Subscribe to Our Youtube Channel
Related Manuals for Fronius DeltaSpot
Summary of Contents for Fronius DeltaSpot
- Page 1 Operating Instructions Spare Parts List Resistance welding gun DeltaSpot 42,0426,0050,EN 022007...
- Page 3 Read the manual carefully and you will soon be familiar with all the many great features of your new Fronius product. This really is the best way to get the most out of all the advantages that your machine has to offer.
- Page 5 Safety rules DANGER! „DANGER!“ indicates immediate and real danger. If it is not avoided, death or serious injury will result. WARNING! „WARNING!“ indicates a possibly dangerous situation. Death or serious injury may result if appropriate precautions are not taken. CAUTION! „CAUTION!“...
- Page 6 General remarks All safety and danger notices on the device (continued) must be kept in a legible state must not be damaged/marked must not be removed must not be covered, pasted or painted over. For the location of the safety and danger notices on the device, refer to the section headed „General remarks“...
- Page 7 Obligations of The operator undertakes to allow only such people to work with the device the operator who: are familiar with the fundamental instructions regarding safety and accident prevention, and have been instructed how to use the device have read and understood the „Safety rules“ section and warning notices in these operating instructions, and then signed them to confirm this are trained to produce the required results.
- Page 8 Protecting Protective clothing refers to a variety of different items. Operators should yourself and others protect eyes and face from UV rays, heat and sparks with regulation (continued) protective visor with filter. wear regulation protective goggles with side protection behind the safety visor.
- Page 9 Danger from Flying sparks may cause fires or explosions. flying sparks Never weld close to flammable materials. Flammable materials must be at least 11 metres (35 ft) away from the welding process, or alternatively covered with a checked cover. A suitable, tested fire extinguisher must be available and ready for use. Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings.
- Page 10 Risks from mains current and Before working on the device, switch it off and disconnect it from the mains welding current supply. (continued) Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from reconnecting it to the mains and switching it on again. After opening the device: discharge all components that are electrically charged ensure that all components in the device are de-energised.
- Page 11 EMC measures d) Earthing the workpiece (continued) If necessary, establish earth connection using suitable capacitors. e) Screening, if necessary screen off other devices nearby screen off entire welding installation Prohibited to persons with pacemakers: The strong magnetic fields generated by resistance welding will interfere with the function of pacemakers.
- Page 12 Specific hazar- Never touch the workpiece, electrodes or process tape during or after wel- dous areas ding - risk of burns. (continued) Welding residues can jump off cooling work pieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately pro- tected.
- Page 13 Safety measures Only operate the device when all protection devices are fully functional. If the in normal mode protection devices are not fully functional, there is a risk of injury or death to the operator or a third party, damage to the device and other material assets belonging to the operator, inefficient operation of the device.
- Page 14 Disposal Do not dispose of this device with normal domestic waste! To comply with the European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of its life must be collected separately and returned to an approved recycling facility Any device that you no longer require must be returned to our agent, or find out about the approved collec- tion and recycling facilities in your area.
-
Page 15: Table Of Contents
Connecting to cooling water supply ......................20 Threading up process tape ........................21 Move to reference point ......................... 22 Sheet thickness correction ........................23 DeltaSpot resistance spot welding ......................25 General remarks ............................ 25 Process tape consumption ........................25 Holder adjustment ..........................26 Influence of the process tape on the welding process ................ - Page 16 General remarks ............................ 53 Every start-up ............................53 Every time you change an electrode ...................... 53 Disposal ..............................53 Technical Data ............................. 54 Special voltages ............................. 54 TR-Unit ..............................54 DeltaSpot welding gun ..........................55 Spare parts lists Fronius worldwide...
-
Page 17: General Remarks
Areas of utilisati- The DeltaSpot spot welding process is designed for joining two or more sheets of stan- dard coated or uncoated steels and all standard aluminium alloys. It is also ideal for welding different combinations and thicknesses of materials (Usibor, CrNi, etc.). -
Page 18: Scope Of Supply
Holder main body x 500 + arms, sandwich design Medium frequency transformer (1000 Hz) water-cooled Holder drive Servo-electric holder adjustment Holder control Industrial PC for graphical display of control functions (Fronius Xplorer) DeltaRemote remote control DeltaRemote plus remote control (optional) Quality assurance system (optional) Process tape... - Page 19 Information for Example: dimensioning the The welding time is 180 ms and cycle time is 4 s welding plant (continued) The on-time is accordingly ED = t / T x 100 % = 0.18 s / 4 s x 100 % = 4.5 % Transformer limiting 30000 Welding time: 50 Per (1s)
-
Page 20: System Components
System components General remarks Using the medium frequency technique the weight of the welding transformer can be significantly reduced. Reaching a greater operating frequency with medium frequency welding can result in a significant reduction of the weight and volume of the welding transformer. 50 / 60 Hz Welding Transformer... -
Page 21: Overview Of System Components
Overview of system compon- ents Fig. 4 Overview of system components (1) Distributor cooling water supply (a) Cooling water supply (2) Cooling unit/cooling network (b) Buses (3) Robot control (c) Transformer supply (4) Holder control (d) Flow monitor signals (5) Power module (6) Welding gun... -
Page 22: Delta Control Connections
Controls and connections General remarks NOTE! As a result of firmware updates, you may find that there are functions available on your unit that are not described in these operating instructions or vice versa. Also, certain illustrations may be very slightly different from the actual controls on your machine. - Page 23 Delta Control X1 Connection of main plug of DeltaSpot welding arm connections to connect the control lead (continued) X2 EMERGENCY OFF external for connection to the robot Pin configuration: + 24 V output (via X5 Pin A, B) Feedback signal + 24 V...
-
Page 24: Welding Transformer Connections
X8 - X 11 reserve (continued) CAN1 communication interface to the PC CAN2 communication interface to the DeltaSpot welding gun F1 DeltaControl 24V supply fuse F2 DeltaSpot welding gun 24V supply fuse F3 Bus coupler 24V supply fuse F4 Welding voltage metre fuse... -
Page 25: Welding Gun Connections
Welding gun (9a) Cooling water supply connection (10a) connections to the upper holder arm (10 a) Cooling water return connection to the upper holder arm (9b) Cooling water supply connection (9a) to the lower holder arm (10 b) Cooling water return connection to the lower holder arm (10b) (9b) -
Page 26: Mechanical Components
Mechanical (12) components (11) (23) (22) (14) (13) (15) (16) (17) (20) (19) (18) (22) (11) (12) (21) Fig. 9 Mechanical components (11) Process tape holder to hold unused process tapes (12) Lock for process tape holder (13) Process tape spooling device with drive to hold used process tape (14) Process tape guide roller (15) Electrode shaft... - Page 27 Mechanical components (continued) (25) (24) Fig. 10 Holder adjustment (24) Holder adjustment to equalise component tolerances or position differences (25) Holder adjustment drive...
-
Page 28: Delta Remote Control
Delta Remote WARNING! Automatically starting machines can cause serious injury and control damage. In addition to these operating instructions, the robot and welding system manufacturer’s safety rules must also be observed. For your personal safety, ensure that all protective measures have been taken and will remain in place for the duration of your stay within the working area of the robot. -
Page 29: Deltaremote Plus Remote Control
DeltaRemote Plus WARNING! Automatically starting machines can cause serious injury and remote control damage. In addition to these operating instructions, the robot and welding system manufacturer’s safety rules must also be observed. For your personal safety, ensure that all protective measures have been taken and will remain in place for the duration of your stay within the working area of the robot. - Page 30 DeltaRemote Plus (36) Reset key remote control to reset faults that have arisen (continued) (37) LED default during commissioning if the reference point has not yet been defined should faults arise during an ongoing operation (38) Open and close welding gun switch to open and close welding gun manually...
-
Page 31: Before Commissioning
Before commissioning General remarks WARNING! Automatically starting machines can cause serious injury and damage. In addition to these operating instructions, the robot and welding system manufacturer’s safety rules must also be observed. For your personal safety, ensure that all protective measures have been taken and will remain in place for the duration of your stay within the working area of the robot. -
Page 32: Guidelines For System Cooling
Note the informati- on provided by the manufacturer of the cooling system Transformer PE Fronius medium frequency transformers comply with protection class 1. conductor con- nection NOTE! Additional safety precautions are required for medium frequency trans- formers in protection class 1 to guard against an isolation failure between the primary and secondary power circuits. -
Page 33: Commissioning
Fig. 13 Connecting DeltaControl (1) DeltaControl (2) Industrial PC Connect the signal cable (7) to the main plug connector of the DeltaSpot (X1) welding gun Connect the analogue signal cable from the power source (3) to the analogue power source connector (X6). -
Page 34: Connecting The Welding Gun
Connecting If applicable, connect the external welding start-up connection cable (5) to the DeltaControl external welding start-up connector (X5) (continued) WARNING! Operating the equipment incorrectly can cause serious injury and damage. The design of external operating equipment or Emergency Stop actuators must comply with valid national and international standards. -
Page 35: Threading Up Process Tape
Threading up process tape "click"... -
Page 36: Move To Reference Point
Move to refe- WARNING! Automatically starting machines can cause serious injury and rence point damage. In addition to these operating instructions, the robot and welding system manufacturer’s safety rules must also be observed. For your personal safety, ensure that all protective measures have been taken and will remain in place for the duration of your stay within the working area of the robot. -
Page 37: Sheet Thickness Correction
Fig. 16 Detail, holder drive in the operating range Sheet thickness correction Weld the point with the necessary sheet thickness If the actual operating point (1) is outside the defined operating range, Fronius Xplorer (2) will give a warning signal. The warning is listed in the status options... - Page 38 Sheet thickness Set the operating point by correcting the sheet thickness to within the defined correction operating range: (continued) Re-weld the point with the required sheet thickness Repeat operating steps 2- 5 until the actual operating range is within the defined operating range.
-
Page 39: Deltaspot Resistance Spot Welding
DeltaSpot resistance spot welding General remarks The most significant feature in the case of DeltaSpot resistance spot welding is the process tape. As well as protecting the electrodes, it offers additional advantages such as the control of the heat application, improvement of efficiency and the ability to bond very different materials. -
Page 40: Holder Adjustment
Holder adjust- The holder adjuster enables the welding gun to be adjusted to fit the workpiece and to ment compensate for part tolerances. Holder adjustment activated If holder adjustment is activated, both holder arms are able to move freely around the axis (1). -
Page 41: Influence Of The Process Tape On The Welding Process
Resistances with DeltaSpot resistance welding: °C (°F) Fig.19 Resistances with DeltaSpot spot welding: Material resistances of the electrode Contact resistances of the electrode - process tape... -
Page 42: Holder Control / Fronius Xplorer
Welding parameters can be set using the programme editor in Fronius Xplorer. You can find further details in the Fronius Xplorer operating instructions. NOTE: As a result of firmware updates, you may find that there are functions available on your device that are not described in these operating instructions or vice versa. -
Page 43: Configuring Deltaspot
Location (company), (plant), (hall), (cell) Define company name and location of welding gun. The names that are entered are stored in Fronius Xplorer as a path (company / plant / hall / cell) and illustrated as a file structure. company/... - Page 44 Configuring Power source (target value before start signal) DeltaSpot This signal will send a short current pulse to activate the power source required to start (continued) the welding process. Welding start-up Signal disabled Welding start-up 3 kA Signal enabled Transformer (max current)
-
Page 45: Calibrating Welding Guns
WARNING! Incorrect details can have serious consequences for equipment. The welding gun must be configured by trained specialist personnel. The manufacturer will not be held responsible for damage due to incorrect set- tings. Configuring DeltaSpot welding gun: Access system configuration via the options menu System configuration Calibration... -
Page 46: Program Options
Program options /system name / system location Overview Diagnosis Program Status FILTER Comments Prog Name Spot Profile Name 1 Name 2 Name 3 Name 4 Name 5 Name 6 Fig. 24 Program option view Create/edit program button Click on profile preview (1) in options sheet to select and click on program editor button to open. -
Page 47: Status Options
Status options In the status view you will find all current warnings and faults related to the welding gun. Overview Program Status Diagnosis Operating range The current operating point is outside the defined operating range Correct sheet thickness. Process tape empty The lower process tape is used up Load new process tape. -
Page 48: Diagnosis View
Diagnosis view The diagnosis view gives information about: Current statuses of the input and output interfaces The connection statuses of the Can devices The device status Overview Program Status Diagnosis Fig. 26 Diagnosis view - interface Overview Program Status Diagnosis Fig. -
Page 49: Creating Welding Parameters In Program Editor
Creating welding parameters in program editor Opening program Select program editor by selecting the required profile and clicking on the create/edit editor profile button. Shortcut: double click on profile Symbols used in Save settings program editor Backup parameter settings. Shortcut: Enter key Reset settings Resets all changes carried out since the last save Current profile button... -
Page 50: Creating Current/Force Profile
Creating current/ Create force profile or current profile: force profile Opening program editor Select button I for current profile or button F for force profile Click on the first spot within the surface diagram and drag to the required position Release the mouse button to fix the point of the first spot Click again to create a new spot and drag to the required position Important! The diagram incorporates an object grid (values 0.1 kN or 0.1 kA) which... -
Page 51: Program Presettings
Program preset- The programme presetting view is for defining mechanical parameters during the wel- tings ding operation. It is also possible to enter a program name and additional comments. Fig.29 Program presettings Program name to define a program name Enable compensation drive to switch the power source on and off. -
Page 52: Signal Description
Signal description General remarks Signals can be transferred via field bus. Description of start_homing * signal inputs Move to reference point start_welding * Start welding process enable_welding_current * Welding current active (high) / welding current off (low) - trial run prog_nummer * Program number from 0 - 255 (spots with different parameter settings) reset_errors... -
Page 53: Description Of Signal Outputs
Description of ready * signal outputs HIGH Commands can be revoked LOW Command is carried out target_position The target position is specified via a higher-level control (robot) warning Warning e.g. process tape running out error Fault referenced Reference point confirmed remote control connected A remote control is connected to the welding gun external_position_control_active (external position specification) -
Page 54: Data In Process Image, Outputs
Data in process Input image, outputs Welding gun Remarks Field Activity ready High Errors High Warning High referenced High remote_control_connected High external_position_control_active High Current position 0 - XX A16 - A23 - High byte A24 - A31 - Low byte... -
Page 55: Signal Waveform
Signal waveform Move to reference point E00 start_homing A03 referenced A00 Ready A01 Error Start welding with external position specification E01 start_welding E15 external_ position_control E 16 - 31 Program number / E32 - E47 Spot number external _position_control_ active A00 Ready Welding process Process tape forward movement... -
Page 56: External Position Check
External position check E15 external_ position_control external_ position_control_active E48 - E63 Target position A16 - A31 Current position Reset error E02 reset_errors A01 Error A00 Ready... -
Page 57: Replace Wearing Parts
Replace wearing parts General remarks WARNING! Operating the equipment incorrectly can cause serious injury and damage. All connections must be carried out by trained and qualified person- nel in compliance with the relevant safety regulations. Note the safety rules in the operating instructions. -
Page 58: Loading New Process Tape
Loading new CAUTION! Risk of injury from springiness of spooled process tape. To avoid process tape injuries caused by the welding wire springing back, hold the end of the wire firmly when feeding it. CAUTION! Danger of injury from sharp edged process tape . Wear safety gauntlets when working with process tape... - Page 59 Loading new CAUTION! Danger of serious damage to property caused by process tape process tape slipping out due to holders and process tape spooling equipment being (continued) incorrectly closed. Before commissioning, make sure that all parts are correct- ly closed and intact. Never use welding gun with defective closures. "click"...
-
Page 60: Adjusting Process Tape Brake
Adjusting pro- cess tape brake Replacing elec- Move robot into the replace position trodes Turn off cooling water supply CAUTION! Danger of burns from hot coolant. Before changing the electrodes, turn off the coolant supply. - Page 61 Replacing elec- trodes (continued) Important! If a large sheet thickness has been set, insert sheet when pushing in the new electrode in order to guarantee that the electrode is held securely.
-
Page 62: Adjusting Holder Arms
Adjusting holder Important! After changing an electrode, check that the electrodes are flush with one arms another. If necessary, adjust the holder arm. Important! Loosen hex socket head screws (figure 1). Do not remove otherwise you will not be able to carry out the adjustment. -
Page 63: Troubleshooting
Troubleshooting General remarks WARNING! An electric shock can be fatal. Before opening the machine Switch the mains switch to „O“ Disconnect the machine from the mains Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again Using a suitable measuring instrument, check to make sure that electri- cally charged components (e.g. -
Page 64: Description Of Error Signals
Description of error 0.XX error signals 0.00 = internal communication Cause: Internal communication error Remedy: Check interface connections 0.01 = main drive Cause: Main motor is not ready Remedy: Reset error, contact service team if necessary 0.02 = spot number Cause: The specified spot number is not included in any programme Remedy:... - Page 65 Description of 0.15 = emergency stop error signals Cause: Emergency Stop has been actuated (continued) Remedy: Disengage Emergency Stop after rectifying the fault 0.16 = main drive position target not reached Cause: The welding gun cannot move the specified electrode distance Remedy: Contact service team 0.17 = invalid dms value...
-
Page 66: Description Of Warning Signals
Description of 0.29 = main drive force target not reached error signals Cause: Specified holder force not achieved (continued) Remedy: Contact service team 0.30 = force sensor not calibrated Cause: The force sensor has not yet been calibrated Remedy: Calibrate force sensor 0.31 = diode protection Cause: Invalid welding parameters... -
Page 67: Care, Maintenance And Disposal
Care, maintenance and disposal Under normal operating conditions the welding gun requires only a minimum of care and General remarks maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years. WARNING! Automatically starting machines can cause serious injury and damage. -
Page 68: Technical Data
Technical Data For machines designed for special voltages, the technical data on the rating plate ap- Special voltages plies. TR-Unit Mains voltage 500 V Frequency 1000 Hz Transformation ratio Idling DC voltage U 11.8 V Continuous direct current I 3780 A Primary current I 86 A Continuous direct current P... -
Page 69: Deltaspot Welding Gun
DeltaSpot wel- Nominal output at 50% dc (medium ferquency) 77. kVA ding gun Welding gun supply voltage 230 V (16 A) Holder force 5 kN Cooling water quantity / holder arm < 4.0 l/min < 1.06 gal/min Cooling water temperature max 30°... - Page 71 Ersatzteilliste Spare Parts List Liste de pièces de rechange Lista parti di ricambio Lista de repuestos Lista de peças sobresselentes Onderdelenlijst Reservdelsliste Seznam náhradních dílů Ñïèñîê çàïàñíûõ ÷àñòåé ud_fr_st_tb_00150 012002...
- Page 72 DeltaSpot Grundkörper 4,300,001 DeltaSpot Zangenkörper X500 44,3000,0001 43,0004,2815 43,0001,1226 S006_41,0018,0051 44,3000,0014 S025_41,0018,0050 43,0001,1252 43,0001,1253 32,0405,0159 43,0003,0900 44,3000,0015 44,3000,0022 43,0001,1251 42,0405,0568 44,3000,0016 43,0001,1267 44,3000,0018 42,0001,3706 44,3000,0030 44,3000,0002 42,0100,0508 44,3000,0031 42,0405,0568 Tab. 1 42,0001,3629 44,3000,0023 Tab. 1 Elektrode R40 42,0001,3656 Elektrode R70...
- Page 73 DeltaControl 4,300,002 43,0004,2927 41,0018,0009 41,0018,0020 43,0001,1277 41,0018,0019 41,0018,0022 41,0018,0010 43,0001,1264 43,0008,0156 43,0008,0157 43,0002,0320 43,0003,0945 43,0002,0305 41,0007,0176 41,0007,0160 43,0004,2923 41,0007,0160 41,0007,0160 41,0007,0166 41,0007,0219 43,0004,2951 41,0018,0049 - IPC C5102-1007 43,0004,2798 40,0003,0284 40,0003,0421 42,0407,0091 42,0407,0091 43,0003,0254 43,0003,0254 43,0003,0584 43,0003,0250 43,0004,2797 Delta Spot Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_pu_01332 022007...
- Page 74 4,047,481 Verb. Schlauchpaket 10m 4,047,473 Verb. Schlauchpaket 20m Tab. 2 Tab. 2 40,0001,0478 43,0003,0378 43,0003,0392 43,0003,0382 43,0003,0564 43,0003,0390 42,0407,0052 43,0003,0940 Tab. 2 43,0003,00392 43,0003,0378 43,0003,0941 40,0003,0423 43,0003,0943 42,0407,0612 42,0407,0052 42,0001,3712 40,0003,0422 43,0003,0382 42,0407,0612 43,0003,0943 42,0001,3712 40,0001,0477 43,0003,0941 43,0003,0392 43,0003,0940 40,0001,0476 40,0003,0420 42,0407,0613 43,0003,0902...
- Page 75 FRONIUS INTERNATIONAL GMBH Buxbaumstraße 2, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations. ud_fr_st_so_00082 012008...
Need help?
Do you have a question about the DeltaSpot and is the answer not in the manual?
Questions and answers