Elektron MULTISPOT M80 Manuel utilisateur

Operating instructions

MULTISPOT M80

Resistance Welder

Item no. 322921

Revision: 3.0 - Translation

Version: 09th, March 2010

Be sure you have read and understood

this operating manual before you carry

out any works on and/or with this

equipment.

Contents page

1.0 Warning notes – explanation of symbols 1

2.0 Description of equipment and overview 3

3.0 Start-up 5

3.1 Assembly of power supply unit and trolley 5

3.2 Compressed air connection 5

3.3 Mains power supply connection 6

3.4 Checking the mains voltage drop during welding 6

3.5 Malfunction indicator 7

4.0 Applications 8

5.0 Technical data 9

6.0 Working with spot-welding tongs 11

6.1 Preparation of welding area 11

6.2 Spot-welding with the tongs 13

6.3 Pulse welding 15

7.0 Operating the welding gun 17

7.1 Push spot welding 19

7.2 Pulling-out dents with washer 21

7.3 Pulling-out dents with high-speed planishing hammer “SAH" 23

7.4 Pushing-in dents 25

7.5 Shrinking sheet metal 25

7.6 Welding-on threaded studs 27

7.7 Welding-on T-pins 29

7.8 Positioning/fixing sheet metal (tacking) 31

8.0 Operating QUICKSPOT 31

9.0 Connection of AIRPULLER 32

10.0 Practical hints 32

11.0 Appendix/self-test and troubleshooting 33

11.1 Self-test 33

11.2 Checking LED displays and the solenoid valves 33

11.3 Mains-supply test and troubleshooting 33

11.4 Manual tool selection 35

11.5 Operating panel malfunction 35

- 1 -

1.0 Warning notes – explanation of symbols



Caution!

Please note the following when using resistance welding units:

The power supply unit and leads of the welding gun and the spot

welding tongs generate a powerful electromagnetic field when in use.

Electromagnetic fields can cause irritations of sense organs, nerve

and muscle cells as well as malfunctions in physical aids (hearing aid,

pacemaker etc.), electronic devices and data storage units.

To prevent these effects, avoid a direct body contact with the welding

cable. A safe distance of 15 cm between cable and body is

recommended.

Caution! Danger!

Ignoring this warning may result in injury!

Observe the notes!

This is the only way to achieve satisfactory welding results.

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

electricians.

Wear protective goggles and gloves!

- 2 -

AB Tool selecting keys (manual) see Appendix

CD Gun functions selecting keys

EF Sheet thickness selecting keys

GH Fine adjustment keys time +/–

Tools

1 Tongs, pulse welding

2 Tongs, spot welding

3 Gun

4 QUICKSPOT

5 AIRPULLER

Working with gun

6 Push spot welding

7 Stud welding

8 Beat-out with washers, T-pins, riveting dies

9 High-speed planishing hammer

10 Anneal/shrink

11 Sheet thickness selector

12 Fine adjustment +/–

13 Mains plug symbos with LED “control mains voltage drop” (15, 16, 17)

14 LED malfunction

- 3 -

2.0 Description of equipment and overview

The MULTISPOT M80 resistance welding unit is designed for the

special requirements of motor vehicle body repair.

The power source is controlled by a micro-processor. After selecting the operating

mode and the sheet steel thickness, the current and weld time will be assigned

automatically and – where necessary and advisable – corrected accordingly. An

audible alarm is performed, if the welding current is too low.

Further functions:

– Automatic tool recognition

– Integrated mains monitor recognises undervoltage

– Automatic current rise, welding, current recognition and repressing

– Easy and distinct operation by means of foil keyboard

– Thermal probe controlled air-cooling for gun and tongs

– Central connection for welding current, compressed air, cooling and control

wiring

– Closed box for accessories in power supply unit

– Sturdy trolley with basin for tools and accessories and electrode arms

60 Tongs holder * * in connection with spot

61 Cable holder welding tongs

62 Trolley frame **special accessories (item no.

63 Central connection socket pls. see from accessories list)

64 Balancer **

65 Filter pressure reducer

66 Mains switch

67 Service box

68 Power supply unit

69 Screws 8 x 16

70 Screws 8 x 16

71 Trolley base

72 Roller

73 Guide wheel

74 Receptacle for pulling tool + SAH

75 Receptacle for electrode arms

76 Fastening screws

77 Electronics / operation panel

- 4 -

- 5 -

3.0 Start-up

3.1 Assembly of power supply unit and trolley

– Screw frame (62) to the trolley base with the screws provided (70)

– Put power supply unit (68) on the trolley and fasten with screws

provided (76).

– Screw tongs holder* (60), cable holder (61), balancer** (64)

to the frame.

– (*= in connection with spot welding tongs

**= special accessories)

item number please see from accessories list).

3.2 Compressed air connection

Connection to a compressed air supply is necessary for operation of the

MULTISPOT M80 in conjunction with the spot welding tongs! The connection with

adjustable filter/pressure reducer (65) is located on the back of the power supply

unit (68). The operating pressure is 8 bar!



Insufficient pressure reduces the electrode contact pressure and increases

electrode wear. Excessive pressure can cause poor welding quality and

damage to the tongs.

When installing another air

connection, ensure that the thread of

the plug connector is screwed into the

filter pressure reducer no deeper than

8 mm, as otherwise the air supply will

be interrupted.

Seal the thread with Loctite.

- 6 -

3.3 Mains power supply connection

400 V 50/60 Hz (automatic switch-over)

Connection to a 32 A Cekon socket

Fuse: 32/35 A slow fuse

32 A automatic circuit-breaker

230 V (190-240 V) 50/60 Hz (automatic switch-over)

Connection to a 63 A Cekon socket

Fuse: 63 A slow fuse

63 A automatic circuit-breaker

3.4 Checking the mains voltage drop during welding

If the full performance of the MULTISPOT M80 is to be obtained, the mains

voltage drop during welding must be kept as small as possible.

The full test is described on Page 35, Chapter 11.3:

Information about the mains drop during welding

Display with 3 LEDs (15, 16, 17) under the mains plug symbol:

Green = mains OK

Green/yellow = mains drop within tolerance range.

Only yellow = considerable mains drop – welding performance

impaired

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

Red and = large mains drop with large drop in performance.

warning tone: Welding is not possible. Welding current too low.

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

After 2 seconds, the display automatically reverts to green.

After each welding operation, any mains voltage drop is displayed

for 2 seconds.

- 7 -

3.5 Malfunction indicator

The red LED (14) indicates

thermal overloading of the

spot-welding tongs/spot-

welding gun. While the LED

(14) is glowing, it is not

possible to continue welding

with the tool connected. The

unit is ready for use again

after the LED (14) has

extinguished.

- 8 -

4.0 Applications

Welding capacity:

Compressed-air pressure 8 bar

Electrode arm 120 mm

Programme switch Material Sheet thickness

Function in mm

Pulse welding with pneu-

matic spot welding tongs sheet steel 3.0 + 3.0

Spot welding with sheet steel 2.0 + 2.0

spot welding tongs pneumatic galvanized steel 1.5 + 1.5

Spot welding with

QUICKSPOT sheet steel 1.0 + 1.0

Push spot welding sheet steel 1.25 + 1.25

Setting for the following functions:

e. g. for sheet thickness 0.8 mm – choose range 1.6 mm

= 2 x 0.8 mm

Straightening out

with washer sheet steel 1.2

Airpuller sheet steel 1.0

Straightening out with

high-speed

planishing hammer sheet steel 0.8

Shrinking sheet steel 0.6 – 1.0

Stud welding Steel bolts Æ 4 – 6 mm

on sheet steel 2.0 mm

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