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Summary of Contents for Fronius DeltaSpot
- Page 1 / Battery Charging Systems / Welding Technology / Solar Electronics Operating Instructions DeltaSpot Spare parts list Resistance welding 42,0426,0050,EN 001-02042012...
- 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.
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Page 5: Table Of Contents
Contents Safety rules ..............................Explanation of safety symbols ......................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.................. - Page 6 Maintenance to be carried out daily or each time the tape is changed..........Weekly maintenance or after every 50000 spots.................. Weekly maintenance or after every 200000 spots................After 250,000 spot welds ........................Disposal ..............................Technical data............................Special voltages............................ TR unit ..............................DeltaSpot spot welding gun ........................Appendix Spare parts list: DeltaSpot .........................
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Page 7: Safety Rules
Safety rules Explanation of DANGER! indicates immediate and real danger. If it is not avoided, death or se- safety symbols rious injury will result. WARNING! indicates a potentially dangerous situation. Death or serious injury may result if appropriate precautions are not taken. CAUTION! indicates a situation where damage or injury could occur. -
Page 8: Proper Use
Proper use The device is to be used exclusively for its intended purpose. The device is intended for the welding process described on the rating plate only. Any use above and beyond this purpose is deemed improper. The manufac- turer shall not be liable for any damage resulting from such improper use. Utilisation in accordance with proper use also comprises carefully reading and following all the instructions given in the operating instructions... -
Page 9: Obligations Of Personnel
Obligations of Before using the device, all persons instructed to do so undertake: personnel to observe the basic instructions regarding safety at work and accident prevention to read these operating instructions, especially the "Safety rules" section and sign to confirm that they have understood them and will follow them. Before leaving the work area, ensure that people or property cannot come to any harm in your absence. -
Page 10: Danger From Flying Sparks
If there is any doubt about whether the extraction system is powerful enough, then the measured toxic emission values should be compared with the permis- sible limit values. The following components are responsible, amongst other things, for the de- gree of toxicity of welding fumes: Metals used for the workpiece Coating of the process tapes Coatings of the materials... -
Page 11: Meandering Welding Flows
Arrange for the mains and device supply to be checked regularly by a qualified electrician to ensure the PE conductor is functioning properly. The device must only be operated on a mains supply with a PE conductor and a socket with an earth contact. If the device is operated on a mains without a PE conductor and in a socket without an earth contact, this will be deemed gross negligence. -
Page 12: Specific Hazards
Supporting measures for avoidance of EMC problems: mains supply if electromagnetic interference arises despite correct mains connec- tion, additional measures are necessary (e.g. use of a suitable line filter). welding leads must be kept as short as possible must run close together (to avoid EMF problems) must be kept well apart from other leads Equipotential bonding Earthing the workpiece... -
Page 13: Safety Measures At The Installation Location And During Transport
Danger of crushing Do not place hands or other body parts between the welding electrodes. Risk of cutting! Wear safety gloves when handling sharp objects. Covers and side panels may only be opened/removed while maintenance or repair work is being carried out. During operation: ensure that all covers are closed and all side panels are fitted properly. -
Page 14: Safety Measures In Normal Operation
Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out. Only set up and operate the device in accordance with the degree of protec- tion shown on the rating plate. When setting up the device, ensure there is an all-round clearance of 0.5 m (1.6 ft.) so that cooling air can flow in and out unhindered. -
Page 15: Safety Inspections
Safety inspec- The manufacturer recommends that a safety inspection of the device is per- tions formed at least once every 12 months. 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. -
Page 17: General Information
General information... -
Page 19: General
Application areas The DeltaSpot spot welding process is designed for joining two or more sheets of standard coated or uncoated steels and all standard aluminium alloys. It is also ideal for welding dif- ferent combinations and thicknesses of materials (Boron steel, CrNi, etc.). -
Page 20: Information For Dimensioning The Welding System
Information for di- CAUTION! Overloading the welding system may result in damage to property. mensioning the Check the inverter and the transformer are configured correctly for the respective welding system application. To prevent components from being overloaded, it is necessary to define the load capacity of the inverter and the transformer in relation to each job. -
Page 21: 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 Fronius Xplorer Cooling network Cooling unit Welding gun Primary-... -
Page 23: Control Elements And Connections
Control elements and connections... -
Page 25: Deltacontrol
DeltaControl General 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. Certain illustrations may also differ slightly from the actual control elements on your device, but these control elements function in exactly the same way. - Page 26 DeltaSpot spot welding gun main plug connector for the control line External Emergency Stop (see EMERGENCY STOP connection diagram) for connecting to the robot Pin configuration: + 24 V output for Emergency Stop + 24 V input EMERGENCY STOP relay (via X5 Pin A, B)
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Page 27: Emergency Stop Connection Diagram
Reserve socket X8-X 11 reserve CAN1 communication interface to the PC CAN2 communication interface to the DeltaSpot spot welding gun DeltaControl 24V supply fuse 3.15 A T DeltaSpot spot welding gun 24V supply fuse 1 A T Bus coupler 24V supply fuse... - Page 28 X2 / NOT-AUS Extern +24 V +24 V extern extern - K1 - K2 - K2 - K1 - K2 x5 / START Extern +24 V START SIGNAL X3 / Anschluss Durchfluss-Überwachung +24 V FLOW Controller...
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Page 29: Welding Transformer And Spot Welding Gun
Welding transformer and spot welding gun Welding trans- Function former connec- tions Transformer measuring signal connection for connection of welding control Coolant flow connection Coolant return connection Transformer primary connection for transformer power supply Ground strap Connection (-) pin Welding transformer connections Welding gun Function cooling water... -
Page 30: Mechanical Components
Mechanical components X-gun mechanical components (14)(13) (12)(11) (10)(9) (4)(5) Mechanical components Lock for process tape holder Process tape holder to hold unused process tapes Process tape securing device prevents process tape from unrolling by itself Process tape brake Process tape spooling device with drive to hold used process tape Electrode shaft Spring... - Page 31 (13) Sheet thickness correction for adjusting to different sheet thicknesses (14) Console with transformer and control box (16) (15) Welding gun adjustment (15) Welding gun adjustment to compensate for component tolerances or positional differences (16) Welding gun adjustment drive...
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Page 32: C-Gun Mechanical Components
C-gun mechani- cal components (2) (3)(4) (5) (6) (8) (9) (10) Mechanical components Console with transformer and control box Flow watchdog Water distribution block Process tape holder for holding the process tape Main drive Process tape spooling device with drive to hold used process tape Sheet thickness correction for adjusting to different sheet thicknesses... - Page 33 (12) (11) Welding gun adjustment (11) Welding gun adjustment to compensate for component tolerances or positional differences (12) Welding gun adjustment drive...
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Page 34: Remote Control
Remote control DeltaRemote re- WARNING! Machines that start up automatically can cause serious injury and mote control 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 re- main in place for the duration of your stay within the working area of the robot. - Page 35 Process tape forward or backward switch (fixed gun arm) for manual feed of process tape Process tape forward or backward switch (moving gun arm) for manual feed of process tape Welding current button No Welding: Press RUN key (32) to simulate a welding program without current but with a predefined force profile Welding: Press RUN (32) key to run a welding program with predefined parame- ters...
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Page 37: Start-Up
Start-up... -
Page 39: 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 re- main in place for the duration of your stay within the working area of the robot. -
Page 40: Transformer Pe Conductor Connection
Note the information provided by the manufacturer of the cooling system. Transformer PE Fronius medium-frequency transformers conform to 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 pri- mary and secondary power circuits. - Page 41 Check compensating currents (shunt currents) Compensating currents ("shunt currents" according to EN 62135-1 ) are currents that flow parallel to the standard "Electrode - Workpiece - Electrode" current flow during welding. They can occur if the workpiece has any form of earth connection. DANGER! Compensating currents can render the "direct PE conductor connec- tion"...
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Page 42: Start-Up
IMPORTANT! If the grid is subject to severe voltage fluctuations, the use of an uninterrupt- ible power supply (UPS) is recommended for the industrial PC. Connect the control line (7) to the main plug connector of the DeltaSpot spot welding gun (X1) Connect the analogue signal cable from the power source (3) to the analogue power source connector (X6) (connection for power source: see "Connecting Bosch PSI... -
Page 43: Connecting The Spot Welding Gun
Connecting the Establish a CAN connection between spot welding gun the PC and the CAN connector (1) Plug DeltaSpot welding gun (2) main connector into connection X1.1 Flow controller connection, upper, lower gun arm and welding transformer Connecting the spot welding gun Connecting the NOTE! Inadequate cooling can cause damage to property. - Page 44 PS5 EA Disk 1 Wiring diagram for Bosch PSI 6xxx.000 power source (inverter) Supplying I/O module with internal 24 V: switching off the mains voltage at the mains in- put of the power module also switches off the I/O module. In this situation, no communica- tion between the power source and the controller is possible.
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Page 45: Loading The Process Tape For The X-Gun
Loading the proc- Place the robot in the change position (tip sideways so that the process tape cannot ess tape for the X- fall out during operation) -
Page 46: Loading The Process Tape For The C-Gun - Upper Holder
"click" "click" Loading the proc- Place the robot in the change position (tip sideways so that the process tape cannot ess tape for the C- fall out during operation) gun - upper hold-... -
Page 48: Loading The Process Tape For The C-Gun - Lower Holder
Loading the proc- Place the robot in the change position (tip sideways so that the process tape cannot ess tape for the C- fall out during operation) gun - lower holder... -
Page 49: Move To Reference Point
Move to reference WARNING! Machines that start up automatically can cause serious injury and point 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 re- main in place for the duration of your stay within the working area of the robot. -
Page 50: Sheet Thickness Correction
Detail showing welding gun drive in the X-gun opera- ting range Adjusting sheet Start the "Sheet thickness compensation" function in Fronius Xplorer (worksheet: thickness correc- "Overview" - option menu "Calibration - sheet thickness compensation") tion... - Page 51 X-gun: Open sheet thickness correction completely C-gun: Open sheet thickness correction completely Click on "Start" button (1)
- Page 52 Press "Start Welding" on the DeltaRemote remote control The spot welding gun closes until the electrodes are at a predefined distance Hold the workpiece to be welded between the electrodes X-gun: Adjust the sheet thickness correction until both elec- trodes are in contact with the workpiece...
- Page 53 Carry out a weld test (without current) and check the operating point If the actual operating point (3) is outside the defined operating range, Fronius Xplorer (4) will issue a warning signal. The warning is listed in the status worksheet:...
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Page 55: Spot Welding
Spot welding... -
Page 57: 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 58 C-gun: Welding gun adjustment deactivated If welding gun adjustment is deactivated, the gun arm is fixed when you switch on the sys- tem. During the welding process, the electrode force is applied via the other gun arm, while the fixed gun arm functions solely as a support. X-gun: C-gun:...
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Page 59: Effect Of The Process Tape On The Welding Process
The lower welding current and the type of alloy used in the process tape provide controlled heat input and control over the position and shape of the weld nugget. ° C (°F) Resistances during DeltaSpot spot welding Material resistances of the electrodes Contact resistances between electrode and process tape... -
Page 61: Troubleshooting And Maintenance
Troubleshooting and maintenance... -
Page 63: Replace Wearing Parts
Replace wearing parts General WARNING! Work that is carried out incorrectly can cause serious injury or dam- age. All work must be carried out by trained and qualified personnel in compliance with the relevant safety regulations. Note the safety rules in the operating instruc- tions. - Page 64 Place the robot in the change position (tip sideways so that the process tape cannot fall out during operation) After it has been stuck together, feed in the tape until the adhesion point is reeled onto the tape reeling de- vice.
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Page 65: Reloading Process Tape C-Gun
"click" "click" Reloading proc- CAUTION! Risk of injury from springiness of spooled process tape. To avoid in- ess tape C-gun juries caused by the process tape springing back, hold the end of the tape firmly when fitting it. CAUTION! Danger of injury from sharp-edged process tape. Wear safety gloves when working with process tape. - Page 66 After it has been stuck together, feed in the tape until the adhesion point is reeled onto the tape reeling de- vice. 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.
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Page 67: Adjusting The Process Tape Brake
"click" Adjusting the IMPORTANT! The process tape must fit snugly but not be under tension. A tensioned process tape process tape can lead to problems with the drive motor. If the process tape is too loose, it brake may slip out of the guide or remain stuck to a component. (1) Process tape brake correctly set (2) Process tape brake under too much tension (3) Process tape brake too loose... -
Page 68: Replacing Electrodes
IMPORTANT! If the spring is noticeably compressed when feeding the process tape, then the process tape brake is too tight. Procedure for process tape brakes that are too loose: Turn the screw anti-clockwise half a turn (+ direction) Manually feed in a short section of process tape Check that the process tape brake is correctly set. -
Page 69: Calibrating Holder Arms
IMPORTANT! If a large sheet thickness has been set, insert the sheet when pushing in the new electrode to ensure that the electrode is held securely. Calibrating holder IMPORTANT! After changing an electrode, check that the electrodes are aligned with each arms another. -
Page 70: Calibrating The C-Gun Arm
Calibrating the C- IMPORTANT! After changing an electrode, check that the electrodes are aligned with each gun arm another. If necessary, calibrate the gun arm. IMPORTANT! Only loosen the hexagon bolts (step 1), do not remove them. You will not be able to adjust the arm if the bolts are removed. - Page 71 11 Nm! 24 Nm!
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Page 72: Troubleshooting
Troubleshooting General 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 73: Care, Maintenance And Disposal
Check that the tape spooling device lock is firmly seated When welding with "adhesive", clean the tape feed mechanism with a detergent rec- ommended by the adhesive manufacturer General visual inspection of the DeltaSpot welding gun for damage and leaks Weekly mainte- Check cooling pipe setting... -
Page 74: Disposal
Disposal Dispose of in accordance with the applicable national and local regulations. -
Page 75: Technical Data
1 x 140 °C 1 x 150 °C Temperature monitor NC (rectifier) 1 x 80 °C 1 x 80 °C Insulation class Weight 29 kg 20 kg DeltaSpot spot Spot welding gun C300 X350 X500 X750 welding gun Gun force 6 kN... - Page 76 Component Weight Installation kit 250 kVA C-Gun (4,100,694) 26.8 kg / 59.1 lb. Installation kit 130 kVA X-Gun (4,100,555) 22.4 kg / 49.4 lb. Installation kit 130 kVA C-Gun (4,100,593) 25.3 kg / 55.8 lb. 130 kVA MF transformer (42,0411,0032) 20.0 kg / 44.1 lb.
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Page 77: Appendix
Appendix... -
Page 78: Spare Parts List: Deltaspot
Spare parts list: DeltaSpot 4,300,001 DeltaSpot Grundkörper 4,100,555 - 130kVA 42,0201,3455 4,100,693 - 250kVA 43,0004,4288 - 550mm 43,0004,2815 - 480mm 42,0201,2736 - 130kVA 42,0201,3456 - 250kVA 4,100,593 - 130kVA 42,0201,2737 4,100,694 - 250kVA 43,0003,0014 42,0201,3462 43,0003,0383 43,0004,2815 43,0003,0379 43,0003,0939 Ø0,14 - 0,37... - Page 79 DeltaSpot Zangenkörper X350 44,3000,0050 DeltaSpot Zangenkörper X500 44,3000,0001 43,0001,1250 DeltaSpot Zangenkörper X750 44,3000,0032 42,0001,3617 44,3000,0022,Z Bei Sonderausführungen siehe Beiblatt In the case of special versions see insert En cas des constructions spéciales voir notice 42,0402,0233 In caso di versioni speciali vedere allegato...
- Page 80 DeltaSpot Zangenkörper C300 44,3000,0046 Bei Sonderausführungen siehe Beiblatt DeltaSpot Zangekörper C70 44,3000,0059 In the case of special versions see insert En cas des constructions spéciales voir notice In caso di versioni speciali vedere allegato En caso de modelos especiales ver la hoja adjunta Em caso de versões especiais vide a folha anexa...
- Page 81 DeltaSpot Hauptantrieb SB50 44,3000,0014,Z DeltaSpot Hauptantrieb PKS1 44,3000,0138,Z 42,0402,0233 44,3000,0124 43,0001,1233 BE2,0201,2556 43,0001,1251 SB50 44,3000,0056,Z 42,0403,0139 43,0001,1253 42,0201,2026 43,0011,0054 42,0402,0233 44,3000,0139 43,0004,4483 BE2,0201,2556 43,0001,1251 PKS1 44,3000,0056,Z 42,0403,0139 43,0001,1253 42,0201,2026 43,0011,0054...
- Page 82 42,0401,0874 1/4"A-1/4"A 42,0001,3739 1/2"-M22x1,5I-90° 42,0001,3676 1/4"A-1/8"A 42,0001,3658 1/4"l - 90° 42,0001,3713 1/2"A-M22x1,5A 42,0201,2879 1/4"A-1/4"A - 90° 42,0401,1080 1/4"l-1/4"A 1/4"l-1/2"A 42,0401,1036 42,0001,3652 1/4"l 42,0300,2787 1/2"A 42,0001,3712 1/2"-M22x1,5I 42,0407,0273 -10,0 40,0001,0479 * øl=6,3;tw=2,2 X350 X500 X750 44,3000,0026 44,0300,0062 44,3000,0066 - C300 44,3000,0054 44,3000,0021 44,3000,0065 44,3000,0025...
- Page 83 DeltaControl 4,300,002 DeltaControl 110V 4,300,004 43,0004,2927 41,0018,0009 - CAN 43,0001,1277 41,0018,0020 - KL 1408 - KL 1408 41,0018,0020 41,0018,0019 - KL 2408 41,0018,0022 - KL 4001 43,0001,1264 41,0018,0062 - KL 3061 41,0018,0010 - KL 9010 43,0008,0156 43,0002,0320 43,0008,0157 43,0002,0305 43,0003,0945 43,0003,0383 43,0003,0379 43,0003,0400...
- Page 84 FRONIUS INTERNATIONAL GMBH Froniusplatz 1, 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...
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