Elektron MULTISPOT MI-100-3 User manual

7
Operating Manual
MULTISPOT MI-100-3
Resistance Welder
Item no. 328 008
Revision: 1.0 - Translation
Version: 29
th
, March 2014
Be sure you have read and understood
this operating manual before you carry
out any works on and/or with this
equipment.

2
© BlitzRotary GmbH
Branch Bremen
Hinterm Sielhof 22
28277 Bremen - Germany
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.elektron-bremen.de
Release:
BlitzRotary GmbH Branch Bremen

Resistance Welder MULTISPOT MI-100-3
3
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
2Health 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 .............................................................11
2.4 Correct behaviour in accidents and dangerous situations ........................................................12
2.5 Measures to be taken in case of work at the device .................................................................12
2.6 Safety devices ...........................................................................................................................13
2.7 Safety labels and markings on this equipment..........................................................................13
2.7.1 On the flap cover ..........................................................................................................13
2.7.2 Signs on the backside ..................................................................................................14
2.7.3 On the balancer ............................................................................................................14
2.8 Spare and wear parts ................................................................................................................14
2.9 Waste management and environmental protection...................................................................15
3Transport, packaging, storage............................................................................... 16
3.1 Safety during transport ..............................................................................................................16
3.2 Symbols on packaging ..............................................................................................................16
3.3 Unpacking..................................................................................................................................16
3.4 Acceptance after shipping .........................................................................................................16
3.5 Handling ....................................................................................................................................17
3.5.1 Forklift truck ..................................................................................................................17
3.5.2 Transport with belts ......................................................................................................17
3.5.3 Moving equipment to the site........................................................................................17
3.6 In case of return of goods / further transport needs ..................................................................18
3.7 Storage ......................................................................................................................................18
4Design and functionality......................................................................................... 19
4.1 Overview....................................................................................................................................19
4.2 Description.................................................................................................................................19
4.3 Display and control elements ....................................................................................................20
4.3.1 On the display and control panel ..................................................................................20
4.3.2 On the inverter control unit ...........................................................................................20
4.4 Connections...............................................................................................................................20
4.4.1 Connections on the front side.......................................................................................20
4.4.2 Connections on the backside .......................................................................................21
4.5 Accessories ...............................................................................................................................21
4.5.1 Optional accessories ....................................................................................................21
4.5.2 Tools required...............................................................................................................21
5Installation ............................................................................................................... 22
5.1 Before installation......................................................................................................................22
5.1.1 Preliminary works .........................................................................................................22
5.2 Filling up cooling water tank ......................................................................................................22

Resistance Welder MULTISPOT MI-100-3
4
5.3
Assembling the balancer ...........................................................................................................23
5.4 Electrical connections ................................................................................................................24
5.5 Connecting the pneumatics .......................................................................................................25
5.6 Connecting the pliers .................................................................................................................26
5.7 Connecting the welding gun ......................................................................................................27
6Operation..................................................................................................................28
6.1 Preliminary works before welding..............................................................................................28
6.1.1 Preparing the sheets.....................................................................................................28
6.1.2 Preparing welding pliers ...............................................................................................28
6.1.3 Checks before switching on..........................................................................................30
6.2 Switching on ..............................................................................................................................31
6.3 Keyboard operation ...................................................................................................................31
6.4 Important information concerning welding.................................................................................32
6.5 Operating the welding gun.........................................................................................................35
6.5.1 Push spot welding.........................................................................................................35
6.5.2 Pulling-out dents with washer .......................................................................................36
6.5.3 High-speed planishing hammer „SAH“ (special accessory) .........................................37
6.5.4 Pushing-in dents ...........................................................................................................38
6.5.5 Shrinking sheet .............................................................................................................38
6.5.6 Welding-on threaded studs...........................................................................................38
6.5.7 Welding-on T-pins.........................................................................................................40
6.5.8 Fixing sheet metal parts (tacking).................................................................................41
6.5.9 Water-cooled spot welding gun (special accessory) ....................................................41
6.5.10 Connection of Airpuller/ Dentpuller ...............................................................................41
7Troubleshooting ......................................................................................................42
7.1 Health and safety during troubleshooting..................................................................................42
7.2 Error messages and troubleshooting tables.............................................................................42
7.2.1 Problems displayed on the control panel.....................................................................42
7.2.2 Possible causes and remedies in case of unsatisfactory welding results ....................42
8Maintenance.............................................................................................................43
8.1 Maintenance schedule...............................................................................................................43
8.2 Carrying out maintenance jobs..................................................................................................43
8.2.1 Cleaning........................................................................................................................44
8.2.2 Maintaining the pneumatic unit .....................................................................................44
8.2.3 Replacing water filter ....................................................................................................45
8.2.4 Empty cooling water tank..............................................................................................46
8.3 Measures to be taken after maintenance ..................................................................................47
9Specifications ..........................................................................................................48
9.1 Dimensions and weights............................................................................................................48
9.2 Power requirements...................................................................................................................48
9.3 Supplies .....................................................................................................................................48
9.4 Working conditions ....................................................................................................................48
9.5 Exposure limit values.................................................................................................................49
9.6 Type plates ................................................................................................................................49
10 Index .........................................................................................................................50
11 Appendix ..................................................................................................................52
Training Report .......................................................................................................................................52

Resistance Welder MULTISPOT MI-100-3
General information
5
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.
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.

Resistance Welder MULTISPOT MI-100-3
General Information
6
Tips, tricks and recommendations
NOTE!
... highlights information that may be helpful to maintain efficient and troublefree operation.
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.

Resistance Welder MULTISPOT MI-100-3
Health and safety
7
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
-
100
-
3
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 super speed steel (HSS), exclusively.
−Do not misuse this equipment for heating, thawing or perhaps even igniting objects.
−Do not use this equipment in explosive atmospheres.
−Do not open, alter, modify and/or manipulate etc. this equipment.
The manufacturer shall not be held liable for any and all damage due to misuse of this equipment.
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
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.
During the entire lifetime of this equipment, the operating company must check in regular
intervals whether such additional operating instructions are still up to date and must update
them when necessary.
The operating company must unambiguously determine and communicate responsibilities
concerning the installation, operation, maintenance and cleaning of this equipment.

Resistance Welder MULTISPOT MI-100-3
Health and safety
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The operating company must make sure that any person handling this equipment has read and
understood this operating manual. Operating personnel, in addition, must be trained in regular
intervals and must be informed about the dangers existing in connection with this equipment.
(For a draft of a training report form, see "Appendix”
The operating company must equip operating personnel with suitable personal protective
equipment (PPE) and check it for proper working condition in regular intervals. Defective PPE
must be replaced with new ones.
The operating company must take appropriate and suitable fire protection measures and make
available fire extinguishers and first aid kits.
The operating company is responsible that the equipment is in proper working order at all times.
Therefore:
The operating company must make sure that any and all maintenance jobs described in this
manual are really carried out.
The operating company must have any and all safety labels, markings etc. on the equipment
checked for integrity and readability in regular intervals.
Symbols the operating company must install on access ways and doors
Symbol
Meaning
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.

Resistance Welder MULTISPOT MI-100-3
Health and safety
9
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.
Furth
ermore:
no long hair, rings, necklaces, watches and/or other sorts of jewellery. Do not carry
easily inflammable objects in your pockets (matches, lighters etc.).

Resistance Welder MULTISPOT MI-100-3
Health and safety
10
2.3 Particular dangers
2.3.1 Dangers due to the equipment
Electricity
DANGER ! Electricity const
itutes 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.)
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.).

Resistance Welder MULTISPOT MI-100-3
Health and safety
11
Hot surfaces
CAUTION ! Hot surfaces pose a risk of burns.
Electrodes may heat up to 80 degrees centigrade approx. Stock may have up to 100 degrees
right after welding. So there is an acute risk of burning yourself. Therefore:
−Never work without proper safety clothes and gloves near hot components.
−Let freshly welded parts cool down to ambient temperature before you go on to work with
them.
Scald hazard
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.
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.
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:
−Move this equipment always using the handles.
−Keep potential obstacles out of the work area.
−Install cables and supply lines in such a way that they do not constitute a stumbling trap.

Resistance Welder MULTISPOT MI-100-3
Health and safety
12
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 dam
age 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.
Danger to control panel
CAUTION ! Control panel may sustain damage.
The control panel may sustain damage when being closed if negligent employees leave objects
lingering on the accessory box beneath. Therefore:
−Never put objects on the accessory box beneath the control panel.
−Proceed with care when closing the flap cover with integrated control panel.
2.4 Correct behaviour in accidents and dangerous situations
Preventive measures
Be prepared to confront accidents and fires.
Be sure to have first aid equipment (kits, blankets etc.) and fire extinguishers ready at hand.
All personnel must know about accident signalling systems, first aid, rescue and escape
equipment.
Keep access ways for ambulances clear and open.
Measures to be taken in case of accidents
Turn off power switch.
Initiate first aid.
Evacuate people from danger zone.
Alert persons in charge.
Alert fire brigade and ambulance service.
Keep access ways for ambulances clear and open.
2.5 Measures to be taken in case of work at the device
De-energise.
Secure against restarting (e. g. pull out mains plug).
Unstressedness determine.
Ground and short circuit.
Neighbouring energized parts cover or provide with gates.

Resistance Welder MULTISPOT MI-100-3
Health and safety
13
2.6 Safety devices
Fig. 1: Power switch on the backside
Power switch
Turning the power switch to position "0" will disconnect the power
supply immediately.
WARNING ! Danger! Equipment may still be unde
r voltage.
After switching off the power switch on the backside of the equipment, there may still be
components inside that are still under voltage. Therefore:
−In order to disconnect this equipment from the power supply, switch off using the power
switch. Earth components, short circuit and check for residual electricity.
2.7 Safety labels and markings on this equipment
2.7.1 On the flap cover
Fig. 2: Warning sign
"Electromagnetic fields"
on the flap cover
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.
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.
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 current
device and an operable earthing device.

Resistance Welder MULTISPOT MI-100-3
Health and safety
14
2.7.2 Signs on the backside
Fig. 3: Warning sign on the backside
Meaning
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 (i.e. if you can't see water in the level
gauge), fill up. (See "5.2".)
2.7.3 On the balancer
Fig. 4: Warning sign on balancer
Meaning
Always pull in the direction the guiding wheels are pointing.
In the event of lateral and/or transverse pull, there is a danger
the wheels jam/block and the equipment tips over.
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:
−Move this equipment always using the handles.
−Keep potential obstacles out of the work area.
−Install cables and supply lines in such a way that they do not constitute a stumbling trap.
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 enta
il errors,
damage and even total destruction. Therefore:
−Always use genuine spare and wear parts made by the manufacturer.
Be sure to buy your spare and wear parts directly from the manufacturer or an authorised dealer.
For contact information , see page 2 of this manual.

Resistance Welder MULTISPOT MI-100-3
Health and safety
15
2.9 Waste management and environmental protection
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.
Electronic components
Electronic components and scrap are subject to hazardous waste management and must be collected by
authorised companies.
Other components
Unless you have concluded a return and/or disposal agreement with the manufacturer, please disassemble
and recycle components.
Scrap metals.
Recycle plastic parts.
Other components must be sorted by materials and disposed of accordingly.

Resistance Welder MULTISPOT MI-100-3
Transport, packaging, storage
16
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
Fig. 5: Top
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 be damaged.
Fig. 6: Do not stack
Do not stack
Fragile goods. Do not stack, otherwise the contents of the packing unit could
be damaged.
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. 7) in case of any further transport needs (return of goods, further
transport).
3. Recycle packing materials.
What to do with packing materials
CAUTIO
N ! 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.
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.

Resistance Welder MULTISPOT MI-100-3
Transport, packaging, storage
17
NOTE!
Be sure to register a complaint as soon as a defect has been detected. Claims for damages may
be brought forward only within the deadlines set for complaints.
3.5 Handling
3.5.1 Forklift truck
Fig. 7: Using a forklift truck
Packing units on pallets may be handled with a forklift truck, as
long as the following conditions are fulfilled:
The forklift truck must be certified for the weight of the packing
unit at hand.
The operator must have a licence to drive forklift trucks.
Packing units may have very high centres of gravity. Make
absolutely sure they cannot tip over.
NOTE!
Keep the original pallet in case of any further
transport needs (return of goods, further
transport).
3.5.2 Transport with belts
Fig. 8: Transport with belts
To unload and transport use suitable device and belts.
The belts must be fixed at the handles in a way that the device
cannot tip over and the belts cannot get out of place.
3.5.3 Moving equipment to the site
Fig. 9: Warning sign on balancer
When moving around, always grip equipment by the handle
provided for that purpose.

Resistance Welder MULTISPOT MI-100-3
Transport, packaging, storage
18
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:
−Move this equipment always using the handles.
−Keep potential obstacles out of the work area.
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.
3.6 In case of return of goods / further transport needs
1. Drain cooling water tank completely. See “8.2.4”.
2. Use original transport pallet. (See Fig. 7)
3. Use packing materials that correspond to original packing materials.
4. Mark packing materials with symbols as shown in “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.
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.

Resistance Welder MULTISPOT MI-100-3
Design and functionality
19
4 Design and functionality
4.1 Overview
1 Running gear
2 Support for tools or electrode
arms, for instance
3 Inverter control unit
4 Welding pliers support
5 Control panel
6 Balancer support
7 Balancer
8 Welding pliers
9 Handle
10 Welding pliers supply lines
10
8
7
6
5
3
1
2
4
9
Fig. 10: Multispot system (standard)
4.2 Description
The MULTISPOT MI-100-3 resistance welding unit is designed for special requirements for the repair and
production of motor vehicle bodies. The inverter power source is controlled by a micro-processor. After
selecting the operating mode, the sheet steel thickness and the welding task, the current and weld time will
be assigned automatically. The current is regulated and always remains at the set level.
An audible alarm is performed if the power supply is too low.

Resistance Welder MULTISPOT MI-100-3
Design and functionality
20
4.3 Display and control elements
4.3.1 On the display and control panel
1 LED “malfunction” →see also
"7.2.1"
2 Touch key for selecting welding
tool
3 Touch key for selecting welding
gun functions
4 Touch key for selecting sheet
gauges
5 Touch key for power selection
1 2 3 4 5
Fig. 11: Display and control panel
4.3.2 On the inverter control unit
Fig. 12: Power switch (in “OFF” position)
The power switch (Fig. 12) is for switching the power
supply on and off.
4.4 Connections
4.4.1 Connections on the front side
Fig. 13: Connections on the front side
1 Pressure gauge
displays input pressure.
2 Pressure reducer
continuous adjustment of input pressure
3 Central connection point for weld current,
compressed air and control voltage of the
welding pliers
4 Coolant outlet
5 Coolant return