Elektron MULTISPOT MTC-6000 Manuale utente

Operating Manual

MULTISPOT MTC-6000

Spot Welding Pliers for Resistance Welder

Article No.

328069

Revision: 1.0 - Translation

Version: Okt. 29th, 2013 Be sure you have read and understood this

operating manual before you carry out any works

on and/or with this equipment.

BlitzRotary GmbH

Hinterm Sielhof 22

28277 Bremen

Germany

Tel. +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

Released by:

BlitzRotary GmbH

MTC 6000

Table of Contents

GENERAL ....................................................................................................................................... 4

1.1

Information on the operating manual..................................................................................... 4

1.2

Explanation of symbols.......................................................................................................... 4

1.3

Warnings for operating resistance welding equipment ......................................................... 5

1.4

Liability disclaimer ................................................................................................................. 6

1.5

Copyright ............................................................................................................................... 6

1.6

Warranty terms ...................................................................................................................... 6

1.7

After-sales service ................................................................................................................. 6

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 ................................................................................... 11

2.6

Signs.................................................................................................................................... 11

TRANSPORT, PACKAGING AND STORAGE............................................................................. 12

3.1

Safety instructions for transport........................................................................................... 12

3.2

Symbols on the packaging .................................................................................................. 12

3.3

Transport inspection ............................................................................................................ 12

DESIGN AND FUNCTION............................................................................................................. 13

4.1

Overview.............................................................................................................................. 13

4.2

Safety equipment................................................................................................................. 14

OPERATION.................................................................................................................................. 15

5.1

Connection and preparation of the spot welder................................................................... 15

5.1.1

Installation of the ring bracket................................................................................. 15

5.1.2

Connecting the pliers .............................................................................................. 16

5.1.3

Preparation of the welding pliers ............................................................................ 17

5.1.3.1

Replacement of the electrode arm ......................................................................... 17

5.1.3.2

Replacement of the electrode caps ........................................................................ 18

5.1.3.3

Aligning the electrodes with one another................................................................ 19

5.2

Preparation of the welding area .......................................................................................... 19

5.3

Welding with the spot welding pliers ................................................................................... 19

5.4

Welding settings with the MI-100control.............................................................................. 20

5.5

List of possible setting options in keyboard mode............................................................... 21

TECHNICAL DATA ....................................................................................................................... 22

INDEX ............................................................................................................................................ 23

MTC 6000

General

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 per-

sonnel in the vicinity of the operator at all times.

1.2

Explanation of symbols

Warnings

This manual uses symbols to highlight important safety information. In addition, there is al-

ways 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 pre-

vented..

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 me-

dium and small injuries unless it is properly avoided and prevented.

Electricity

… indicates an electric shock hazard

Elect

romagnetic 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.

MTC 6000

General

Risk of crushing

… indicates a risk or danger of injury as long as the equipment is in op-

eration.

Hot surface

… indicates a risk or danger of burns from hot surfaces.

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

NOTE!

…highlights useful tips and recommendations and information for effi-

cient and trouble-free operation.

1.3

Warnings for operating resistance welding equipment

Attention!

When operating resistance welding equipment, the operator must ob-

serve 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 gen-

erate 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.

Transformer pliers:

Ensure the exposure limits of the EU Directive 2004/40/EC and the iden-

tical basic values of accident prevention regulation BGV B11 perpen-

dicularly to the pliers window are duly observed for distances of 20 cm.

Shorter distances may be necessary in some cases.

Only very low flux densities occur in the area of the welding cables at the

transformer pliers. The admissible values are not exceeded even at the

surface of the power supply cable package. Maintaining a distance of 1

cm between the cable package and your head or spine is recommend-

ed.

Furthermore, long lengths of cable along your spine should be avoided.

The distances here refer to the distance between the centre of the weld-

ing window and the head and spinal cord of the welder operator. In most

applications, this distance can be kept without the need for further

measures due to the operator's body dimensions. Any auxiliary persons

("2nd man") must also observe these distances.

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 pro-

cess and do not put your head through the welding window.

•Do not allow the welding cable to run along your spine.

MTC 6000

General

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 tech-

nical developments, the actual scope of supply may differ from that illustrated and described

here.

1.5

The present operating manual must be treated confidentially. It is intended only for the per-

sons employed to work with the equipment. The provision of the operating manual to third par-

ties without the written approval of the manufacturer is not permitted. The texts, drawings, fig-

ures and other representations contained are protected by copyright and are subject to the in-

dustrial 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.

MTC 6000

Safety

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 sub-

ject to the statutory obligations for occupational health and safety.

In addition to the health and safety instructions given in this operating manual, the safety, ac-

cident 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 partic-

ular 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 neces-

sary.

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.

MTC 6000

Safety

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 opera-

tor 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 sur-

faces.

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 mate-

rials 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 man-

ual to reduce health hazards and avoid dangerous situations.

MTC 6000

Safety

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 electri-

cians.

−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 other

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 influ-

enced 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. There-

fore:

–

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.

MTC 6000

Safety

Hot surfaces

CAUTION! Risk of burns due to hot surfaces!

The electrodes can reach temperatures of approx. 80°C, the plates imme-

diately 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.

NOTE!

For further information on the locations of the safety devices, see chapter

"Design and function".

The following safety devices are installed:

Emergency stop palm button

Pressing the emergency stop palm button triggers an emergency stop.

When the emergency stop palm button has been pressed, it has to be released again by twist-

ing before the machine can be switched on again.

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