Elektron MULTISPOT MI-90 T Operating Manual
Operating Manual
MULTISPOT MI-90 T
Resistance welder
Item no. 327527
Revision: 3.0 - Translation
th
Version: 9
, December 2008
Be sure you have read and understood
this operating manual before you carry
out any works on and/or with this
equipment.
© ELEKTRON-BREMEN
Elektrotechnik GmbH
Am Hohentorshafen 17-19
28197 Bremen - Germany
Phone: +49 (0) 54 90 6-906
Fax: +49 (0) 54 90 6-19
Email: vertrieb@elektron-bremen.de
Web: www.elektron-bremen.de
Release:
ELEKTRON-BREMEN
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Resistance Welder MULTISPOT MI-90 T
1 General information .................................................................................................. 5
1.1 Information concerning the operating manual ............................................................................... 5
1.2 Copyright........................................................................................................................................5
1.3 Symbols .........................................................................................................................................5
1.4 Disclaimer ......................................................................................................................................6
1.5 Warranty and guarantee ................................................................................................................6
1.6 Customer service ........................................................................................................................... 6
2 Health and safety ......................................................................................................7
2.1 Intended purpose ........................................................................................................................... 7
2.2 Responsibilities of the operating company ....................................................................................7
2.2.1 General responsibilities .................................................................................................. 7
2.2.2 Requirements to personnel ............................................................................................ 8
2.2.3 Personal protective equipment (PPE) ............................................................................9
2.3 Particular dangers........................................................................................................................10
2.3.1 Dangers due to the equipment.....................................................................................10
2.3.2 Dangers due to the work environment ......................................................................... 11
2.3.3 Dangers to this equipment and other property ............................................................. 12
2.6 Safety devices..............................................................................................................................13
2.7 Safety labels and markings on this equipment ............................................................................ 13
2.7.1 Signs on top..................................................................................................................13
2.7.2 Signs on the cooling unit ..............................................................................................14
2.8 Spare and wear parts...................................................................................................................14
2.9 Waste management and environmental protection .....................................................................14
3 Transport, packaging, storage............................................................................... 15
3.1 Safety during transport.................................................................................................................15
3.2 Symbols on packaging.................................................................................................................15
3.3 Unpacking ....................................................................................................................................15
3.4 Acceptance after shipping............................................................................................................16
3.5 Handling.......................................................................................................................................16
3.5.1 Forklift...........................................................................................................................16
3.5.2 Moving equipment to the site........................................................................................16
3.6 In case of return of goods / further transport needs.....................................................................17
3.7 Storage.........................................................................................................................................17
4 Design and functionality ........................................................................................ 18
4.1 Overview ......................................................................................................................................18
4.2 Description ...................................................................................................................................18
4.3 Display and control elements.......................................................................................................19
4.3.1 On the control panel ..................................................................................................... 19
4.3.2 On the back ..................................................................................................................19
4.4 Connections .................................................................................................................................20
4.4.1 Connections on the front side.......................................................................................20
4.4.2 Connections on the backside .......................................................................................20
4.4.3 Connections cooling water tank....................................................................................21
4.5 Accessories..................................................................................................................................21
5 Installation ............................................................................................................... 22
5.1 Before installation ........................................................................................................................22
5.1.1 Preliminary works .........................................................................................................22
5.1.2 Filling up cooling water tank .........................................................................................22
5.2 Electrical connections ..................................................................................................................22
5.3 Connecting the pneumatics .........................................................................................................23
5.4 Connecting the pliers ...................................................................................................................24
5.5 Connecting air supply of the cooling water tank ..........................................................................26
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Resistance Welder MULTISPOT MI-90 T
6 Operation..................................................................................................................27
6.1 Preliminary works before welding ............................................................................................... 27
6.1.1 Preparing the sheets.................................................................................................... 27
6.1.2 Preparing welding pliers .............................................................................................. 27
6.1.3 Checks before switching on......................................................................................... 29
6.2 Switching on................................................................................................................................ 29
6.3 Basic settings .............................................................................................................................. 29
6.3.1 Keyboard operation...................................................................................................... 29
6.3.2 List of possible setting options..................................................................................... 29
6.4 Important information concerning welding .................................................................................. 29
7 Troubleshooting ......................................................................................................29
7.1 Health and safety during troubleshooting ................................................................................... 29
7.2 Error messages and troubleshooting tables ............................................................................... 29
7.2.1 Problems displayed on the control panel..................................................................... 29
7.2.2 Possible causes and remedies in case of unsatisfactory welding results................... 29
8 Maintenance.............................................................................................................29
8.1 Maintenance schedule ................................................................................................................ 29
8.2 Carrying out maintenance jobs ...................................................................................................29
8.2.1 Cleaning....................................................................................................................... 29
8.2.2 Maintaining the pneumatic unit.................................................................................... 29
8.2.3 Replacing water filter ................................................................................................... 29
9 Specifications ..........................................................................................................29
9.1 Dimensions and weights ............................................................................................................. 29
9.2 Power requirements .................................................................................................................... 29
9.3 Supplies....................................................................................................................................... 29
9.4 Working conditions...................................................................................................................... 29
9.5 Exposure limit values .................................................................................................................. 29
9.6 Type plates.................................................................................................................................. 29
Index..................................................................................................................................29
Appendix...........................................................................................................................29
Training Report...................................................................................................................................... 29
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Resistance Welder MULTISPOT MI-90 T
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 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.
Tips, tricks and recommendations
DANGER
… indicates a situation that is imminently dangerous and will entail the death of
people and severe injuries unless it is properly avoided 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
unless properly avoided and prevented.
NOTE
... highlights information that may be helpful to maintain efficient and troublefree
operation.
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Resistance Welder MULTISPOT MI-90 T
General information
1.4 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.
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.
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.
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Resistance Welder MULTISPOT MI-90 T
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 troublefree 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 MULTISPOT MI-90 T resistance welder serves the sole purpose of spot welding during
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 misusive and may entail dangerous situations.
WARNING
Misuse may entail danger
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 high strength steel (HSS), exclusively.
– Do not misuse this equipment for heating, thawing or perhaps even igniting objects.
– Do not use this equipment in explosive atmospheres.
The manufacturer shall not be held liable for any and all damage due to misuse of this equipment.
2.2 Responsibilities of the operating company
2.2.1 General responsibilities
This equipment has been designed for professional use. The owner/operator or operating company
therefore being a businessman or commercial company, they are subject to any and all legal
obligations 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 work
During the entire lifetime of this equipment, the operating company must check in regular
The operating company must unambiguously determine and communicate responsibilities
The operating company must make sure that any person handling this equipment has read and
– Do not open, alter, modify and/or manipulate etc. this equipment.
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.
intervals whether such additional operating instructions are still up to date and must update
them when necessary.
concerning the installation, operation, maintenance and cleaning of this equipment.
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".)
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Resistance Welder MULTISPOT MI-90 T
Health and safety
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
Electromagnetic fields – hazard to persons with pacemakers.
Persons who may suffer health risks due to the influence of electromagnetic fields must
not approach this equipment.
Electromagnetic fields – hazard to persons with magnetisable implants.
Persons who may suffer health risks due to the influence of electromagnetic fields must
not approach this equipment.
Symbols the operating company must install in the immediate vicinity of the equipment
Symbol Meaning
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.
2.2.2 Requirements to personnel
WARNING
People with insufficient skills may suffer injuries.
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.
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Resistance Welder MULTISPOT MI-90 T
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
refers 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.
2.2.3 Personal protective equipment (PPE)
CAUTION
Insufficient protection against injuries
Defective safety clothing may not constitute a proper protection against injuries.
Therefore:
– Be sure to check PPE for integrity and good working condition before you start any works.
– Replace 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.
Non-inflammable safety clothing
is a tight-fitting sort of special clothing that is not inflammable, covers arms and legs
completely and tears easily (instead of getting pulled in). Its main purpose is to protect against
burns.
Face screen
protects the face and eyes against splashes, flying sparks and other hot particles.
Welder's gloves
protect the hands against splashes, flying sparks and other hot particles, and prevent contact
with hot surfaces. Never use wet welder's gloves.
Safety shoes
protect the wearer's feet against falling objects, slippery surfaces and being run over by
vehicles.
Furthermore:
no long hair, rings, necklaces, watches and/or other sorts of jewellery. Do not carry easily
inflammable objects in your pockets (matches, lighters etc.).
Health and safety
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Resistance Welder MULTISPOT MI-90 T
Health and safety
2.3 Particular dangers
2.3.1 Dangers due to the equipment
Electricity
DANGER ! Electricity constitutes a danger to life and limb.
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
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
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 1 cm between cable assemblies and people's heads / spines.)
Scald hazard
DANGER! Scalding may occur due to hot water coming out!
While pulling out the cooling water hoses hot water may come out. Therefore:
– Wear gloves.
– Pull out water hoses carefully.
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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.
Resistance Welder MULTISPOT MI-90 T
Health and safety
Splashes, flying sparks
WARNING ! Splashes and flying sparks constitute a danger of fire and
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
CAUTION ! Hot surfaces pose a risk of burns.
Electrodes may heat up to 80 degrees centigrade (176°F) approx. Stock may have up
to 100 degrees centigrade (212°F) right after welding. So there is an acute risk of
burning yourself. Therefore:
– Never work without proper safety clothes and gloves near hot components.
– Let freshly welded parts cool down to ambient temperature before you go on to
work with them.
2.3.2 Dangers due to the work environment
Vapours
WARNING ! Vapours may constitute a danger to your health.
Stock that has not been properly 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
WARNING ! Possibility of injuries due to stumbling and falling.
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.
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Resistance Welder MULTISPOT MI-90 T
Health and safety
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 obstacle or transverse pull, for instance), there is a danger the equipment tips
over. Therefore:
– 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.
CAUTION ! Equipment rolling away may cause damage to property.
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.
2.4 Correct behaviour in accidents and dangerous situations
2.5 Measures to be taken in case of work at the device
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.
Measures to be taken in case of accidents
Turn off power (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.
De-energise.
Secure against restarting (e. g. pull out mains plug).
Unstressedness determine.
Ground and short circuit.
Neighbouring energized parts cover or provide with gates.
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Resistance Welder MULTISPOT MI-90 T
2.6 Safety devices
WARNING! Danger! Due to insufficient protection against residual current!
Connection to electrical socket: the device may only be plugged into a socket with a residual curren
device and an operable earthing device.
Fig. 1
: Power switch on the backside
WARNING ! Danger! Equipment may still be under voltage.
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.
Secure against unintentional restart. Earth components, short circuit and check for residual
electricity.
Health and safety
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).
2.7 Safety labels and markings on this equipment
2.7.1 Signs on top
Meaning
Welding generates electromagnetic fields. Electromagnetic fields pose a
potentially fatal hazard to people with pacemakers or other magnetisable implants.
Electromagnetic fields also affect magnetisable objects, like e.g. watches, smart
cards etc.
Fig. 2:
Warning sign
"Electromagnetic
fields" on the flap
cover
DANGER ! Electromagnetic fields pose a mortal danger to persons with pacemakers.
Electromagnetic fields affect the functionality of pacemakers and other magnetisable implants.
Electromagnetic fields can 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
1 cm.
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