Elektron MULTISPOT M20 Bedienungsanleitung

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Operating instructions

MULTISPOT M20

ELEKTRON Bremen GmbH Hinterm Sielhof 22 D-28277 Bremen

Fon +49/(0)421/54906-906 Fax +49/(0)421/5490619 vertrieb@elektron-bremen.de www.elektron-bremen.de

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Contents page

1.0 Warning notes – explanation of symbols 3

2.0 Description of equipment and overview 5

3.0 Start-up 6

3.1 Connection to power supply 6

3.2 Mains power supply connection 6

4.0 Applications 7

5.0 Technical data 7

6.0 Operating the welding gun 9

6.1 Pulling-out dents with washer 11

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

6.3 Pushing-in dents 15

6.4 Shrinking sheet metal 15

6.5 Welding-on threaded studs 17

6.6 Welding-on T-pins 19

6.7 Positioning/fixing sheet metal (tacking) 21

7.0 Appendix/self-test and troubleshooting 22

7.1 Self-test 22

7.2 Checking the LED displays 22

7.3 Mains-supply test and troubleshooting 23

7.4 Manual tool selection 24

7.5 Operating panel malfunction 24

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1.0 Warning notes – explanation of symbols

Caution!

The power supply unit and leads of the welding gun

and other tools generate a powerful electromagnetic

field when in use. This can cause malfunctions in heart

pacemakers, quartz watches and other electronic devi-

ces. Electromagnetic storage devices, e.g. on credit

cards, may be erased.

Caution! Danger!

Ignoring this warning may result in injury!

Observe the notes!

This is the only way to achieve satisfactory welding re-

sults.

Work on the power supply unit may ONLY be per-

formed by qualified electricians.

Wear protective goggles and gloves!



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Tool selecting keys (manual) see Ap-

pendix

CD Gun functions selecting keys

GH Fine adjustment keys time +/–

Tools

1 Gun

2 Special (e.g. AIRPULLER)

Working with gun

3 Welding of corrugated wire

4 Stud welding/Copper shrinking

5 Beat-out with washers, T-pins,

Special

6 High-speed planishing hammer

7 Anneal/shrink

8 Fine adjustment +/–

9 Mains plug symbols with

LED "control mains voltage drop"

(15, 16, 17)

10 LED malfunction

11 Mains plug

12 Mains cable

16 Indicator

17 “control mains voltage drop“

18 Ground cable

19 Flange socket

20 Welding socket

M20 – front

M20 – back

18 19 20

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2.0 Description of equipment and overview

The MULTISPOT M20 resistance welding unit is designed for the

special requirements of motor vehicle body repair.

The power source is controlled by a micro-processor. After selec-

ting the operating mode, the current and weld time will be as-

signed automatically.

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

Further functions:

– Automatic tool recognition

– Integrated mains monitor recognises undervoltage

– Automatic current rise, welding and current recognition

– Easy and distinct operation by means of foil keyboard

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3.0 Start-up

3.1 Compressed air connection 8 bar

The compressed air connection (8 bar) is located on the back of

the power supply unit. The compressed air supply is necessary for

operating special tools (e.g. Airpuller) and cooling the welding gun.

3.2 Connection to power supply

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

Connection to a 16 A socket 16A-CEE-socket

Fuse: 16 A slow fuse

16 A automatic circuit-breaker

3.3 Checking the mains voltage drop during welding

If the full performance of the MULTISPOT M20 is to be obtained,

the mains voltage drop during welding must be kept as small as

possible. The full test is described on page 20 Chapter 8.3:

Information about the mains drop during welding

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

symbol:

Green = mains OK

Green/yellow = mains drop within tolerance range.

Only yellow = considerable mains drop – welding

performance impaired

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

thicker cables.

Red LED and = large mains drop with high loss in performance

warning tone: Welding is not possible. Welding current too

low.

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

thicker cables.

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

– After each welding operation, any mains voltage drop is

displayed for 2 seconds.

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4.0 Applications

Programme switch Material Max. sheet

Function thickness

in mm

Dent-pulling

with washer sheet steel 1.0

T-pins 3 mm Ø sheet steel 1.0

Dent-pulling with other tools sheet steel 1.0

(e.g. Airpuller)

Dent-pulling with

high-speed

planishing hammer sheet steel 1.0

Shrinking sheet steel 0.6 - 1.0

Stud welding Steel bolts Ø 4 - 5 mm

on sheet steel 2.0 mm

Corrugated wire on sheet steel 1.0

Copper shrinking sheet steel 1.0

5.0 Technical data

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

Supply voltage 1x230 V (1~) 400V (2~)

Slow fuse 16 A 16A

Mains frequency 50/60 Hz 50/60 Hz

Power supply cord 3.3 kVA 3.3 kVA

Max. welding capacity 11 kVA 11 kVA

Open-circuit voltage 8 V AC 8 VAC

Welding current max. 3000 A 3000 A

Ambient temperature 40 °C 40 °C

Type of protection IP21 IP21

Power supply unit with Dinse-plug

Dimensions H/W/D in mm 285/220/340

Weight 21 kg

(standard version)

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33 Welding gun

34 Button of welding gun

35 Grounding cable

36 Copper shoe

37 Lever clamp

38 Connection piece

A B

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6.0 Operating the welding gun

Preparation:

Insert the central plug of the welding gun (33) into the central

socket (63) until limit stop. Arrow on the plug pointing up-

wards.

The unit will switch automatically to the "gun" symbol.

Select the "gun" tool with key AB (uncoded gun only).

Connect the copper shoe (36) of the grounding cable (35) to

a bare point on the bodywork to be welded. Use lever clamp

(37) provided or a mole wrench.

Before using the lever clamp (37), you have to weld on two

8 mm washers as close to the point of weld as possible, see

section 6.1! In this case, press the copper shoe (36) of the

grounding cable (35) firmly onto the metal sheet. This is the

only way to obtain a good current transfer.

Attention!

The copper shoe (36) must always be connected to the metal

sheet below the metal part of the body to be worked on.

In any case avoid current transfer via hinges, door and bon-

net locks, as these might otherwise be damaged!!



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40 Contact piece UB

41 Pulling tool

A B C D G H

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