Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Troubleshooting
Subscribe to Our Youtube Channel
Related Manuals for Fronius DeltaSpot Series
Summary of Contents for Fronius DeltaSpot Series
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions DeltaSpot Spare parts list Stationary welding system Resistance welding 42,0426,0242,EN 012-09052019 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
- Page 3 Thank you for the trust you have placed in our company and congratulations on buying this high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer.
-
Page 5: Table Of Contents
Contents Safety rules ..............................General ..............................Proper use ............................Environmental conditions........................Obligations of the operator........................Obligations of personnel ........................Protecting yourself and others ......................Danger from toxic gases and vapours ....................Danger from flying sparks ........................Risks from mains current and welding current..................EMC measures ............................. - Page 6 Threading the process tape ........................Moving to the home position ......................... Spot welding DeltaSpot resistance spot welding......................General ..............................Process tape consumption........................Adjusting the height of the movable arm....................Effect of the process tape on the welding process ................Troubleshooting and maintenance Replacing wearing parts and consumables ....................
-
Page 7: Safety Rules
Safety rules General The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: injury or death to the operator or a third party, damage to the device and other material assets belonging to the operating company, inefficient operation of the device. -
Page 8: Obligations Of The Operator
The surrounding air must be free from dust, acids, corrosive gases or substances, etc. Can be used at altitudes up to 1000 m (3280 ft.) This welding unit is not intended for use in living areas in which the power supply is provid- ed via a public low-voltage system. -
Page 9: Danger From Flying Sparks
Fumes and hazardous gases must not be breathed in, must be extracted from the working area using appropriate methods. Ensure an adequate supply of fresh air. Otherwise, a protective mask with an air supply must be worn. If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values. -
Page 10: Emc Measures
If the device is operated on a mains supply without a ground conductor and using a socket without a ground conductor contact, this will be deemed gross negligence. The manufac- turer shall not be held liable for any damage arising from such usage. If necessary, provide an adequate earth connection for the workpiece. -
Page 11: Specific Hazards
Specific hazards If untrained operating personnel have access to the device, measures must be implement- ed to ensure that the entire system is switched off for the duration of the work in this area and that it is prevented from starting up again accidentally as the result, for example, of a control fault. -
Page 12: Safety Measures In Normal Operation
Special regulations apply in rooms at risk of fire or explosion. Observe relevant national and international regulations. Use internal work instructions and checks to ensure that the workplace environment is al- ways clean and clearly laid out. Only set up and operate the device in accordance with the degree of protection shown on the rating plate. -
Page 13: Disposal
A safety inspection should be carried out by a qualified electrician After any changes are made After any additional parts are installed, or after any conversions After repair, care and maintenance has been carried out At least every twelve months For safety inspections, follow the appropriate national and international standards and di- rectives. -
Page 15: General Information
General information... -
Page 17: General
General Principle The DeltaSpot resistance spot welding system is a revolution in spot welding technology. It uses continuous process tapes that enable you to join steel, galvanised sheets and alu- minium, as well as dissimilar materials such as steel and aluminium. The process tapes protect the electrodes and prevent spattering. - Page 18 100 % = 10 % 60 s IMPORTANT! The transformer user documentation will be supplied with your system or can be requested from Fronius Technical Support. Calculating the maximum permitted welding currents for diodes (I_max_Diodes) and transformer (I_max_Transf):...
-
Page 19: Warning Notices On The Device
400 ms 2000 ms IMPORTANT! The inverter user documentation will be supplied with your system or can be requested from Fronius Technical Support. Calculating the maximum permitted welding current in the inverter load diagram Find the inverter load diagram Draw a vertical line on the diagram for the calculated inverter duty cycle... - Page 21 Do not use the functions described here until you have fully read and under- stood the following documents: these operating instructions all the operating instructions for the system components, especially the safety rules Welding is dangerous. The following basic requirements must be met to en- sure the equipment is used properly: Anyone performing automated welding must be sufficiently qualified Suitable protective equipment must be used...
- Page 22 Lifting point for transport The welding system can be transported by a forklift truck at the two points in- dicated by this symbol. Important! There are four suspension points on the switch cabinet for trans- port by crane. These may only be used for the switch cabinet – not when the stationary welding system and the switch cabinet are joined together.
-
Page 23: Assembly And Installation Of The Stationary Welding System
Assembly and in- stallation of the WARNING! stationary weld- ing system Falling objects can cause serious injury and damage: ► The unit must be assembled and instal- led vertically. ► The mounting surface must be able to safely withstand dead weights and per- mitted loads. -
Page 24: System Components
H-bridge circuit transfers the DC voltage to the welding transformer at a frequen- cy of 1 kHz. The welding current is rectified in the welding transformer. System compo- nents overview coolant supply CAN and control cable Fronius Xplorer spot welding gun welding system cooling GunControl network... -
Page 25: Control Elements And Connections
Control elements and connections... -
Page 27: Guncontrol
GunControl General NOTE! Due to firmware or software updates, you may find that your device has certain func- tions that are not described in these operating instructions or vice versa. Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way. -
Page 28: Guncontrol 110/230 Connection Sockets
GunControl 110/ 230 connection CAN GUN CAN IPC Key ext. sockets DeltaSpot spot welding gun main plug connection socket for connecting the control line External Emergency Stop (see EMERGENCY STOP connection diagram) for connecting to the robot Pin assignment: + 24 V + 24 V EXTERNAL IN GND EXTERNAL IN EMERGENCY STOP_A1... - Page 29 Reset error Power source OK Current actual value signal GND current actual value Status "1" Status "2" Status "4" Status "8" Status "16" External welding start for starting the welding process externally without Hold to Run function Pin assignment: SAFETY CIRCUIT_B1 SAFETY CIRCUIT_B2 + 24 V output for initiating welding start-up 24 V feedback signal for welding start-up initiation...
- Page 30 Communication interface to the DeltaSpot spot welding gun Communication interface to the industrial PC Plug for optional external keylock switch ext. Power supply fuse 10 A T 48 V fuse 8 A F GunControl & bus coupler 24V supply fuse 3.15 A T DeltaSpot spot welding gun 24V supply fuse 1 A T...
-
Page 31: Welding Transformer And Spot Welding Gun
Welding transformer and spot welding gun Welding trans- former connec- tions Welding transformer connections Function Transformer primary connection for transformer power supply Transformer measuring signal connection for connection of welding control Coolant flow connection Coolant return connection... -
Page 32: Mechanical Components
Mechanical components Mechanical com- ponents Control box Main drive Tape spool device for holding used and unused process tape Controls on the welding system Hydraulic height adjustment of movable arm Electrode shaft Height adjustment of fixed arm Cooling water connection with flow watchdogs... -
Page 33: Remote Control
Remote control RemoteControl WARNING! Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturer of the robot and welding systems 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 34 Start homing button for defining the home position for the main drive and compensation drive (X-gun and C-gun) before start-up Reset button for resetting a fault that has occurred Error LED lights up in the following situations: during commissioning if the home position has not yet been defined if faults arise during an ongoing operation Homing position LED lights up as soon as the homing position is defined...
-
Page 35: Start-Up
Start-up... -
Page 37: Before Commissioning
Before commissioning General WARNING! Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturer of the robot and welding systems 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 38: Mains Connection
Mains connection The devices are designed for the mains voltage specified on the rating plate. The fuse pro- tection required for the mains lead can be found in the "Technical data" section. If there is no mains cable or mains plug on your device, fit one that conforms to national standards. NOTE! An inadequately dimensioned electrical installation can cause serious damage. -
Page 39: Transformer Pe Conductor Connection
IMPORTANT! We recommend fitting water-cooled components with flow controllers. The switching point of a flow controller on a gun arm is approx. 4.0 l/min (1.0 gal./min). The switching point of a flow controller on the transformer can be found in the transformer data sheet. - Page 40 DANGER! Inadmissibly high contact voltages are possible. A non-functioning MPE bridge renders the "direct PE conductor connection" safety meas- ure ineffective. A failure of insulation (primary/secondary circuit) can therefore be life- threatening. Do not start a system with "direct PE conductor connection" if the check revealed any prob- lems.
-
Page 41: Start-Up
Start-up General WARNING! An electric shock can be fatal. If the machine is connected to the mains electricity supply during installation, there is a high risk of very serious injury and damage. Disconnect from the power supply before carrying out any work on the device. WARNING! Work that is carried out incorrectly can cause serious injury and damage. -
Page 42: Threading The Process Tape
Threading the Threading the process tape at the top process tape... - Page 43 Threading the process tape at the bottom...
-
Page 44: Moving To The Home Position
Moving to the WARNING! home position Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturer of the robot and welding systems 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 45: Spot Welding
Spot welding... -
Page 47: Deltaspot Resistance Spot Welding
DeltaSpot resistance spot welding General 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 con- trol of the heat input, improvement of efficiency and the ability to bond very different mate- rials. -
Page 48: Effect Of The Process Tape On The Welding Process
Adjusting the movable arm upwards Each lift of the hydraulic height adjustment moves the movable arm up around 1 mm. Effect of the pro- The use of process tape results in additional resistances being generated between the cess tape on the electrodes and the workpiece. - Page 49 ° C (°F) Resistances with DeltaSpot spot welding: Material resistances of the electrode Contact resistances between electrode and process tape Material resistances of process tape Contact resistances between process tape and workpiece Material resistances of the workpiece Contact resistance from workpiece to workpiece Weld nugget formation with multi-sheet joints Weld nugget formation when using different materials, material thicknesses and the same process tapes.
-
Page 51: Troubleshooting And Maintenance
Troubleshooting and maintenance... -
Page 53: Replacing Wearing Parts And Consumables
Replacing wearing parts and consumables General WARNING! Work that is carried out incorrectly can cause serious injury or damage. All work must be carried out by trained and qualified personnel in compliance with the rel- evant safety regulations. Note the safety rules in the operating instructions. IMPORTANT! Check electrodes for wear and replace if necessary each time a new process tape is loaded. - Page 54 After it has been stuck together, feed in the tape until the adhesion point is reeled onto the tape reeling de- vice. * 3 sec CAUTION! Danger of serious material damage resulting from ejection of process tape due to incorrect closing of holders and process tape spooling device. Before commissioning, make sure that all parts are correctly closed and intact.
-
Page 55: Adjusting The Process Tape Brake
Adjusting the pro- IMPORTANT! cess tape brake The process tape must fit snugly but not be under tension. A process tape under too much tension can lead to problems with the drive motor. If the process tape is too slack, it may slip out of the guide or remain stuck to a component. (1) Process tape brake set properly Process tape brake slack - turn in (+) direction (2) Process tape brake too tight... -
Page 56: Replacing Electrodes
Procedure for process tape brakes that are too tight: Turn the screw clockwise by half a turn (- direction) Manually feed in a short section of process tape Check that the process tape brake is set correctly. If not, repeat steps 1 and 2 Replacing elec- Switch off the coolant supply trodes... -
Page 57: Adjusting The Gun Arms
IMPORTANT! If a large sheet thickness has been set on the sheet thickness compensation, insert the sheet when pushing in the new electrode to ensure that the electrode is held se- curely. Adjusting the gun IMPORTANT! arms After replacing an electrode, check that the electrodes are aligned with each other. If necessary, adjust the gun arm. - Page 58 Lower gun arm...
-
Page 59: Troubleshooting
Troubleshooting General remarks WARNING! An electric shock can be fatal. Before opening the device ► Turn the mains switch to the "O" position ► Unplug the machine from the mains ► Prevent it from being switched on again ► Using a suitable measuring instrument, check to make sure that electrically charged components (e.g. -
Page 60: Care, Maintenance And Disposal
Care, maintenance and disposal General Under normal operating conditions the spot welding gun requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the weld- ing system remains in a usable condition for many years. In terms of maintenance intervals, always select the earlier time. -
Page 61: After 250,000 Spot Welds
Flow control: If flow sensors are not used to check the individual circuits, external flow sensors are used to check the flow on the gun arms, transformer and power source If flow sensors are used to check the individual circuits, check the LED indicators of the flow sensors Check plug connections for corrosion After 250,000 spot... -
Page 62: Technical Data
Technical data Special voltages For devices designed for special voltages, the technical data on the rating plate applies. MF transformer Transformer 250 kVA MF trans- 130 kVA MF trans- former former Nominal output with a 20% duty cycle 250 kVA 130 kVA Mains voltage 500 V... -
Page 63: Appendix
Appendix... -
Page 64: Spare Parts List: Deltaspot G2
Spare parts list: DeltaSpot G2 GunControl 110V / 230V 4,300,011... - Page 65 Verbindung Schlauchpaket 5m - 35mm² 4,051,001 Verbindung Schlauchpaket 5m - 70mm² 4,051,002 Verbindung Schlauchpaket 10m - 35mm² 4,051,003 Verbindung Schlauchpaket 10m - 70mm² 4,051,004 Verbindung Schlauchpaket 20m - 35mm² 4,051,005 Verbindung Schlauchpaket 20m - 70mm² 4,051,006...
- Page 66 RemoteControl PRO 4,300,006...
- Page 67 (technische Dokumentation) (technical documents) (technique documentation) Ing. Josef Feichtinger Ing. Josef Feichtinger Ing. Josef Feichtinger Günter Fronius Straße 1 Günter Fronius Straße 1 Günter Fronius Straße 1 A - 4600 Wels-Thalheim A - 4600 Wels-Thalheim A - 4600 Wels-Thalheim 2016 ppa.
- Page 68 FRONIUS INTERNATIONAL GMBH Vorchdorfer Straße 40, A-4643 Pettenbach, Austria E-Mail: sales@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations...
Need help?
Do you have a question about the DeltaSpot Series and is the answer not in the manual?
Questions and answers