ........................................................................................ 83
8.3 Measures to be taken after maintenance ............................................................................... 84
9
Specifications ...................................................................................................... 85
9.1 Dimensions and weights ......................................................................................................... 85
9.2 Power requirements ................................................................................................................ 85
9.3 Supplies .................................................................................................................................. 86
9.4 Working conditions .................................................................................................................. 86
9.5 Exposure limit values .............................................................................................................. 86
9.6 Type plates ............................................................................................................................. 86
10 Index .................................................................................................................... 87
11 Appendix.............................................................................................................. 89
11.1 Training Report ....................................................................................................................... 89
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Resistance welder MULTISPOT MI-100control
General Information
1 General Information
1.1 Information concerning the operating manual
This operating manual will enable you to work efficiently and safely with this equipment.
The manual is an essential part of this product and must be stored ready at hand not far from the
equipment so that people can use it at any time without any problems. Operators must read and
understand the manual before they carry out any works. Compliance with any and all information
contained herein concerning health, safety and safe behaviour and procedures is a prerequisite for
safe work.
Shall apply in addition: Any and all local accident prevention regulations, any and all general safety
regulations that may apply to the scope of application of this equipment.
Pictures, drawings etc. contained in this operating manual are supposed to convey a general
understanding of facts. In details, they may deviate from the reality you encounter.
Besides this operating manual, there may be specific instructions for units, components etc.
They shall apply accordingly.
1.2 Copyright
This operating manual is protected by copyright. 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 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, and the long-standing insights and experience of our
staff.
The manufacturer cannot be made liable for damage due to:
Non-compliance with this operating manual
Non-compliance with the purpose and intent of this equipment
Deployment of unskilled personnel
Unauthorised constructional changes, alterations etc.
Unauthorised changes, modifications etc. to design and engineering etc.
Use of unauthorised spare and wear parts
The scope of the delivery you actually receive may deviate from explanations and / or representations
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 Contract was concluded.
We constantly strive to further develop and improve our products and their functionality. We, therefore,
reserve the right to implement technical changes without notice.
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Resistance welder MULTISPOT MI-100control
DANGER!
WARNING!
CAUTION!
CAUTION!
Electric current!
Electromagnetic fields!
Crushing!
Hot surfaces!
Hot liquids!
1.4 Symbols
Safety information
This manual uses symbols to highlight important safety information. In addition, there is always a
signal word heading the information indicating the severity of the danger or hazard that may be
encountered.
Be sure to comply with any and all safety information. Proceed with care and circumspection.
Prevent accidents and damage to people and property.
Warnings
General Information
… indicates a situation that is imminently dangerous and will entail the death of people
and severe injuries unless it is properly avoided and prevented.
... indicates a situation that may become dangerous and may entail the death of people
and severe injuries unless it is properly avoided and prevented.
... indicates a situation that may become dangerous and may entail medium and small
injuries unless it is properly avoided and prevented.
… indicates a situation that may become critical and may entail damage to property
unless properly avoided and prevented.
Electricity constitutes a danger to life and limb.
Life hazard for persons with heart pacemakers, or other magnetically influenced
implants. Damage to equipment.
As long as the unit is in operation, risk of injury.
Risk of burns from hot surfaces.
Danger of scalding from escaping hot coolant!
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Resistance welder MULTISPOT MI-100control
Harmful substances!
Risk of stumbling!
Slip hazard!
Electromagnetic fields!
Electromagnetic fields!
Electromagnetic fields!
S
afety clothing
Safety shoes
Face screen
Welder's gloves
General Information
Danger of toxic, harmful vapours at least.
Risk of injury due to falls.
Risk of slipping due to leaking water.
Prohibitions
Hazard to persons with pacemakers.
Persons who may suffer health risks due to the influence of electromagnetic fields must
not approach this equipment.
Mandatorys
Hazard to persons with magnetisable implants.
Persons who may suffer health risks due to the influence of electromagnetic fields must
not approach this equipment.
Hazard to magnetisable objects
Magnetisable data carriers and similar objects that may suffer from magnetism must not
be brought close to this equipment.
…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.
…protects the wearer's feet against falling objects, slippery surfaces and being run over
by vehicles.
…protects the face and eyes against splashes, flying sparks and other hot particles.
8
…protect the hands against splashes, flying sparks and other hot particles, and prevent
contact with hot surfaces.
Never use wet welder's gloves.
Resistance welder MULTISPOT MI-100control
Tips, tricks and recommendations
NOTE!
... highlights information that may be helpful to maintain efficient and trouble-free
operation.
1.5 Warranty and guarantee
The guarantee conditions shall 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 products that may be helpful for their future
improvement.
General Information
9
Resistance welder MULTISPOT MI-100control
MULTISPOT MI
-
100control
WARNING!
Misuse may entail danger
!
Health and safety
2 Health and safety
This section contains an overview of the most important health and safety at work aspects in order to
protect employees and to guarantee safe and trouble-free operation.
Non-compliance with any and all of the information, safe behaviour and procedures etc. contained
herein may entail severe health and safety risks.
2.1 Intended purpose
This equipment has been designed and built for the following purpose(s), exclusively, and shall be
used accordingly:
The
maintenance work on car bodies, for stock of up to 3 mm sheet gauge and combinations of up to three
sheets within its specifications and limits of use ( see “Specifications”).
“Intended use” and “intended purpose” shall include proper compliance with any and all information
contained in this operating manual.
Any and all use diverting from and / or going beyond the limits as set by the equipment's intended
purpose and use shall be deemed misuse and may entail dangerous situations.
Misuse of this equipment may entail dangerous situations.
Therefore:
Do not operate this equipment unless clearly within 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 not be held liable for any and all damage due to misuse of this equipment.
resistance welder serves the sole purpose of spot welding during
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 concerning health and safety at work.
That means, in addition to this operating manual, any and all accident prevention, health and safety at
work and environmental regulations pertaining to this equipment's scope of application shall apply as
well.
This means in particular:
The operating company must be informed about any and all pertinent health and safety at
10
work regulations and must carry out a risk assessment in order to determine additional
hazards existing under the specific conditions in the specific work environment at the place
of operation. Any and all findings from such a risk assessment must then be used to draw up
additional operating instructions for the operation of this equipment.
Resistance welder MULTISPOT MI-100control
Electromagnetic fields!
Electromagnetic fields!
Electromagnetic fields!
Health and safety
During the entire lifetime of this equipment, the operating company must check in regular
intervals whether such additional operating instructions are still up to date and must update
them when necessary.
The operating company must unambiguously determine and communicate responsibilities
concerning the installation, operation, maintenance and cleaning of this equipment.
The operating company must make sure that any person handling this equipment has read
and understood this operating manual. Operating personnel, in addition, must be trained in
regular intervals and must be informed about the dangers existing in connection with this
equipment. (For a draft of a training report form, see “Appendix”)
The operating company must equip operating personnel with suitable personal protective
equipment (PPE) and check it for proper working condition in regular intervals.
Defective PPE must be replaced with new ones.
The operating company must take 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 etc. on the equipment
checked for integrity and readability in regular intervals.
Symbols the operating company must install on access ways and doors
Symbol Meaning
Hazard to persons with pacemakers.
Persons who may suffer health risks due to the influence of electromagnetic fields must
not approach this equipment.
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
Hazard to magnetisable objects
Magnetisable data carriers and similar objects that may suffer from magnetism must not
be brought close to this equipment.
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Resistance welder MULTISPOT MI-100control
WARNING!
People with insuffic
ient skills may suffer injuries!
Health and safety
2.2.2 Requirements to personnel
Inexpert handling may entail severe damage to persons and property.
Therefore:
Make sure that any and all activities are carried out by skilled personnel, only.
This equipment may be operated only by persons who can be relied on to do their work
properly.
Persons whose capability of reaction is impaired, e. g. by drugs, alcohol or medication, must
not be allowed to handle this equipment.
When selecting suitable operating personnel, be sure to respect occupational regulations
and legislation concerning skills, age etc.
This operating manual specifically names the following types of personnel who must have the
following skills:
Operator / welder
has extensive skills and experience in the field of resistance welding and with the
corresponding preliminary and 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 representative / dealer.
Such service personnel have the professional training, skills and experience as well as
knowledge of pertinent regulations to carry out the jobs they accept and to identify, avoid
and prevent hazards on their own and without additional support.
Skilled electrician
has the professional training, skills and experience as well as knowledge of pertinent
regulations to carry out jobs on electrical equipment and to identify, avoid and prevent
hazards on his own and without additional support. A skilled electrician is needed, for
instance, if the conductor cross-section and fuse protection of the operating company's
power grid must be adapted to the special requirements of resistance welding.
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Resistance welder MULTISPOT MI-100control
CAUTION!
Insufficient protection
against injuries
!
S
afety clothing
Safety shoes
Face screen
Welder's gloves
Furthermore
2.2.3 Personal protective equipment (PPE)
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 defective PPE.
Consider manufacturer's instructions and expiration dates, when and where
applicable.
Wearing PPE during work is essential to minimise health and safety risks.
Be sure to be always wearing the appropriate PPE for the job at hand.
Be sure to take note of and comply with warning signs concerning PPE that may be installed
at the workplace.
When working, always wear:
Health and safety
…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.
…protect the wearer's feet against falling objects, slippery surfaces and being run over
by vehicles.
In case of special work wear:
…protects the face and eyes against splashes, flying sparks and other hot particles.
…protect the hands against splashes, flying sparks and other hot particles, and prevent
contact with hot surfaces.
Never use wet welder's gloves.
…no long hair, rings, necklaces, watches and / or other sorts of jewellery. Do not carry
easily inflammable objects in your pockets (matches, lighters etc.).
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Resistance welder MULTISPOT MI-100control
DANGER!
Electricity consti
tutes a danger to
life and limb!
DANGER!
Electromagnetic fields pose a potentially fatal hazard to people with
Health and safety
2.3 Particular dangers
2.3.1 Dangers due to the equipment
Electricity
Touching live components can result in a fatal electrical shock.
Therefore:
As soon as you notice any damage to insulation, disconnect the power supply and
have the damage repaired.
Do not open this equipment yourself. Have all repairs carried out by service
personnel, exclusively. Have works on electrical equipment carried out by skilled
electricians, exclusively.
Before any and all electrical works: disconnect power, earth and short. Check
whether equipment is really dead.
Keep live components away from liquids and humidity. They may cause short
circuits.
Protect cables against running over, contact with oils, aggressive substances, tools,
pointed and / or hot objects.
When pulling from a socket: Never pull on the cable. Pull 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
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 warning signs on access ways and doors leading to the work area.
Do not guide welding cables along people's heads or spines. (To comply safely with
permissible exposure limits, keep distances ≥ 20 cm. Keep a distance of at least
2 cm between cable assemblies and people's heads / spines.)
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Resistance welder MULTISPOT MI-100control
WARNING!
Splashes and flying sparks constitute a danger of fire and
CAUTION!
Hot surfaces pose a ris
k of burns!
DANGER!
Scalding may occur due to hot water coming out!
DANGER!
Slip hazard due to water coming out!
Health and safety
Splashes, flying sparks
explosion. Splashes and flying sparks pose a risk of injuries!
Welding generates sparks and - hot spatter. They can ignite combustible materials and
generate explosions. Contact with body parts may entail injuries.
Therefore:
Before you tackle any welding jobs, make sure there are no combustible and / or
explosive materials in the work 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 objects in your pockets (matches, lighters etc.).
Hot surfaces
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 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.
Scald hazard
While pulling out the cooling water hoses hot water may come out.
Therefore:
Wear gloves.
Pull out water hoses carefully.
Slip hazard
While pulling out the cooling water hoses water may come out.
Therefore:
Remove water from the floor.
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Resistance welder MULTISPOT MI-100control
WARNING!
Vapours may constitute a dange
r to your health!
WARNING!
Possibility of injuri
es due to stumbling and falling!
CAUTION!
Tipping and toppli
ng may cause damage to property!
CAUTION!
Equipment rolling aw
ay may cause damage to property!
Health and safety
2.3.2 Dangers due to the work environment
Vapours
Stock that has not been properly ground and cleaned before welding may be
contaminated with 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.
Stumbling hazards
The work environment may pose stumbling risks. Stumbling and falling may lead to
severe injuries.
Therefore:
Before you tackle any welding jobs, make sure the work area is tidy and free of
clutter and offers enough freedom to move.
Install cables and supply lines in such a way that 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
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 that they do not constitute a stumbling
trap.
There is a danger the equipment rolls away because the wheels must not be blocked due to the
tipping and toppling hazard
The wheels of the equipment must not be blocked because this would cause a tipping
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.
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Resistance welder MULTISPOT MI-100control
CAUTION!
Display and c
ontrol panel may sustain damage!
Dangers to display and control panel
The display and control panel may sustain damage when being closed if negligent
employees leave objects lingering on the accessory box beneath.
Therefore:
Never put objects on the accessory box beneath the display and control panel.
Proceed with care when closing the flap cover with integrated display and 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 signalling systems, first aid, rescue and escape
equipment.
Keep access ways for ambulances clear and open.
Health and safety
Measures to be taken in case of accidents
Actuate emergency stop. ( see “2.6”.)
Initiate first aid.
Evacuate people from danger zone.
Alert persons in charge.
Alert fire brigade and ambulance service.
Keep access ways for ambulances clear and open.
2.5 Measures to be taken in case of work at the device
De-energise.
Secure against restarting (e. g. pull out mains plug).
Unstressedness determines.
Ground and short circuit.
Neighbouring energized parts cover or provide with gates.
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Resistance welder MULTISPOT MI-100control
WARNING!
Danger! Due to insufficient protection against residual current!
WARNING!
Danger
of life and limb
! Equip
ment may still be under voltage!
Health and safety
2.6 Safety devices
Connection to electrical socket: the device may only be plugged into a socket with a
residual current device and an operable earthing device.
Fig. 1: Emergency stop pushbutton
Emergency stop pushbutton
Hitting the emergency stop pushbutton will shut down the
equipment immediately. After the emergency stop has been
actuated, it must be turned clockwise (cw) to unlock before
the equipment can be switched on again.
Fig. 2: Power switch on the backside
The emergency stop will shut down the equipment, but will not disconnect the power
supply. To accomplish that, push the power switch on the backside of the equipment.
Even then, there may still be components inside that are still under voltage.
Therefore:
In order to disconnect this equipment from the power supply, switch off using the
power switch. Earth components, short circuit and check for residual electricity.
Do not unlock the emergency stop pushbutton before danger has been completely
removed.
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).
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Resistance welder MULTISPOT MI-100control
DANGER!
Electromagnetic fields pose a mortal da
nger to persons with
CAUTION!
Pump damage due to dry running!
2.7 Safety labels and markings on this equipment
2.7.1 On the flap cover
Meaning
Welding generates electromagnetic fields.
Electromagnetic fields pose a potentially fatal hazard to
Fig. 3: Warning sign “Electromagnetic fields” on
the flap cover
pacemakers!
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
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.
people with pacemakers or other magnetisable implants.
Electromagnetic fields also affect magnetisable objects, like
e. g. watches, smart cards etc.
Health and safety
2.7.2 Signs on the backside
Fig. 4: Warning sign on the backside
Pump may sustain damage when running dry.
Pump running dry may sustain damage.
Therefore:
Before starting up, check cooling water level at the level gauge.
If necessary (i. e. if you can't see water in the level gauge), fill up. ( see “5.2”.)
Meaning
Do not operate pump without cooling water.
Pump running dry may sustain damage.
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Resistance welder MULTISPOT MI-100control
CAUTION!
Tipping and toppli
ng may cause damage to property!
WARNING!
Wrong spare and
wear parts constitute a hazard!
Health and safety
2.7.3 On the balancer
Fig. 5: Warning sign on balancer
Danger of tipping by relatively high centre of gravity and any obstacles in the path
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 that they do not constitute a stumbling
trap.
Meaning
Always pull in the direction the guiding wheels are pointing.
In the event of lateral and / or transverse pull, there is a
danger the wheels jam / block and the equipment tips over.
2.7.4 On the control board
Fig. 6: Warning sign on the control board
2.8 Spare and wear parts
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.
Be sure to buy your spare and wear parts directly from the manufacturer or an authorised dealer.
For contact information see page 2 of this manual or the service menu on the control panel.
Meaning
Do not pull compact flash card unless equipment has been
properly switched off.
Compact flash card might be destroyed otherwise.
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Resistance welder MULTISPOT MI-100control
CAUTION!
Inexpert handling may consti
tute an
environmental hazard!
2.9 Waste management and environmental protection
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 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 hazardous waste management and must be collected
by authorised companies.
Health and safety
Other components
Unless you have concluded a return and / or disposal agreement with the manufacturer, please
disassemble and recycle components.
Scrap metals.
Recycle plastic parts.
Other components must be sorted by materials and disposed of accordingly.
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Resistance welder MULTISPOT MI-100control
CAUTION!
Improper transpo
rt may cause damage to property!
CAUTION!
Improper waste disposal
may cause environmental hazards!
Transport, packaging, storage
3 Transport, packaging, storage
3.1 Safety during transport
Inexpert transport
Improper transport may cause damage to property.
Therefore:
When you unload packing units and move them across your premises, proceed with
care. Consider symbols and information on packaging.
Be sure to transport equipment as described hereinafter. ( see “3.5”.)
3.2 Symbols on packaging
Top
The arrows point towards the ‘roof’ of the packing unit. This
side up. The arrows must always point up; otherwise the
Fig. 7: Top
contents of the packing unit could be damaged.
Fig. 8: Do not stack
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 materials
Do not stack
Fragile goods. Do not stack; otherwise the contents of the
packing unit could be damaged.
Packing materials are valuable raw materials. In many cases, they can be recycled,
i. e. used again for packaging or in some other way or they can be further processed or
treated in some way.
Therefore:
Be sure to dispose of packing materials in sustainable manner and / or according to
local laws and regulations.
Observe local waste management legislation. In case of doubt, contact a
specialised company.
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Resistance welder MULTISPOT MI-100control
3.4 Acceptance after shipping
Check packing units immediately after delivery. Check for integrity, missing pieces and damage.
If you detect any external shipping damage, proceed as follows:
Do not accept delivery; or accept under reserve.
Report damage on carrier's shipping papers or delivery ticket.
Initiate complaint procedure.
NOTE!
Be sure to register a complaint 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
Transport, packaging, storage
Fig. 9: Using a forklift truck
NOTE!
Keep the original pallet in case of any further transport needs (return of goods, further
transport).
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 have a licence to drive forklift trucks.
Packing units may have very high centres of gravity.
Make absolutely sure they cannot tip over.
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Resistance welder MULTISPOT MI-100control
CAUTION!
Tipping and toppli
ng may cause damage to property!
CAUTION!
Equipment rolling aw
ay may cause damage to property!
Transport, packaging, storage
3.5.2 Moving equipment to the site
Fig. 10: Warning sign on balancer
There is a danger of tilting
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.
Securely stow cables and wires.
When moving around, always grip equipment by the handle
provided for that purpose.
There is a danger the equipment rolls away because the wheels must not be blocked due to the
tipping and toppling hazard.
The wheels of the equipment must not be blocked because this would cause a tipping
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.
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Resistance welder MULTISPOT MI-100control
CAUTION!
Improper transport conditio
ns may cause damage to property!
Transport, packaging, storage
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. 9)
3. Use packing materials that correspond to original packing materials.
4. Mark packing materials with symbols as shown in “3.2”.
Packaging with inappropriate dimensions, quality or weight, or cooling water 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.
Storage temperature: -10 to 50 degrees centigrade.-50 to 122 degrees Fahrenheit.
Rel. humidity: 85 % max.; no dew.
When storing equipment longer than three months, check general conditions of all parts and
packaging in regular intervals. If and when necessary, refresh or renew corrosion protection.
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Resistance welder MULTISPOT MI-100control
Design and functionality
4 Design and functionality
4.1 Overview
1 Running gear
2 Support for tools
3 Inverter control unit
4 Cable or welding pliers support
5 Display and control panel
6 Balancer support
7 Balancer
8 Welding pliers
9 Handle
10 Welding pliers supply lines
Fig. 11: MULTISPOT system (standard)
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 automatic current adjustment facilitates a perfect reproducibility of welding results.
The additional power needed for adjustment is taken from the mains.
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Resistance welder MULTISPOT MI-100control
1
4.3 Display and control elements
4.3.1 On the display and control panel
1 Display
see also Fig. 13
2 Selection elements
see also Fig. 14
3 Touch key for power selection
4 Touch key for selecting welding jobs
(from top to bottom):
high strength steel (HSS)
3 layer sheets
galvanised sheets
5 Touch key for selecting sheet gauges
6 Touch key for selecting a welding gun
Design and functionality
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. 14: Detail from Fig. 12
Fig. 12: Display and control panel
Fig. 13: Detail from Fig. 12
1 LED “Malfunction”,
see “7.2.2”, work cannot continue as long as the
LED is on.
2 Control knob,
for selecting and confirming menu items.
3 “ESC”,
can have different functions: “Cancel” or “Pump
OFF”, depending on menu.
4 “Service”,
for selecting the service menu.
see “6.7.1” and “6.7.2”.
5 “Info”,
calls up welding parameters; see “6.6”.
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