Elektron MULTISPOT MI-90 T Operating Manual

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Operating Manual

MULTISPOT MI-90 T

Resistance welder

Item no. 327527

Revision: 3.0 - Translation

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.

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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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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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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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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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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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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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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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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.

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.

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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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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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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.

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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Health and safety

2.7.2 Signs on the cooling unit

Do not operate pump without cooling water. Pump running dry may sustain damage.

CAUTION ! 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, fill up. ( See "5.1.2".)

Fig. 3: Warning sign on the backside

2.8 Spare and wear parts

WARNING ! Wrong spare and wear parts constitute a hazard.

Wrong and/or defective spare and wear parts may constitute a safety hazard and may entail errors, damage and even total destruction. Therefore:

2.9 Waste management and environmental protection

Batteries

Electronic components

Other components

– 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.

CAUTION ! Inexpert handling may constitute an environmental hazard.

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 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 and scrap are subject to hazardous waste management and must be collected by authorised companies.

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.

Meaning

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3 Transport, packaging, storage

3.1 Safety during transport

Inexpert transport

CAUTION ! Improper transport may cause damage to property.

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 contents of the packing unit could

Fig. 4: Top

be damaged.

Transport, packaging, storage

Do not stack

Fragile goods. Do not stack goods, otherwise the contents of the packing unit could be damaged.

Fig. 5 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. 6) in case of any further transport needs (return of goods, further transport).

3. Recycle packing materials.

What to do with packing materials

CAUTION ! Improper waste disposal may cause environmental hazards.

Packing materials are valuable raw materials. In many cases, they can be recycled, i.e. used again for 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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Transport, packaging, storage

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

Packing units on pallets may be handled with a forklift, as long as the following conditions are fulfilled:

 The forklift must be certified for the weight of the packing unit at

hand.

 The operator must have a licence to drive forklift.  Packing units may have very high centres of gravity. Make

absolutely sure they cannot tip over.

NOTE

Fig. 6: Using a forklift

3.5.2 Moving equipment to the site

There is a danger of tipping and toppling of the device because of its centre of gravity

CAUTION ! Tipping and toppling may cause damage to property.

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.

Keep the original pallet in case of any further transport needs (return of goods, further transport).

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3.6 In case of return of goods / further transport needs

1. Drain cooling water tank completely.

2. Use original transport pallet. (See Fig. 6.)

3. Use packing materials that correspond to original packing materials.

4. Use symbols on packaging according to 3.2

CAUTION Improper transport conditions may cause damage to property.

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.

Transport, packaging, storage

 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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Design and functionality

4 Design and functionality

4.1 Overview

1 Control panel

2 Support for welding

pliers supply lines

3 Cooling water tank

4 Support for tools or

electrode arms, e. g.

5 Running gear

6 Welding pliers support

7 Welding pliers

Fig. 7 : Overview Multispot System (Standard)

4.2 Description

The MULTISPOT MI-90 T 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. .

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4.3 Display and control elements

4.3.1 On the control panel

1 LED display

“Mains voltage drop”

2 Touch key for

selecting welding jobs (from top to bottom): – high strength

steel (HSS) – 3 layer sheets – galvanised

sheets

3 Touch key for

power selection

4 Touch key for

selecting sheet gauges

5 LED display

“Malfunction”

Design and functionality

3 2 4 5

Fig. 8: Control panel

4.3.2 On the back

Fig. 9: Power switch (in "OFF" position)

The power switch (Fig. 9) is for switching the power supply on and off.

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Resistance Welder MULTISPOT MI-90 T

Design and functionality

4.4 Connections

4.4.1 Connections on the front side

1 Connection for sensors

2 Central connection for weld current

3 Air supply for pliers

4.4.2 Connections on the backside

1 Compressed air filter unit

2 Pressure gauge

3 Air supply for pump

4 mains supply

5 Power switch

1 2 3

Fig. 10: Connections on the front side

Fig. 11: Connections on the backside

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4.4.3 Connections cooling water tank

1. Cooling water tank cap

2. Coolant return

3. Coolant outlet

4. Fastening screw

5. Pump

6. Air supply for pump

4.5 Accessories

see Accessory List

Design and functionality

Fig. 12: Connections cooling water tank

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Resistance Welder MULTISPOT MI-90 T

Installation

5 Installation

5.1 Before installation

5.1.1 Preliminary works

 Check operating conditions according to specifications.( See "9.4".)  If necessary, allow equipment time to adapt to ambient temperature SLOWLY.  Make sure that operating company's supply systems comply with specifications.

( See “9.2”.)

 Before you start any works, make sure the work area is tidy, clean and free of clutter and offers

enough room to move.

 Make sure your tools are complete and in good working order.  Do wear safety shoes.

5.1.2 Filling up cooling water tank

1. Twist off cap.

2. Fill about 15 litres / 4 gal. of cold, clean drinking

water into the tank.

3. Add chlorine-free disinfectant to prevent growth of algae and bacteria.

4. Replace cap properly. Check for tightness.

5. Check water level before each use.

6. Fill up, when necessary. Keep water level close

underneath the tank cap.

Fig. 13: Filling opening

5.2 Electrical connections

Fig. 14: Power grid specifications

CAUTION Insufficient conductor cross-sections and fuse protection may make the grid collapse and/or trigger the fuses and make efficient welding impossible.

Therefore: – Before you connect the welder to the mains,

make sure conductor cross-sections are sufficient (at least 6 mm² per 10 metres / AWG 10 per 33 ft of cable length).

– Before you connect the welder to the mains,

make sure the grid is properly protected by fuses (at 32 A).

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Resistance Welder MULTISPOT MI-90 T

Fig. 15: Connecting welder to power supply

5.3 Connecting the pneumatics

Installation

1. Take the power cord from its support.

2. Run the power cord along a safe route.

WARNING Stumbling hazards

Power cords may constitute a stumbling hazard when improperly laid or installed and may cause people to fall and hurt themselves. In this particular case, the cable could block the wheels of the welder and make it tip over. Therefore: – Run the power cord along a safe route.

3. Connect the power cord to the mains.

4. Use strain relief clamps to protect cables.

1. Take the supply line from the pneumatic grid of the plant and

plug it on to the welder (Fig. 16).

2. The plant's pneumatic mains must provide about 6 bar (87 Psi) input pressure to the welder.

NOTE

6 bar (87 Psi) input pressure generate a contact force of the electrodes of 3.5 kN (787 lb f) approx. To adjust the contact force of the electrodes, proceed as described below.

Fig. 16: Connecting compressed-air supply

Fig. 17: Pressure gauge and pressure regulator

CAUTION ! Improper pressure of compressed air may damage property.

Low pressure reduces the contact force of the electrodes which, in turn, increases wear of the electrodes. High pressure, on the other hand, may damage the spot welding pliers. Therefore: – Check the pressure gauge before you switch on the welder. Compare to the parameters of

the welding program selected.

– Maintain the pressure between 6 and 10 bar (87 and 145 Psi).

3. Check the pressure supplied at the pressure gauge (Fig. 17/2). If necessary, use the pressure regulator (Fig. 17/1) to set the pressure as required (depending on welding program and manufacturer's specs). – Turn the regulator in the "+" direction to increase the input

pressure. (Max. admissible: 10 bar / 145 Psi)

– Turn the regulator in the "-" direction to decrease the input

pressure. (Min. admissible: 6 bar / 57 Psi)

4. When decreasing the input pressure, actuate the pliers from time to time to let the air escape.

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Resistance Welder MULTISPOT MI-90 T

Installation

5.4 Connecting the pliers

Fig. 18: Connections for pliers

1. Main plug

2. Sensors

3. Air supply

4. Coolant outlet

5. Coolant return

1. Push the main plug of the welding

pliers into the main socket of the equipment (Fig. 19/1).

2. Push down the clamps (Fig. 19/2) to lock the connection.

Fig. 19: Connecting the pliers

Fig. 20: Connecting air supply of the pliers

3. Connect the air supply system of the

pliers. Push the hose into the connection until it locks.

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Resistance Welder MULTISPOT MI-90 T

Fig. 21: Connecting sensors of the pliers

Installation

4. Connect the sensors of the pliers.

1. Connect the coolant return of the

pliers to the cooling tank (Fig. 22/1)

2. Connect the coolant outlet of the pliers to the cooling tank (Fig. 22/2)

Fig. 22: Connecting water supply

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Resistance Welder MULTISPOT MI-90 T

Installation

5.5 Connecting air supply of the cooling water tank

1. Connect the air supply of the cooling

tank (Fig. 23/1) to the connection on the back side of the unit (Fig. 23/2)

Fig. 23: Connecting air supply

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Resistance Welder MULTISPOT MI-90 T

Operation

6 Operation

6.1 Preliminary works before welding

6.1.1 Preparing the sheets

 When using insulating layers (e.g. spot welding primer), you must first establish an auxiliary connection

(using a vise-grip wrench, for instance) in order to establish the electrical contact

 Contact faces must be ground down to the bare metal on all sides.

WARNING Do not hurt yourself during grinding.

Grinding sheets may constitute a hazard of injuries. Therefore: – Be sure to deploy employees who are experienced in this type of jobs. – Strictly observe any manuals etc. that come with the grinding tools.

 Galvanised sheets should not be damaged, if possible.  Make sure the sheets are always stacked with their faces parallel to each other.

Otherwise, it will not be possible to apply clean spot welds.

6.1.2 Preparing welding pliers

WARNING Unintentional startup of welder may constitute a hazard of injuries.

If the new tool is switched on during retooling, the weld current and/or unintentional movements of the pliers may be actuated. There is a danger of pinching and crushing. Therefore: – Be sure to tool up first, and only then switch on the welder. – If retooling is unavoidable during the work, be sure to switch OFF before you do anything.

NOTE

For more detailed information on preparing / tooling up the welding pliers,  see separate operating instructions.

CAUTION Switch off cooling first before changing electrodes !

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Resistance Welder MULTISPOT MI-90 T

Operation

Exchanging electrode arms

Fig. 24: Unbolting electrode arm

Fig. 25: Removing the electrode arm

Exchanging electrode caps

Fig. 26: Exchanging electrode caps

Deploying the electrode arm

1. To unbolt the electrode arm, use the Allen key provided for that

purpose (Fig. 24).

2. Remove the electrode arm simply by pulling it out. (Fig. 25).

3. Insert the new electrode arm and bolt down.

1. To loosen the electrode caps, use the special key provided for

that purpose (or some equivalent tool) (Fig. 26)

2. Turn clockwise, otherwise the cone comes loose.

3. Put the new caps on the electrode head and press in position.

NOTE

The perfectly sound condition of the caps is essential for good welding results. Electrode caps must be milled (or replaced) after 50 welding jobs, especially when working with super speed and/or galvanised steel.

1. Switch the locking device of the electrode arm from position "locked" (Fig. 27/A) to position "open" (Fig. 27/B) as shown in the picture.

Fig. 27: Unlocking the arm

Locking the electrode arm

Fig. 28: Locking the arm

2. Push the electrode arm without much force into the locking device until you feel and hear it engage (Fig. 28).

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Adjusting the distance between electrodes

Fig. 29: Adjusting the distance between electrodes

Aligning electrodes

Operation

 Make sure the distance between the electrodes is

6 to 8 mm. Carry out the first welds, and then check the distance again. Re-adjust, if necessary.

Use an Allen key SW5 as gauge in between the tips:

Electrode tip Allen key Electrode tip

Fig. 30: Distance between electrode tips

 Be sure to look from different angles. Electrodes must align no

matter how you look.

Fig. 31: "Electrode must be in true alignment"

6.1.3 Checks before switching on WARNING ! Unskilled employees may hurt themselves and others. Inexpert operation

constitutes a hazard of injuries.

Inexpert and/or negligent handling of this equipment and/or ignorance of hazards and dangers may entail the most severe injuries. Therefore: – Make sure this equipment is put to use by skilled welding operators with sufficient training

and experience in spot welding, exclusively.

– Before operation, consult the manual and make sure any and all preconditions are fulfilled,

any and all checks and preliminary works etc. have been carried out.

– Work place must be clean and tidy - no clutter. Make sure you have enough room to move.

 Be sure to be wearing adequate PPE. ( See "2.2.3".)  Check any and all connections. ( See "5".)  Check input pressure. ( See "5.3".)  Check cooling water level. ( See "5.1.2".)  Check your tools / welding pliers. Re-tool now, if necessary.

( See "6.1.2" and/or separate operating instructions for welding pliers.)

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Operation

 Checking cooling water level. ( See XXX.)

6.2 Switching on

Fig. 32: Power switch

6.3 Basic settings

6.3.1 Keyboard operation

1 LED display

“Mains voltage drop”

2 Touch key for

selecting welding jobs (from top to bottom): – high strength

steel (HSS) – 3 layer sheets – galvanised

sheets

3 Touch key for

power selection

4 Touch key for

selecting sheet gauges

5 LED display

“Malfunction”

1. Once the welder has been installed and prepared according to instructions, you may switch it on by turning the power switch (Fig. 32).

3 2 4 5

Fig. 33: Control panel

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Resistance Welder MULTISPOT MI-90 T

6.3.2 List of possible setting options

Welding job Ratio of

sheets

d1 = d2 = d3

Sheet gauges

up to about

0,8 + 0,8 + 0,8

1,0 + 1,0 + 1,0

1,5 + 1,5 + 1,5

2,0 + 2,0 + 2,0

2,0 + 0,8 + 0,8

0,8 + 1,0 +1,0

Operation

Set value Selection

d2  d3

0,8 + 1,5 + 1,5

0,8 + 2,0 + 2,0

0,8 + 3,0 + 3,0

d1 < d2 < d3

d1 + d2 + d3 ≤

Select next

higher set value.

(*) optionally ON or OFF

(!) "3 sheets" OFF

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Resistance Welder MULTISPOT MI-90 T

Operation

6.4 Important information concerning welding

Electromagnetic fields

DANGER Electromagnetic fields pose a potentially fatal hazard to people with pacemakers or other magnetisable implants.

1 cm / 0.4”.

Splashes, flying sparks

WARNING Splashes and flying sparks constitute a danger of fire and explosion. Splashes and flying sparks pose a risk of injuries.

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.).

Vapours

Hot surfaces

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.

CAUTION Hot surfaces pose a risk of burns.

them.

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Resistance Welder MULTISPOT MI-90 T

Operation

Tipping and toppling hazards due to high centre of gravity and obstacles during travel

CAUTION Tipping and toppling may cause damage to property.

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.

 Be sure to operate this equipment only on a flat and even floor.  Proceed with care when moving this equipment.

Personal protective equipment (PPE)

Non-inflammable safety clothing

is a tight-fitting sort of special clothing that is not inflammable, covers arms and legs completely and tears easily (instead of getting pulled in). Its main 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.

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.).

 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.

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Resistance Welder MULTISPOT MI-90 T

Operation

Adjusting the contact force

Fig. 34: Contact force ≤ 1.8 kN

Lifetimes of electrode caps

NOTE

Be sure to set the correct contact force with respect to the current welding, because:

– If the contact force of the electrodes is too high,

the electrical resistance will be too low which, in turn, will affect the welding job.

– If the contact force is too low, the welding spots

may erode and leave holes in the sheets.

CAUTION Danger to property.

When using the electrode arm configuration shown to the left, 12-mm electrodes will slightly bend if the contact force is set higher than 1.8 kN (405 lb f). Therefore: – Ask yourself, whether the job at hand could be

handled just as well with a different configuration.

– When you have to use the configuration as

shown here, make sure the contact force does not exceed 1.8 kN (405 lb f) / 6 bar (87 Psi).

NOTE

The perfectly sound condition of the caps is essential for good welding results. Electrode caps must be milled (or replaced) after 50 welding jobs, especially when working with high strength and/or galvanised steel ( see "6.1.2").

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7 Troubleshooting

7.1 Health and safety during troubleshooting

WARNING People with insufficient skills may suffer injuries.

If you carry out troubleshooting and repairs yourself, you may encounter certain risks and hazards that may entail severe injuries. Therefore: – Do not open the welder. Do not modify the welder. Do not try to carry out repairs yourself. – For any and all troubleshooting measures not explicitly mentioned and/or described in this

manual, you should call service personnel and/or contact the manufacturer. – Be sure to adhere strictly to the hierarchy of responsibilities defined in the table. – When you're in doubt: do contact service personnel / manufacturer. – If a damage does occur: minimise, contain and avert consequential damage.

NOTE

In the event that problems occur more frequently due to above-average workloads, you must adapt the inspection and maintenance intervals accordingly.

7.2 Error messages and troubleshooting tables

7.2.1 Problems displayed on the control panel

Troubleshooting

Fig. 35: LED display

1 LED display green: mains OK LED display green/yellow: mains drop within tolerance range

LED display yellow: considerable mains drop

LED display red: mains drop out of tolerance range

5 LED display red: thermal overload (see next page)

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Resistance Welder MULTISPOT MI-90 T

Troubleshooting

Symptom Possible cause Remedy WHO should do

LED red The red LED indicates thermal

overloading of the spot welding pliers or power source.

7.2.2 Possible causes and remedies in case of unsatisfactory welding results

Symptom Possible cause Remedy WHO should do

Weld spot too small

Weld current too weak.

Weld time too short.

Welding spot burns up, excessive spattering, sheets not strong enough.

Weld current too high.

Weld time too long.

Welding job flawed Sheets may have been

insufficiently prepared.

It is not possible to continue working while the LED is on. The unit is ready for use again once the tool, power source or coolant has cooled down and the LED has gone off again.

Do not switch off the unit and cooling during the cooling-down phase to prevent any heat congestion.

Adapt welding parameters. Operator

 "6.1.1" Operator

it?

Operator

it?

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Maintenance

8 Maintenance

8.1 Maintenance schedule

8.2 Carrying out maintenance jobs

Personnel

 The maintenance jobs described here may be carried out by operators, if not explicitly stated otherwise.  Have works on electrical equipment carried out by skilled electricians, exclusively.

8.2.1 Cleaning

Intervals What must be done? WHO should do it?

Visually check the welder and its periphery for damage, dirt, contamination etc. Clean, if necessary

Check connections for tight fit. Check compressed-air supply.

before ANY

maintenance job

Check cooling water level? Fill up, if necessary.

Operator

Visually check electrode caps. If necessary, clean, mill and/or replace.

Check distance and -alignment of electrodes. Check PPE for functionality. Replace, if and as soon as

necessary. Check purity and quality of operating company's

every 6 months

compressed-air supply. Check the work environment. Does it still fulfil all the

operating requirements? Check actual input current and voltage. Take your own

measurements.

Operator

Skilled electrician

Visually check the water separator and air filter of the

whenever necessary

pneumatic unit. Carry out jobs as required. Visually check the water filter. Replace, if necessary.

Operator

Empty cooling water tank. Refill.

CAUTION ! Failure to carry out and/or negligent or improper cleaning jobs may entail damage to property.

If you do not clean the welder at all or use aggressive cleaning agents or -methods, there is a danger of damage to property. Therefore: – Do not use aggressive cleaning agents and/or -methods. – Do not use steam cleaners and/or pressure washers. – Be particularly careful with the display. – Be sure to clean the welder on a regular schedule, especially around air vents. Adequate

dissipation of heat must be ensured.

 Clean the welder with a dry, lint-free cloth. For persistent dirt, use a textile cloth that has been

slightly damped with a mild detergent.

 As for the display: just dust. Be careful not to scratch the display.

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Maintenance

8.2.2 Maintaining the pneumatic unit

1. Visually check the compressed-air filter (Fig. 36).

Replace, when you see any accumulation of dirt.

2. Visually check the water separator under the compressed-air filter for residues of water.

If you find any accumulations of water, pull of the cap in the

direction indicated by the arrow and empty water from the separator.

Fig. 36: Pneumatic unit

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8.2.3 Replacing water filter

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.

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.

Maintenance

1. Loosen the 4 fastening screws (Fig. 37/4) on the

pump support plate.

Fig. 37: Cooling tank

2 Lift the pump support plate. (Fig. 38). 3 Visually check the water filter. If you detect clear

signs of dirt.

4. Switch off the welder. Wait, until the pump stops pumping.

5. Separate the cooling water supply from the pump.

6. Pull the water filter unit from the hoses to the left and

right. However, do not loosen the hose clips.

7. Replace the old filter with a new one and insert the new water filter between the hoses.

8. Re-connect the cooling water supply to the pump.

Fig. 38: Water filter underneath pump support plate

8.3 Measures to be taken after maintenance

When you finish maintenance and before you switch the welder back on, carry out the following:

1. Re-establish any and all connections you loosened and/or removed before. Check for tight fit.

2. Make sure any and all safety devices, covers etc. you may have removed are properly back in place.

3. Make sure you have properly removed and taken away from the work area any and all tools, materials etc. you may have used.

4. Clean the work area. If there have been any leaks, spills etc., clean up.

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Resistance Welder MULTISPOT MI-90 T

Specifications

5. Set sheet gauges on the welder using above table.

9 Specifications

9.1 Dimensions and weights

9.2 Power requirements

Power supply

Compressed-air supply

9.3 Supplies

9.4 Working conditions

Ambient conditions

9.5 Exposure limit values

Welding pliers

Item Value Unit

Height 1000 / 39 mm / in Width 480 / 19 mm / in Depth 750 / 30 mm / in Weight (w/o accessories) 69 /152 Kg /lb

Item Value Unit

Mains voltage 400 / 3 ~ /

V / Ph / Hz

50/60 Admissible voltage range 380 – 415 V (AC) Power cord 6

AWG 10

mm2 / 10 m

33 ft Mains fuse, max. 32 A slow Installed power 21 kVA Rated output at 50 % duty cycle 30 kVA No load voltage, max. 16 V (AC) weld current, regulated 13000 A (DC) Enclosure IP21

Item Value Unit

Operating pressure, min. – max. 6 – 10

87 – 145

Quality clean, dry, free of oil

Bar

Psi

Item Value Unit

Cooling water - tank capacity 15 / 4 l / gal approx. Chlorine-free disinfectant accor. dosing

instructions

Item Value Unit

Ambient temperature, max. 40 / 104 °C / °F Rel. humidity, max. (no dew) 85 %

Item Compliance

Exposure limit values accor. EU directive 2004/40/EC

Keep a distance of at least 1 cm between cable assemblies and people's heads / spines

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Resistance Welder MULTISPOT MI-90 T

9.6 Type plates

Fig. 39: Type plate on the backside

Specifications

1 Manufacturer 2 Inverter type 3 Item no. 4 Input voltage (in VAC) 5 Frequency (in Hz) 6 Power consumption (in kVA) 7 Enclosure 8 Production no. 9 Duty cycle (in %) 10 Max. current (in A) 11 Output voltage (in VDC) 12 Appeal: Read operating manual. Comply with operating

manual.

1 Manufacturer 2 Designation 3 Type 4 Item no. 5 Production no. 6 Flow rate in l/h

-1

7 Rated pressure in bar 8 Operating pressure in bar 9 Volume in l

Fig. 40: Type plate on water cooling unit

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Index

Accessories........................................................ 21

Adjusting the distance between electrodes ....... 29

Appendix ............................................................ 43

Batteries............................................................. 14

Cleaning............................................................. 37

Compressed-air supply...................................... 40

Connecting air supply of cooling water tank ...... 26

Connections ....................................................... 20

electrical ......................................................... 22

pliers............................................................... 24

pneumatics ..................................................... 23

power requirements ....................................... 40

Connections cooling water tank......................... 21

Connections on the backside............................. 20

Connections on the front side ............................ 20

Contact force...................................................... 34

Contact person..................................................... 6

Control elements................................................ 19

Control panel...................................................... 19

Customer service ................................................. 6

Description ......................................................... 13

Dimensions ........................................................ 40

Disinfection .................................................. 22, 40

Display and control elements............................. 19

Electromagnetic fields.................................. 10, 32

Environmental protection ................................... 14

Error messages.................................................. 35

Filling up cooling water tank .............................. 22

Further transport needs ..................................... 17

Guarantee ............................................................ 6

Handling............................................................. 16

Intended purpose................................................. 7

Intended use ........................................................ 7

Inverter control unit ............................................ 19

Liability ................................................................. 6

Maintaining the pneumatic unit .......................... 38

Maintenance schedule ....................................... 37

Misuse.................................................................. 7

Operating company.............................................. 7

Overview ............................................................ 18

Personnel ............................................................. 8

maintenance ................................................... 37

Power requirements........................................... 40

Power supply...................................................... 40

Power switch ...................................................... 13

PPE ................................................................ 9, 33

Preparing the sheets.......................................... 27

Preparing welding pliers..................................... 27

Problems

not displayed on the control panel.................. 35

welding flaws .................................................. 36

Replacing water filter ......................................... 39

Responsibilities of the operating company .......... 7

Return of goods.................................................. 17

Safety devices.................................................... 13

Safety labels and markings................................ 13

Service ................................................................. 6

Settings .............................................................. 30

contact force ................................................... 34

Spare and wear parts......................................... 14

Specifications ..................................................... 40

Storage............................................................... 17

Supplies ............................................................. 40

Switching on....................................................... 30

Symbols

on equipment.................................................. 13

to be installed by operating company............... 8

Symbols on packaging....................................... 15

Symbols used in the operating manual................ 5

Training Report .................................................. 43

Troubleshooting ................................................. 35

Type plates......................................................... 41

Waste management........................................... 14

Weights .............................................................. 40

Working conditions............................................. 40

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Appendix

Training Report

NOTE Master copy. Do not fill in. Make copies.

Date Name Type of training Trainer Signature