Operating Manual
MULTISPOT MTX 4900
Spot welding pliers for Resistence Welder
Article No. 328079
Revision: 0.1 – Translation Be sure you have read and
Version: 6
th
, January 2014 understood this operating manual.
2
© BlitzRotary GmbH
Branch Bremen
Hinterm Sielhof 22
D-28277 Bremen
Germany
Phone: +49 (0)421 / 54 90 6 - 906
Fax: +49 (0)421 / 54 90 6 - 19
E-Mail: vertrieb@elektron-bremen.de
Internet: www.elektron-bremen.de
Release:
BlitzRotary GmbH Branch Bremen
MTX 4900
Content
3
CONTENT
1 GENERAL ....................................................................................................................................... 4
1.1 Information on the operating manual ..................................................................................... 4
1.2 Explanation of symbols .......................................................................................................... 4
1.3 Warning for operation of resistance welding equipment ....................................................... 5
1.4 Liability disclaimer ................................................................................................................. 5
1.5 Copyright ............................................................................................................................... 6
1.6 Warranty terms ...................................................................................................................... 6
1.7 After-sales service ................................................................................................................. 6
2 SAFETY ........................................................................................................................................... 7
2.1 Responsibility of the owner.................................................................................................... 7
2.2 Personal protective equipment .............................................................................................. 7
2.3 Special hazards ..................................................................................................................... 8
2.4 Safety equipment ................................................................................................................. 10
2.5 Response to dangers and accidents ................................................................................... 10
2.6 Signs .................................................................................................................................... 11
3 TRANSPORT, PACKAGING AND STORAGE ............................................................................. 12
3.1 Safety instructions for transport ........................................................................................... 12
3.2 Symbols on the packaging .................................................................................................. 12
3.3 Transport inspection ............................................................................................................ 12
4 DESIGN AND FUNCTION ............................................................................................................. 13
4.1 Overview .............................................................................................................................. 13
4.2 Safety equipment ................................................................................................................. 14
5 OPERATION .................................................................................................................................. 15
5.1 Connection and preparation of the spot welding pliers ....................................................... 15
5.1.1 Mounting ring bar .................................................................................................... 15
5.1.2 Connecting the pliers .............................................................................................. 16
5.1.3 Preparation of the welding pliers ............................................................................ 17
5.1.3.1 Exchanging electrode arms ..................................................................... 17
5.1.3.2 Exchanging electrode caps ...................................................................... 18
5.1.3.3 Deploying and locking the electrode arm ................................................ 18
5.1.3.4 Adjusting the distance between electrodes ............................................. 19
5.2 Preparation of the welding area .......................................................................................... 19
5.3 Welding with the spot welding pliers ................................................................................... 20
5.4 Welding settings with the MI-100control .............................................................................. 21
6 TECHNICAL DATA ....................................................................................................................... 22
7 INDEX ............................................................................................................................................ 23
MTX 4900
General
4
1 General
1.1 Information on the operating manual
This operating manual contains important information on the use of the device. A precondition
for operator safety is the compliance with all the safety precautions and working instructions.
Furthermore, observe any and all local accident prevention regulations as well as any and all
general safety regulations which may apply to the operation of this equipment.
Read and understand the operating manual carefully prior to operating the devise! This manual
forms an integral part of the devise and must be stored where it is readily available to the personnel in the vicinity of the operator at all times.
1.2 Explanation of symbolsFehler! Textmarke nicht definiert.
Warnings
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.
Observe such information at all times and work carefully to avoid accidents, personal injury
and damage to property
.
DANGER
!
… indicates a situation that is imminently dangerous and will entail the death of
people and severe injuries unless 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
!
… draws attention to a potentially dangerous situation which can lead to slight or
minor injuries if not avoided.
CAUTION!
… indicates a situation that may become dangerous and may entail medium and
small injuries unless it is properly avoided and prevented.
Electricity
… indicates an electric shock hazard
Electromagnetic fields
… indicates a risk of death for persons with heart pacemakers or other magnetically influenced implants and devises as well as a risk or danger to property.
Moving machine
parts
… indicates a risk of personal injury as long as the equipment is moving.
Health
-
endangering substances
… indicates a risk or danger from toxic or harmful fumes.
Hot surface
… indicates a risk or danger of burns from hot surfaces.
MTX 4900
General
5
Risk of slipping
… indicates a risk of slipping due to escaping water.
Risk of tripping
… indicates a risk of injury from tripping, stumbling or falling.
Tips and recommendations
i
NOTE!
…highlights useful tips and recommendations and information for efficient and
trouble-free operation.
1.3 Warning for operation of resistance welding equipment
Attention!
When operating resistance welding equipment, the operator must observe the
accident prevention regulations
BGV B11 (Electromagnetic Fields) and the BG rules BGR B11. The power
pack and cables of the welding gun and spot welding pliers generate a strong
electromagnetic field during operation. Electromagnetic fields can cause irritation to sensory organs, nerve and muscle cells and malfunctions of medical
aids (hearing aids, heart pacemakers, etc.) and of electronic devices and data
storage systems.
Further information on dealing with magnetic fields:
• Magnetic fields occur only during the welding process (current flow times).
• Do not touch the electrodes with your head during the welding process and
do not put your head through the welding window.
• Do not allow the welding cable to run along your spine.
1.4 Liability disclaimer
All information and data contained in this operating manual have been compiled giving due
consideration to the latest applicable standards and regulations, the state-of-the-art and our
many years of practice and experience.
The manufacturer assumes no liability for damage or injury resulting from:
Failure to observe the operating manual
Use of the equipment for other than its intended purpose
Employment of unqualified personnel
Unauthorised modifications
Technical changes
Use of unauthorised spare parts
In the event of special designs, the ordering of additional options or in line with the latest technical developments, the actual scope of supply may differ from that illustrated and described
here.
MTX 4900
General
6
1.5 Copyright
The present operating manual must be treated confidentially. It is intended only for the persons employed to work with the equipment. The provision of the operating manual to third parties without the
written approval of the manufacturer is not permitted. The texts, drawings, figures and other representations contained are protected by copyright and are subject to the industrial property rights. Any improper use shall be liable to prosecution.
1.6 Warranty terms
The warranty terms can be found as a separate document in the sales documentation
.
1.7 After-sales service
Our after-sales service department is at your disposal for further technical information.
Information on the responsible contact person can be obtained at any time by telephone, fax,
e-mail or via the Internet, see manufacturer's address on page 2.
MTX 4900
Safety
7
2 Safety
This section gives an overview of all the important safety aspects for optimum protection of the
personnel and for safe and trouble-free operation.
Failure to observe the working instructions and safety precautions given in this operating manual
can result in considerable hazards.
2.1 Responsibility of the owner
The equipment is for professional industrial use. The owner of the equipment is therefore subject to the statutory obligations for occupational health and safety.
In addition to the health and safety instructions given in this operating manual, the safety, accident prevention and environmental protection regulations applicable at the place of operation
for such equipment apply accordingly. This means in particular:
The owner must familiarise himself with the relevant health and safety regulations and
carry out a risk assessment to determine any additional hazards resulting from the particular working conditions at the place of operation of the equipment. He must implement
these in the form of operating instructions for the operation of the equipment.
During the entire lifetime of the equipment, the owner must regularly check whether such
additional operating instructions are still up-to-date and must update them when necessary.
The owner must clearly and unquestionably determine and communicate the responsibili-
ties for installation, operation, maintenance and cleaning of the equipment.
The owner must ensure that all persons operating and/or working with this equipment
have read and understood this operating manual.
Furthermore, the personnel must be trained at regular intervals and be informed of the
risks and dangers associated with the operation of this equipment.
The owner is also responsible for ensuring that the equipment is in proper working order at all
times, therefore:
The owner must ensure that the maintenance operations described in this operating
manual are duly conducted.
The owner must check all safety signs and markings on the equipment
for integrity and legibility at regular intervals.
2.2 Personal protective equipment
Operating personnel must wear personal protective equipment (PPE) when working with the
equipment to minimise health and safety risks.
• Always wear the appropriate PPE for the job at hand whiles operating the equipment.
• Observe the warning signs concerning PPE be installed at the place of work.
MTX 4900
Safety
8
Always wear
When operating the equipment always wear:
Protective work clothes
… are tight-fitting working clothes of low tear strength with narrow sleeves
and without protruding parts. It serves predominantly to prevent the operator being caught up and pulled into moving machine parts.
Do not wear rings, chains or other jewellery.
Safety shoes
… as protection against falling heavy objects and slipping on slippery surfaces.
Wear for all special operations
Special protective equipment is necessary when carrying out special operations. Attention is
drawn specifically to this in the individual chapters of this manual. This special protective
equipment is described below:
Face mask
… as protection for the face and eyes against flames, sparks or hot materials and against hot particles and fumes.
Ear protectors
… as protection against hearing damage.
Gloves
… as protection for the hands against flames, sparks or hot materials and
against hot particles.
2.3 Special hazards
The following section describes the residual risks identified during the risk analysis.
Observe the safety precautions given here and the warnings in the other chapters of this manual to reduce health hazards and avoid dangerous situations.
MTX 4900
Safety
9
Electricity
DANGER! Electric shock hazard!
Contact with live parts entails an immediate risk of electric shock. Damage
to the insulation or individual parts can create a very great hazard.
Therefore:
− If damage to the insulation is discovered, switch off the power supply
immediately and have the necessary repairs carried out.
Have work on the electrical system carried out only by qualified electricians.
− Before all work on the electrical system, disconnect the power, earth
and short.
− Before maintenance, cleaning and repair work, switch off the power
supply and secure to prevent restarting.
− Do not bypass or deactivate fuses or circuit breakers. Use only fuses
with the correct amperage for replacement.
Keep moisture away from live parts. This can result in short-circuits.
Electromagnetic fields
DANGER! Risk of death for persons with heart pacemakers or oth
er
magnetically influenced implants!
Electromagnetic fields impair the function of heart pacemakers and other
magnetically influenced implants. Electromagnetic fields can cause irritation
to sensory organs, nerve and muscle cells. Therefore:
– Keep persons with heart pacemakers and other magnetically influenced
implants away from the working area.
– Post signs at the working area accordingly.
– Post signs at the accesses and doors to the working area accordingly.
– Do not run welding cables over your head or along your spine. (The ex-
posure limits are safely observed for distances of ≥ 20 cm. Maintain a
minimum distance of 1 cm between the cable package and your head or
spine!).
Electromagnetic fields – Danger for magnetisable property!
Keep magnetisable data media and other magnetically influenced objects
away from the working area.
Weld spatter and flying sparks
WARNING! Fire and explosion hazard from weld spatter and flying
sparks! Risk of injury from weld spatter and flying sparks!
Weld spatter and sparks can occur during welding. These can cause fires
and explosions. These can cause injuries if they contact the body. Therefore:
– Before starting welding work, ensure that there are no inflammable or
explosive materials in the vicinity of the working area.
– Do not carry out welding work in particular in the vicinity of pressure
vessels, tanks, oil drums, paint and lacquer drums or in areas with a
potentially explosive atmosphere.
– Have fire fighting equipment on hand.
– Keep access and escape routes clear.
– During all welding work, always wear a face mask, fireproof protective
working clothes and welder's gloves.
– Do not carry easily inflammable items such as matches or cigarette
lighters with you.
MTX 4900
Safety
10
Hot surfaces
CAUTION! Risk of burns due to
hot surfaces!
The electrodes can reach temperatures of approx. 80°C, the plates immediately after welding even 100°C. Risk of burns. Therefore:
– Always wear protective working clothes and protective gloves when
working in the vicinity of hot parts.
– Ensure that the plates have cooled to room temperature again before
carrying out any other work in these areas.
Fumes
WARNING! Danger from health
-
endangering fumes!
If the plates have not been properly ground and cleaned before welding,
they may be contaminated with residues of glues, paints, undercoats, etc.
that may generate harmful or even toxic fumes during welding.
Therefore:
– Ensure that the plates you wish to weld have been properly ground
and cleaned and are completely free of residues before starting weld-
ing.
– Always wear a face mask during all work. Respiratory equipment may
be recommendable in case of doubt.
Risk of tripping
WARNING! Risk of injury from falling!
The work environment may pose stumbling risks. Stumbling and falling may
lead to severe injuries. Therefore:
– Ensure that the working area is tidy and uncluttered and offers enough
freedom to move before starting welding work.
– Lay cables and supply lines in such a way that they do not constitute a
stumbling hazard.
– When welding, always assume a safe and stable working position.
2.4 Safety equipment
WARNING!
Danger from malfunctioning safety equipment!
Safety equipment ensures the maximum possible safety during work. Even
if safety equipment makes work processes more laborious, they must on no
account be bypassed or deactivated. Safety is only ensure when the safety
devices are intact.
Therefore:
− Check that the safety devices are correctly installed and functional
before starting work.
i
NOTE!
For further information on the locations of the safety devices, see chapter
"Design and function".
2.5 Response to dangers and accidents
Preventive measures
Always be prepared for accidents or fires!
Have first aid facilities (first aid box, blankets etc.) and fire extinguishers accessible at all
times.
Familiarise the personnel with accident reporting, first aid and rescue procedures.
Keep the access routes free for the rescue services.
MTX 4900
Safety
11
If the worst comes to the worst: Act correctly
Immediately switch off the equipment at the emergency stop button.
Initiate first aid measures.
Remove persons from the danger zone.
Inform the responsible person at the place of work.
Call a doctor and/or the fire brigade.
Clear the access routes for the rescue services.
2.6 Signs
The following symbols and signs can be found in the working area. They are related to the
immediately surrounding area in which they are posted.
WARNING!
Risk of injury due to illegible symbols!
Over the course of time, labels and symbols on the equipment may become
soiled or otherwise made illegible.
Therefore:
− Keep all safety, warning and operating instructions on the equipment in
a clean and legible condition at all times.
− Immediately replace any damaged signs or labels.
Observe the operating manual
Use the equipment marked with this symbol only when you have read the
operating manual.
Moving machine parts
Maintenance work on open machines may only be carried out by specially
qualified personnel. There is a risk of injury as long as the machine is moving.
Electricity
Only qualified electricians may be allowed to work in rooms marked with this
symbol.
Unauthorised persons must not enter the marked places of work or open the
marked cabinet.
MTX 4900
Transport, Packaging and Storage
12
3 Transport, Packaging and Storage
3.1 Safety instructions for transport
Improper transport
3.2 Symbols on the packaging
None
3.3 Transport inspection
Check the delivery for completeness and transport damage immediately on receipt.
In the event of visible signs of damage, proceed as follows:
Do not accept the delivery or accept only conditionally.
Record the extent of the damage on the transport documents or on the shipping agent's
delivery note.
Submit the appropriate complaint.
i
NOTE!
Report all damage as soon as it is detected. Claims for damages can only be made
within the statutory periods for complaints.
CAUTION!
Damage due to improper transport!
Improper transport can result in considerable material damage.
Therefore:
− Handle the packages carefully during unloading on delivery and during in-plant
transport and observe the symbols on the packaging.
− Use only the lifting points provided.
− Remove the packagings only shortly before installation.
MTX 4900
Design and function
13
4 Design and function
4.1
Overview
Fig. 1: Overview Welding pliers
1. Welding pliers
2. Electrode arm receptacle
3. Adjusting and release button for movable electrode arm
4. Electrode arm, movable, Ø 25 mm
5. Electrode caps
6. Electrode arm, stationary, Ø 25 mm
7. Ring bar
8. Release button
9. Welding cable
10. Hexagon screw for fixing the electrode arm
4
3
2
5
1
2
6
10
7
Necessary distance
8
6-8mm
9
MTX 4900
Design and Function
14
4.2 Safety equipment
Emergency stop button (on the resistance welder)
Fig. 2: Locations of the safety devices
The figure shows the location of the emergency stop button.
It is indicated by the symbol shown on the left.
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Operation
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5 Operation
5.1 Connection and preparation of the spot welding pliers
5.1.1 Mounting ring bar
1. Mounting ring bar
2. Put in screws with plastic sleeves (isolation)
3. Fix screws tight
4. Ring bar fixed at pliers
Fig. 3: Mounting ring bar
MTX 4900
Operation
16
5.1.2 Connecting the pliers
Fig .4: Connecting the pliers
1
.
Push the main plug of the welding pliers into the main
socket of the equipment (Fig .4/1).
2. Push down the clamps to lock the connection. (Fig .4/2).
Fig. 5: Water cooling system for the
pliers
3
.
Connect the water cooling system of the pliers.
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Operation
17
5.1.3 Preparation of the welding pliers
Risk of scalding
CAUTION! Risk of scalding from escaping hot water!
Hot water can splash out when disconnecting the coolant hoses. Therefore:
– Wear protective gloves.
– Pull off the coolant hoses carefully.
Risk of slipping
CAUTION! Risk of slipping due to escaping water!
Water can splash out when disconnecting the coolant hoses. Therefore:
– Wipe up any water on the floor.
The device switches automatically to the correct pliers symbol.
Place the electrode arm into the pliers (s. 5.1.3.1).
Lock in movable electrode arm.
Adjust distance of electrodes between 6 and 8 mm (s. 5.1.3.4).
Tighten the hexagon screw.
After the first welds check again the distance of the electrodes and adjust, if neces-
sary!
5.1.3.1 Exchanging electrode arms
Fig. 6: Unbolting electrode arm
1. To unbolt the electrode arm, use the Allen key provided
for that purpose (Fig. 6).
Fig. 7: Removing the electrode arm
2
.
Remove the electrode arm simply by pulling it out (Fig. 7).
3. Insert new electrode arm and tighten with Allen key.
WARNING! Risk of injury from sudden release of the welding tool!
When changing a tool with the machine switched on, welding current or pliers move-
ments can be accidentally triggered. Risk of crushing. Therefore:
– First prepare the welding pliers/welding gun and then switch on the machine.
– If tool changing is necessary during work, be sure to switch off the machine first.
ATTENTION!
Switch off the coolant pump before changing the electrode arm.
MTX 4900
Operation
18
5.1.3.2 Exchanging electrode caps
Fig. 8: Replacement of the electrode
caps
1. Loosen the electrode caps using the electrode cap wrench or an
equivalent tool (Fig. 8).
2. Turn in clockwise direction, otherwise the cone will be loosened.
3. Push new electrode caps onto the electrode head and press into position.
NOTE!
A good condition of the electrode caps is important for
good welding results.
Particularly when welding HSS plates and coated
plates, the electrode caps have to be milled or replaced
after 50 welding operations at the latest (milling tool,
see accessory catalogue).
5.1.3.3 Deploying and locking the electrode arm
Deploying the electrode arm
Fig. 9: Unlocking the arm
1. Switch the locking device of the electrode arm from position "locked" (9/A) to position "open" (9/B) as shown in the
picture.
Locking the electrode arm
Fig. 10: Locking the arm
2. Push the electrode arm without much force into the locking device until you feel and hear it engage (10).
MTX 4900
Operation
19
5.1.3.4 Adjusting the distance between electrodes
Fig. 11
: Adjusting the distance be-
tween electrodes
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
Aligning electrodes
Fig. 12
: "Electrode must be in true
alignment"
Be sure to look from different angles. Electrodes must
align no matter how you look.
5.2 Preparation of the welding area
The plates must be ground down to the bare metal at the contact point of the spot electrode
with the plate.
Take care not to damage galvanised surfaces. In the case of insulating intermediate layers
such as spot welding primer, electrical contact (auxiliary connection) first has to be made using a vice-grip wrench. Then set the first welding point directly alongside this contact
MTX 4900
Operation
20
5.3 Welding with the spot welding pliers
Warning:
Electromagnetic fields!
Wear protective goggles and protective gloves!
The electrodes get hot!
Flying sparks!
− Turn on the machine at the mains switch (see operating manual
of the power pack)
− Connect the machine to the compressed air grid.
− Important: At the end of the welding operation, allow the coolant
pump to run for a few more minutes to prevent any build-up of
heat.
i
Ensure an adequate supply of compressed air, working pressure
min. 8 bar!
Working pressure is 8 bar! For the MTX 4900 pliers the value
should be 6 bar / 90 psi.
MTX 4900
Operation
21
5.4 Welding settings with the MI-100control
Fig. 13: Selection of welding operation
i
If you stop pushing the release button (Fig. 1) before the welding starts, the welding
will be stopped as well. If you keep pressing the release button, the post-pressing
time will be prolonged.
Note: Aborting the welding is not possible.
Select the welding operation with the buttons EF, e.g.
a - HSS plates
)
b - 3-layer plate joint ) see Fig. 13
c - Galvanised plates )
Several options can be selected at the same time.
During welding, hold the trigger knob of the pliers depressed until the welding process is terminated automatically.
Example of a welding programme sequence (see Fig. 14):
A – Prepressing 1 sec.
C – Welding time, depending on setting
A – Post-pressing 1 sec.
Fig. 14: Welding programme
sequence
MTX 4900
Technical data
22
6 Technical data
With direct welding current measurement in the pliers head (pneumatic, water-cooled)
Weight
Specification Value Unit
With cable + 190mm
electrodes
9,7 kg
Compressed air supply
Specification Value Unit
Working pressure 8,5 – 10 bar
Quality Clean, dry and oil free
Ambient conditions
Specification Value Unit
Ambient temperature, max. 40 °C
Relative humidity, max.
(no condensation)
85 %
Welding
pliers
Specification
Degree of fulfilment
Exposure limits in accordance
with EU Directive 2004/40/EC
• reliably satisfied at dis-
tances ≥ 20 cm
perpendicularly to the
pliers window
• reliably satisfied at
distances of ≥ 1 cm
from the welding cable
MTX 4900
Index
23
7 INDEX
A
Adjusting the distance between electrodes 19
After sales service 6
Aligning electrodes 19
C
Caution 4
Compressed air supply 22
Coolant pump 20
Copyright 6
D
Danger 4
E
Ear protectors 8
Electricity 4, 11
Electrode arm 17
Electromagnetic fields 4, 20
Emergency stop button 14
Explanation of symbols 4
F
Face mask 8
Flying sparks 20
Function 13
H
Health-endangering substances 4
Hot surface 4
L
Liability disclaimer 5
M
Mounting ring 15
Moving machine parts 4, 11
N
Note 5
O
Operation 15
P
Packaging 12
Peronal protective equipment 7
Protective work clothes 8
R
Risk of slipping 5
Risk of tripping 5
S
Safety 7
Safety shoes 8
Signs 11
Special hazards 8
Storage 12
T
Technical data 22
Transport 12
Transport inspection 12
Trigger knob 21
W
Warning 4
Warranty terms 6
Welding area 19
Welding operation 21
Welding programme sequence 21
Working pressure 20
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