Fronius SpotWelding Operating Instructions Manual
  1. Manuals
  2. Brands
  3. Fronius Manuals
  4. Controller
  5. SpotWelding
  6. Operating instructions manual
Fronius SpotWelding Operating Instructions Manual

Fronius SpotWelding Operating Instructions Manual

Gun controller, resistance welding
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
/ Perfect Charging /
Perfect Welding
SpotWelding gun controller
42,0426,0111,EN 007-10102019
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Solar Energy
Operating Instructions
Resistance welding

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SpotWelding and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Fronius SpotWelding

Summary of Contents for Fronius SpotWelding

  • Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions SpotWelding gun controller Resistance welding 42,0426,0111,EN 007-10102019 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

  • Page 3: Table Of Contents

    Contents General Gun control/Fronius Xplorer ........................General ..............................Setting automatic time synchronisation ....................Changing the default input language ....................SpotWelding system configuration......................Spot welding system configuration - spot welding gun ................. Calculating the maximum welding current .................... Manual and automatic backup ......................
  • Page 4 CAN over EtherCAT........................... CAN over EtherCAT requirements......................Preparing a network interface ....................... Activating the CAN over EtherCAT option in the Configurator.............. Interfaces SpotWelding interface signal description ....................Description of signal inputs ........................Description of signal outputs......................... DeltaSpot 1.6 interface ..........................Inputs ..............................
  • Page 5 DeltaCon interface (7th axis) 1.0 ....................... Inputs ..............................Outputs ..............................Process data length ..........................SpotWelding interface signal waveform ..................... Moving to the home position ......................... External position check ......................... Welding start-up with external position specification ................100 Resetting errors ............................ 100 Deactivating actual value monitoring when welding without current.............

  • Page 7: General

    General...

  • Page 9: Gun Control/Fronius Xplorer

    You will find further details about Fronius Xplorer in the Fronius Xplorer Operating Instruc- tions. If the Fronius Xplorer does not support all the functions made available through the server, a note will be displayed to update the Fronius Xplorer:...

  • Page 10: Changing The Default Input Language

    The menu items displayed may vary depending on the spot welding gun. Name Give a name to the spot welding gun (to identify it in Fronius Xplorer) Location (company), (plant), (hall), (cell) Enter the name of the company and location of the spot welding gun. The names entered are copied to Fronius Xplorer as a path and displayed in the folder structure.
  • Page 11 Autobackup-Ringbuffer-Size The ring buffer size indicates how many backup files are stored in the entered location. Autobackup-Starttime A start time can be specified for the automatic backup. If a backup was not created upon start-up in the last interval, one is created immediately. If a backup is already available, the next one will be created at the specified time.

  • Page 12: Spot Welding System Configuration - Spot Welding Gun

    In addition to the emergency stop safety circuit, another safety circuit can be activated. This function must be supported by the hardware (SpotWelding Control). If the safety circuit is interrupted, all drives are stopped and error "E2.23" is output. This error is filtered out in the logbook.
  • Page 13 Transformer (max. current) Define the maximum available current of the built-in welding transformer. (see following section "Calculating the maximum welding current"). Transformer (transmission ratio) The input/output transmission ratio of the welding transformer (see following section "Cal- culating the maximum welding current"). Tape length (movable arm), (fixed arm) Define length of the process tape that is used.

  • Page 14: Calculating The Maximum Welding Current

    The manual backup is started via the "Tools  Backup" menu. The spot welding gun and data to be backed up can be selected in the dialog box. The settings for the automatic backup can be defined in the system configuration (see the section "SpotWelding system configuration").

  • Page 15: Worksheets

    Worksheets Overview work- Gun-relevant information about current settings is displayed in the worksheet overview sheet (Overview): serial number, gun number, article number, base type Interface Program number, spot number, part number, part item number Actual gun code, expected gun code Electrode distance in millimetres (the position must be calibrated for this to be displayed - see section "Setting position...
  • Page 16 Example: Overview worksheet for a DeltaSpot system Overview worksheet Indicates the length of the process tape remaining Indicates the number of welding spots that are still possible Reset counter button (Reset): Press the button to reset the counter. This is possible even when the spot weld- ing gun is switched off or undocked.

  • Page 17: Operator Worksheet

    Operator work- The Operator worksheet is only visible to users with certain rights. sheet On this tab, the spot welding gun can be controlled directly with Xplorer. Operator worksheet - Service Operator worksheet - Welding "Activate" button activates the function in Xplorer, does not work if a remote control is connected to the spot welding gun "Service"...

  • Page 18: Programs Worksheet

    "Error Reset" button resets a fault that has occurred. Compensation drive and main drive are moved back to the starting position. The next time welding is started, and before the spot welding gun is closed, the tape is automatically moved forward, provided current was flowing before the error occurred.

  • Page 19: Status Worksheet

    Copy program button (Copy) Select the required program and press the button to save to the clipboard. Shortcut: Ctrl + C Paste program button (Paste) Click to select the required position and press the button to paste a previously copied program. In a dialogue window, it can be specified whether the names and comments from the old program are to be retained.

  • Page 20: Logbook Worksheet

    Logbook work- The Logbook worksheet records all of the following events, together with the associated sheet user: Status changes (errors, warnings), including gun code, spot number and program number Program changes Configuration changes Stepper changes Electrode resets (gun code, gun arm, number of welds, number of welds still possible) Length of process tape resets (gun code, gun arm, length of process tape used, length of process tape not used) The display of the various changes can be filtered.

  • Page 21: Diagnostic Worksheet

    Program comparison when changing programs: Program comparison The program comparison (select "Program change" and click on "Detail") displays a graph of the old and new programs. Using the "Copy old" and "Copy new" buttons, you can copy the program to the clipboard and recover it by pasting into the Programs worksheet.

  • Page 22: Actual Values Worksheet (Optional)

    Diagnostic worksheet - Devices Actual values The worksheet presents a graphical depiction of the following data: worksheet (op- Actual current and force curves tional) Voltage, resistance and motor position curve (if present) A line indicating the target current and target force curves The following information is shown in the bar at the top of the graph: Device serial number, component item number, component serial number Spot number, program number, stepper correction value, program name...
  • Page 23 Actual values worksheet Zoom/resetting zoom Left click to select a zoom window Zoom out by double-clicking or clicking the "Zoom out" button Exporting a graph Click the "Export" button Select the export format in the window that opens: PNG ... Image (pixel graphic) XPS ...

  • Page 24: Spotwelding.configurator

    The installed hardware options and the fieldbus system that is used can be configured in the SpotWelding.Configurator. This tool can be found in the Start menu under "Programs" -> "Fronius Product Group" -> "SpotWelding.Configurator". It must be executed after every software update in order to check and enable the configuration.
  • Page 25 DeltaCon (Combined Control) SpotWelding Options The different input/output add-ons can be enabled or disabled here. The add- ons must first be installed in the SpotWelding Control. Stationary System The fieldbus settings are automatically disabled when this option is selected. Max. speed limit The DeltaCon X450 and DeltaCon C-guns are capped to a max.

  • Page 26: Deltaq, Harms & Wende Inverter

    DeltaQ, Harms & Wende inverter General The DeltaQ inverter from Fronius and the Sinius inverter type from Harms & Wende are supported by the control system. These inverters are connected via EtherCAT. Before using EtherCAT with DeltaSpot systems, a network card must be prepared accord-...

  • Page 27: Operation

    Operation...

  • Page 29: Settings In The System Configuration

    Settings in the system configuration General Only the parameters that are relevant for the particular system (DeltaSpot, DeltaCon, etc.) or for the particular gun are displayed in the system configuration. The display of system parameters for configured guns is adapted according to the gun in question, e.g.: for configured guns without compensation, all system parameters relating to compensation are hidden.

  • Page 30: Reversing The Byte Sequence On Fieldbus Interfaces

    System configuration - Enabling/disabling the actual values monitoring Setting the values for the actual values monitoring: On the Programs worksheet, double-click on the required program Set the tolerances on the "Actual values monitoring" tab Setting the values for the actual values monitoring Reversing the It is possible to reverse the byte sequence on fieldbus interfaces.

  • Page 31: Short-Term Storage Of Welding Operations

    "Docu state monitoring" parameter is set to "active". If there is a problem with the welding documentation, the warning 2.0 "docu state buffering" will be displayed in Fronius Xplorer. Welding operations are temporarily stored for a certain period of time to bridge any system failures.

  • Page 32: Two-Stage Welding Start

    Two-stage weld- A pedal remote control with two switching thresholds can be used with the DeltaCon sta- ing start tionary system. The gun is closed by the first switching threshold (= prestroke). The welding process is started by the second switching threshold. If necessary, incorrect component positioning can still be corrected by the two-stage weld- ing start.

  • Page 33: Calibrating The Spot Welding Gun Components

    Calibrating the spot welding gun components 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 the welding system, and the spot welding gun Operating Instructions, must also be observed.

  • Page 34: Calibrating The Position Limit

    Calibrating the Calibrating the position limit (included angle) of the spot welding gun position limit From the Options menu, choose  Calibration  Position limit Open the sheet thickness correction of the gun as far as possible Remove the electrodes Click "OK"...

  • Page 35: Calibrating The Force Controller

    Click "Start" Hold the sheet in the spot welding gun Press "Run" on the SpotWelding Control The spot welding gun performs the calibration. Test welding is carried out without a current at various P-factors. This process may take somewhat longer.
  • Page 36 System configuration - Enabling/disabling the position display in millimetres Calibrating the position: From the Options menu, choose  Calibration  Main drive position In the position calibration window, add several data points. Five points are usually suf- ficient. More points are only necessary if the inaccuracies are too great. Points that have already been added are marked red.

  • Page 37: Calibrating The Compensation Drive Position

    Calibrating the main drive position From the Options menu, choose  Calibration  Compensation drive position Calibrating the compensation Click "Start" drive position Enter the distance between the home position and electrode under "Position in milli- metres" Click "Save position" (gun automatically moves to next position) Measure and enter the distance between the home position and electrode Repeat steps 4 and 5 for the other positions Setting the compensation drive position calibration...

  • Page 38: Calibrating The Sheet Thickness Monitoring

    Calibrating the NOTE! sheet thickness monitoring This section only describes manual calibration. In a robot application, sheet thickness calibration must be carried out regularly via the robot control interface from either the robot control system or a higher-level control system. From the Options menu, choose ...

  • Page 39: Calibrating The Current

    Calibrating the Calibration to determine the power source correction and actual value conversion factor. current For power sources for which analogue target and actual values are transferred. This menu item is not displayed for digital power sources. Only relevant data for the particular gun are displayed under "Current calibration". From the Options menu, choose ...

  • Page 40: Calibrating The Harms & Wende Sinius Inverter

    NOTE! The "Position" compensation mode is automatically enabled when calibrating the current on a stationary system with welding gun adjustment. From the Options menu, choose  Calibration  Harms & Wende Sinius inverter Calibrating the Harms & Wende Follow the instructions in the dialogue window Sinius inverter NOTE! The "Position"...

  • Page 41: Measurement System Calibration

    From the Options menu, choose  Calibration  Position limit Measurement system calibra- tion Enter the target current Enter the target force If required enable the forward movement of the tape for the moveable and fixed arms. Click "Start" Carry out two welds with current Enter and apply the measured current (= actually flowing current) The calculated factors are displayed and automatically entered in the gun configuration fol- lowing confirmation.
  • Page 42 NOTE! The "Position" compensation mode is automatically enabled when calibrating the measurement system on a stationary system with welding gun adjustment.

  • Page 43: Assigning A Gun Code

    The control does not recognise the spot welding gun and outputs an error message: In Fronius Xplorer, a code must be assigned to the spot welding gun via the Options menu  "Assign gun code" Enter the number and click "Save" (the spot welding gun can be assigned a number between 0 and 7) The code is now assigned to the spot welding gun.
  • Page 44 Access the system configuration (Options menu  "System configuration") Set values and click "OK" Further control of the spot welding gun is via the robot signals described...

  • Page 45: Carrying Out The Firmware Update

    Carrying out the Before the CAN firmware update is carried out, the connection to the SpotWelding server CAN firmware up- must be terminated. The configuration must be activated once before the update via the date Configurator.
  • Page 46 Click "DeltaSpot" under "I/O devices" and select the "FC51xx" tab Click "Firmware Update" Select the update file and click "Open" After the update, switch TwinCat to "Run mode"...
  • Page 47 Check the green TwinCat symbol in the task bar. The symbol should not be blue or red/ yellow.

  • Page 48: Creating The Stepper Function

    Creating the stepper function General CAUTION! Incorrect inputs can have serious consequences for material and equipment. ► The spot welding gun may only be configured by trained specialist personnel. The manufacturer will not be held liable for damage caused by incorrect settings. The stepper function extends the electrode service life by compensating for electrode wear.

  • Page 49: Creating The Stepper Function

    From the Options menu, choose  Stepper function Creating the step- per function All available stepper configurations are displayed. These can be edited, removed or added to. Click on "Add" to create a new stepper function This opens the Stepper Editor...

  • Page 50: Stationary System With Welding Gun Adjustment: Adjusting The Tripod

    Stationary system with welding gun adjustment: Ad- justing the tripod Stationary sys- From the Options menu, choose  tem with welding "Move compensation drive" gun adjustment: Enter the target position in mm Adjusting the tri- Click "Start" Follow the instructions in the program Adjusting the tripod Using this function the welding gun adjuster can be driven into a specific position so as to align the tripod precisely.

  • Page 51: Restore Device Id

    If an empty device ID memory is detected by the system, the function "Restore Device ID" will become available in the Fronius Xplorer. Available gun type data from the cache can be re-written to the device ID memory with the "Restore Device ID"...

  • Page 52: Creating Welding Parameters In Program Editor

    Creating welding parameters in program editor Opening the pro- Open the program editor by selecting the required profile and clicking on the Create/edit gram editor profile button. Shortcut: double-click on profile Symbols used in "Options" button the Program Edi- The following settings can be chosen under Options: Grid (normal/detailed): For creating current and force profiles a normal or detailed grid can be set in the diagram (only affects the time axis) Snap: When the Snap function is enabled, new points in the diagram are au-...

  • Page 53: Creating The Current/Force Profile

    Program Editor Scroll bar For moving the visible area Zoom For enlarging or reducing the screen view Force profile (blue) For controlling the force profile during the welding process Current profile (red) For controlling the current profile during the welding process Creating the cur- To create the current profile or force profile: rent/force profile...

  • Page 54: Editing The Current/Force Profile

    IMPORTANT! The diagram incorporates an object grid (values 0. 3 kN or 0.3 kA) that positions newly created spots level with the previously selected spot. This function makes it easier to create a uniform welding parameter. It can be disabled in Options if necessary.

  • Page 55: Program Editor - Parameters

    Parameters the welding process. It is also possible to enter a program name and the spot numbers. NOTE! A Fronius Xplorer version of at least 2.2 or higher is required when to create a weld- ing program. Process Position (synchronous mode)

  • Page 56: Program Editor - Actual Values Monitoring

    Welding gun compensation mode For defining the welding gun compensation mode Position Position (synchronous mode) Weight compensation v2 Weight compensation v2 (synchronous mode) Position (for stationary systems with welding gun adjustment) The compensation drive first travels to a predefined position and only then is the gun closed.

  • Page 57: Program Editor - Notes

    (ideally the sheet thickness to be welded, as well as the sheet thickness to be welded plus 1 mm and minus 1 mm). The sheet thicknesses can be recorded via the robot interface or via Fronius Xplorer. The process is described in detail in the following section "Recording sheet thicknesses".

  • Page 58: Recording The Sheet Thickness

    Process Position (synchronous mode) Program Editor - Enabling/disabling the sheet thickness monitoring parameter Setting the values for the sheet thickness monitoring: In Program Editor set the "Expected sheet thickness [mm]" and "Tolerance +/- [mm]" parameters for the sheet thickness monitoring Recording the To enable the sheet thickness monitoring, at least 3 different sheet thicknesses must be sheet thickness...
  • Page 59 "Recording sheet thickness" program sequence Wait until "sheet thickness recorded" = 1 Set "record sheet thickness" = 0 Insert 2 mm sheet Start welding (without current) Set "sheet thickness" to 200 Set "record sheet thickness" = 0 Wait 100 ms Set "record sheet thickness"...

  • Page 61: Bus Systems

    Bus systems...

  • Page 63: Bus Systems

    General Signals can be transferred via a fieldbus. The process image is the same for all bus types. The robot programmer can use the Diagnostic worksheet in Fronius Xplorer to check whether all the inputs and outputs are correctly connected.

  • Page 64: Canopen

    CANopen Topology CAN is a 2-wire bus system, to which all nodes are connected in parallel. To avoid reflec- tions, a terminating resistor must be connected to each end of the bus (R = 120 Ohm). Ter- minating resistors are also required for very short cable lengths. Device n Device 1 CAN-High...

  • Page 65: Devicenet

    DeviceNet Topology DeviceNet is a 2-wire bus system, similar to CAN, to which all nodes are connected in par- allel. To avoid reflections, a terminating resistor must be connected to each end of the bus (R = 120 Ohm). Terminating resistors are also required for very short cable lengths. Device 1 Device n CAN-High...

  • Page 66: Profibus

    Profibus Default parameter Node ID: 2 settings Baud rate: 12 Mbps Interface card Profibus interface card Pin assignment Pin assignment of 9-pin Sub-D plug: Signal Description RxD/TxD-P Sends and receives data (+) DGND Data ground and supply connection (-) Terminating resistor supply voltage (+) RxD/TxD-N Sends and receives data (-) Design of the terminating resistor:...

  • Page 67: Interbus

    Interbus Topology Interbus is a ring system. Each node receives the signal and passes it on. Terminating re- sistors are not required in a ring system. Default parameter Ident. - Code: 3 settings Baud rate: can be set using DIP switches on the card Interface card The interface card is available in two versions: fibre optic cable or copper.

  • Page 68: Digital I/O Interface (Version 1.6)

    Digital I/O interface (Version 1.6) Outputs - ready - error actual position bit 8 - warning actual position bit 9 - referenced actual position bit 10 - remote control actual position bit 11 connected actual position bit 12 - external position actual position bit 13 control active actual position bit 14...

  • Page 69: Inputs

    Inputs...

  • Page 70: Profinet

    W8-SW-CX5140-1.2.0 ProfiNet communication can be carried out through the standard Ethernet port on the Beckhoff IPC. The DIN rail PC built into the switch cabinet is supported with the SpotWelding 4.1 software version or later. Installing the The ProfiNet driver is located under "C:\Tools" or on the driver CD which is delivered when ProfiNet driver a ProfiNet licence is ordered.
  • Page 71 Select (click) the relevant network card under "Compatible devices" Click "Install" – A "TwinCAT-Intel PCI Ethernet Adapter" entry now appears under "Installed and ready to use devices" Close the window...

  • Page 72: Activating The Profinet Card

    Activating the Start the SpotWelding Configurator ProfiNet card Under the "ProfiNet" fieldbus system, select the corresponding settings and activate the ProfiNet card by clicking "Activate Configuration"...

  • Page 73: Ethernet/Ip

    Ethernet/IP communication can be carried out through the standard Ethernet port on the Beckhoff IPC. The DIN rail PC built into the switch cabinet is supported with the SpotWelding 4.1 software version or later. Installing the The Ethernet/IP driver is located under "C:\Tools"...
  • Page 74 Select (click) the relevant network card under "Compatible devices" Click "Install" – A "TwinCAT-Intel PCI Ethernet Adapter" entry now appears under "Installed and ready to use devices" Close the window...

  • Page 75: Activating The Ethernet/Ip Card

    Activating the Start the SpotWelding Configurator Ethernet/IP card Under the "Ethernet/IP" fieldbus system, select the corresponding settings and acti- vate the Ethernet/IP card by clicking "Activate Configuration" Setting the cycle To change the cycle time (the default is 10 ms), proceed as follows: time Select "Ethernet/IP Slave Protocol"...

  • Page 77: Can Over Ethercat

    CAN over EtherCAT CAN over Ether- NOTE! CAT require- ments The CAN over EtherCAT bus system is only intended for specific DeltaSpot systems and is not for communicating with a robot A special DeltaSpot-GunControl, as well as a bus converter box, is required for use with DeltaSpot systems.
  • Page 78 – A "TwinCAT-Intel PCI Ethernet Adapter" entry now appears under "Installed and ready to use devices" Close the window Tick the "Show bindings" box and make sure that only "TwinCAT Ethernet Protocol" is enabled for the network interface Close the window and the system manager Assign a static IP address to the network interface...

  • Page 79: Activating The Can Over Ethercat Option In The Configurator

    Activating the Open the SpotWelding Configurator CAN over Ether- Select the "CAN over EtherCAT" field and activate the option by clicking "Activate CAT option in the Configuration" Configurator...

  • Page 81: Interfaces

    Interfaces...

  • Page 83: Spotwelding Interface Signal Description

    Activates docking mode. If this signal is set to 1, the drives are deactivated and errors that would occur through docking are prevented. Warnings remain in place. Existing errors are acknowledged upon reset. Depending on the SpotWelding Control version, the 48 V drive power supplies are inter- rupted to avoid arcing on undocking. expected gun code The expected gun code.

  • Page 84: Description Of Signal Outputs

    save sheet thickness calibration Activates the data recorded during sheet thickness calibration enable external position control (compensation drive) With a rising edge, the compensator is moved to the target position defined by the "com- pensation drive target position" signal. As long as this signal is active, no other actions (welding, error reset, etc.) can be per- formed.
  • Page 85 manual mode The control is in manual mode compensation drive at home position Set when the compensation drive is at the home position gun at home Set when the compensation and main drives are at the home position welding current enabled Confirmation of the "enable welding current"...
  • Page 86 spot number not found error Spot number not found duplicate spot number found error The selected spot number has been assigned to more than one program homing error The home position could not be found tape empty (movable arm) error Process tape on the movable arm is empty tape empty (fixed arm) error Process tape on the fixed arm is empty...
  • Page 87 tape brake too loose (fixed arm) warning Braking force has been set too low on the fixed arm tape end warning The process tape is running out and must be replaced soon electrode service life warning The electrode service life limit value has been reached and the electrodes must be re- placed soon.

  • Page 88: Deltaspot 1.6 Interface

    DeltaSpot 1.6 interface Inputs Input Comment Spot welding start homing start welding (no htr) reset errors main drive open main drive close tape drive forward (movable arm) tape drive backward (movable arm) tape drive forward (fixed arm) tape drive backward (fixed arm) tape length reset (movable arm) tape length reset (fixed arm) reset electrode service life (movable arm)

  • Page 89: Process Data Length

    Process data Interbus length 4 Words CANopen TxPDO1: 2 Words RxPDO1: 4 Words DeviceNet 4 Words Input 4 Words Output Profibus 2x "1 Word Slave-Out / Master-In" 4x "1 Word Slave-In / Master-Out"...

  • Page 90: Deltaspot 1.8 Interface

    DeltaSpot 1.8 interface Inputs Input Comment Spot welding start homing start welding (no htr) reset errors main drive open main drive close tape drive forward (movable arm) tape drive backward (movable arm) tape drive forward (fixed arm) tape drive backward (fixed arm) tape length reset (movable arm) tape length reset (fixed arm) reset electrode service life (movable arm)

  • Page 91: Process Data Length

    Process data Interbus length 8 words CANopen TxPDO1: 2 words RxPDO1: 4 words RxPDO2: 4 words DeviceNet Input: 8 words 2 words Output Profibus 2x "1 word Slave out/Master in" 4x "1 word Slave in/Master out" 2x "4 byte Slave in/Master out"...

  • Page 92: Deltaspot 1.10 Interface

    DeltaSpot 1.10 interface Inputs Input Comment Spot welding start homing start welding (no htr) reset errors main drive open main drive close tape drive forward (movable arm) tape drive backward (movable arm) tape drive forward (fixed arm) tape drive backward (fixed arm) tape length reset (movable arm) tape length reset (fixed arm) reset electrode service life (movable arm)

  • Page 93: Process Data Length

    Spot welding Comment gun output tape end warning electrode service life warning lubrication warning actual values monitoring power source ready current flow started current flow finished docking mode activated invalid gun code A18 - A20 device id sheet thickness calibration reset sheet thickness recorded sheet thickness calibration saved welding current enabled...

  • Page 94: Deltaspot 3.1 Interface

    DeltaSpot 3.1 interface Inputs Input Comment Spot welding start homing start welding (no htr) reset errors main drive open main drive close tape drive forward (movable arm) tape drive backward (movable arm) tape drive forward (fixed arm) tape drive backward (fixed arm) tape length reset (movable arm) tape length reset (fixed arm) reset electrode service life (movable arm)
  • Page 95 Spot welding Comment gun output extPos_ctrl_active manual mode tape end warning electrode service life warning lubrication warning actual values monitoring power source ready current flow started current flow finished flow controller not ok docking mode activated invalid gun code A18 - A20 device id sheet thickness calibration reset sheet thickness recorded...

  • Page 96: Process Data Length

    Process data Interbus length 12 Words DeviceNet 12 Words Input 12 Words Output CANopen TxPDO1: 8 byte TxPDO2: 8 byte TxPDO3: 8 byte RxPDO1: 8 byte RxPDO2: 8 byte RxPDO3: 8 byte Ethernet/IP 12 Words Input 12 Words Output ProfiNet 12 Words Input 12 Words Output ProfiBus...

  • Page 97: Deltacon Interface (7Th Axis) 1.0

    DeltaCon interface (7th axis) 1.0 Inputs Input Comment Spot welding reset errors reset electrode service life start welding (htr) enable welding current activate docking mode E05 - E07 expected gun code program selection data valid tips dressed operate force sensor (Disables the reset of the force sensor.) E16 - E23 program number E32 - E63...

  • Page 98: Process Data Length

    Spot welding Comment gun output A23 - A25 docu state (State of the welding documentation) 0 = docu state monitoring not enabled; 1 = ok; 2 = buffering; 4 = buffer full /data loss possible A32 - A47 target force A48 - A63 target weld time A64 - A79...

  • Page 99: Spotwelding Interface Signal Waveform

    SpotWelding interface signal waveform Moving to the When the system is switched on, the drives must move to the home position. To do this, home position set the "start homing" signal and wait until the "referenced" signal goes high. start homing...

  • Page 100: Welding Start-Up With External Position Specification

    Welding start-up During the welding process, the "external position control active" signal is low. The build- with external po- up of force is created by the gun controller and during this time the robot has no control sition specifica- over the included angle of the gun. As soon as the welding process is over, the "external tion position control active"...

  • Page 101: Docking

    In the event of a power failure (SpotWelding Control switches off), an attempt is still made to request the motor angles. However, this may be unsuccessful due to time constraints.

  • Page 102: Deltaspot Signal Waveform Example

    DeltaSpot signal waveform exam- Gun controller commands: enable external position control: Robot requirement to move the gun arms. external position control active: Enables the gun arms to be moved. target position: Specifies the gun included angle. actual position: Output of actual gun included angle (0 = gun open, max. = gun closed).

  • Page 103: Deltacon Signal Waveform Example

    The command to open the gun cannot be executed during the welding process. The gun only opens again when the welding process has finished Welding process commands: start welding: Start of the welding process. enable welding current: Specifies whether welding is to be carried out with or with- out current (test welding).

  • Page 105: Troubleshooting And Maintenance

    Troubleshooting and maintenance...

  • Page 107: Troubleshooting

    ► The housing screws must not be replaced by any other screws without a reliable ground conductor connection. Exporting invert- Log files for Fronius inverters can be downloaded and saved as a zip file for problem anal- er log files ysis.
  • Page 108 0.01 = main drive Cause: Main drive is not ready Remedy: Reset error, contact After-Sales Service if necessary 0.02 = spot number Cause: The specified spot number is not included in any program Remedy: Make sure that the spot number is specified correctly and that it is also en- tered into a program.
  • Page 109 0.14 = compensation drive position target not reached Cause: The compensation drive could not reach the target position Remedy: Reset error, contact After-Sales Service if necessary 0.15 = emergency stop Cause: Emergency Stop has been actuated Remedy: Reset Emergency Stop after rectifying the fault 0.16 = main drive position target not reached Cause: The spot welding gun cannot approach the specified electrode distance...
  • Page 110 1.02 = internal system error Cause: Internal system error Remedy: Restart the system Remedy: If the problem persists, contact the Fronius Technical Support team 1.04 = wrong terminal configuration Cause: Wrong terminal configuration Remedy: Contact After-Sales Service 1.05 = wrong main drive servo firmware...
  • Page 111 1.09 = wrong can card firmware Cause: Incompatible firmware version for CAN card found Remedy: Perform firmware update on CAN card 1.10 = can card firmware read error Cause: CAN card read error Remedy: Contact After-Sales Service 1.11 = position calibration Cause: The position has not been calibrated yet (electrode spacing) Remedy:...
  • Page 112 Remedy: Check whether the "blizzard.tsm" (DeltaSpot) or "config.tsm" (DeltaSpot G2) and CAN card were activated correctly Remedy: Save configuration, uninstall and reinstall SpotWelding Control software 2.1 = wrong servo firmware Cause: A motor controller contains the wrong firmware Perform firmware update (can be done via the Options menu  "Firmware up- Remedy: date")
  • Page 113 2.3 = wrong servo hardware (compensation drive) Cause: Wrong servo hardware (compensator) Remedy: Plug in correct drive controller (compensator) 2.4 = wrong servo hardware (tape drive movable arm) Cause: Wrong servo hardware (tape drive for movable arm) Remedy: Plug in correct drive controller (tape drive for movable arm) 2.5 = wrong servo hardware (tape drive fixed arm) Cause: Wrong servo hardware (tape drive for fixed arm)
  • Page 114 An error occurred while reading the config mem (device ID). Remedy: Switch off SpotWelding Control for a few seconds and then turn it on again. If the problem persists, contact Fronius Technical Support. 2.25 = no config mem found / no device id found (from version 3.3.92 upwards) Cause: No config mem found (device ID).
  • Page 115 3.5 = damaged config mem / damaged device id (from version 3.3.92 upwards) Cause: Config mem (device ID) faulty Remedy: Contact Fronius Technical Support 3.6 = main drive temperature sensor fault Cause: Temperature sensor of the main drive is faulty...
  • Page 116 Calibrate power source 3.11 = deliocan measurement system Cause: The DellOCAN measurement system has reported an error Remedy: Contact Fronius Technical Support 3.12 = power source firmware (HWH inverter) Cause: The power source has incompatible firmware Remedy: Contact Fronius Technical Support 3.13 = power source hardware (HWH inverter)
  • Page 117 No valid servo configuration has been found for at least one of the drive com- ponents of the currently connected gun. Remedy: Contact Fronius Technical Support. 3.23 = hardware type error Cause: At least one component with an incompatible hardware type has been found.

  • Page 118: Description Of Warning Signals

    8.1 = target position invalid Cause: The target position specified by the robot is outside the maximum gun open- Remedy: Check program flow 8.2 = main drive system Cause: Error in the main drive system Remedy: Check the main drive system 8.3 = compensation drive system Cause: Error in the compensation system...
  • Page 119 0.02 = lubrication Cause: Lubrication will soon no longer be sufficient Remedy: Lubricate gun and reset counter 0.03 = electrode service life (movable arm) Cause: The electrode on the movable arm is reaching the end of its service life Remedy: Replace electrode immediately and reset counter 0.04 = electrode service life (fixed arm) Cause:...
  • Page 120 0.16 = sheet thickness monitoring recalibration Cause: The sheet thickness monitoring is not correctly calibrated or recalibration is required (e.g. after homing) Remedy: Recalibrate the sheet thickness monitoring 0.17 = main drive overloaded Cause: The main drive has reached its temperature limit Remedy: Reduce welding duration or electrode force 0.18 = actual current monitoring...
  • Page 121 0.28 = tape spool unit cover plate fixed arm open Cause: The cover on the spool unit is open (fixed arm) Remedy: Close the cover on the spool unit (fixed arm) 0.29 = tape unspool unit cover plate fixed arm open Cause: The cover on the tape unspool unit is open (fixed arm) Remedy:...
  • Page 122 Contact Fronius Technical Support. 2.6 = Warning "fault current" Cause: Increased fault current is measured Remedy: Contact Fronius Technical Support., so that the system can be checked. A "fault current" error may occur in the following cases (max. fault current limit was exceeded.)
  • Page 124 FRONIUS INTERNATIONAL GMBH Froniusstraße 1, 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...

Table of Contents