FRO­NIUS DeltaSpot Series Guide

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42,0426,0242,EN 012-09052019
DeltaSpot
Stationary welding system
Operating Instructions
Spare parts list
Resistance welding
EN

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EN
Dear reader,
Introduction 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. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
Explanation of
safety notices DANGER!
Indicates immediate danger.
► If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
► If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
► If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT!
Indicates tips for correct operation and other particularly useful information.
This does not indicate a potentially hazardous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.

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Contents
Safety rules ................................................................................................................................................ 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 7
Environmental conditions...................................................................................................................... 7
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Protecting yourself and others .............................................................................................................. 8
Danger from toxic gases and vapours .................................................................................................. 8
Danger from flying sparks ..................................................................................................................... 9
Risks from mains current and welding current...................................................................................... 9
EMC measures ..................................................................................................................................... 10
Specific hazards.................................................................................................................................... 11
Safety measures at the installation location and during transport ........................................................ 11
Safety measures in normal operation ................................................................................................... 12
Commissioning, maintenance and repair.............................................................................................. 12
Safety inspection................................................................................................................................... 12
Disposal ................................................................................................................................................ 13
Safety symbols...................................................................................................................................... 13
Data protection...................................................................................................................................... 13
Copyright............................................................................................................................................... 13
General information 15
General ...................................................................................................................................................... 17
Principle ................................................................................................................................................ 17
Application areas .................................................................................................................................. 17
Information for dimensioning the welding system ................................................................................. 17
Warning notices on the device.............................................................................................................. 19
Assembly and installation of the stationary welding system ................................................................. 23
System components .................................................................................................................................. 24
General ................................................................................................................................................. 24
System components overview .............................................................................................................. 24
Control elements and connections 25
GunControl................................................................................................................................................. 27
General ................................................................................................................................................. 27
GunControl 110/230 controls ................................................................................................................ 27
GunControl 110/230 connection sockets .............................................................................................. 28
Welding transformer and spot welding gun................................................................................................ 31
Welding transformer connections ......................................................................................................... 31
Mechanical components ............................................................................................................................ 32
Mechanical components ....................................................................................................................... 32
Remote control........................................................................................................................................... 33
RemoteControl Pro ............................................................................................................................... 33
Start-up 35
Before commissioning................................................................................................................................ 37
General ................................................................................................................................................. 37
Measures for the safe operation of the device with untrained personnel.............................................. 37
Proper use ............................................................................................................................................ 37
Setup regulations .................................................................................................................................. 37
Mains connection .................................................................................................................................. 38
Guidelines for system cooling ............................................................................................................... 38
Transformer PE conductor connection ................................................................................................. 39
Start-up ...................................................................................................................................................... 41
General ................................................................................................................................................. 41
Connecting the remote control.............................................................................................................. 41
Establishing the coolant connections.................................................................................................... 41

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Threading the process tape .................................................................................................................. 42
Moving to the home position ................................................................................................................. 44
Spot welding 45
DeltaSpot resistance spot welding............................................................................................................. 47
General ................................................................................................................................................. 47
Process tape consumption.................................................................................................................... 47
Adjusting the height of the movable arm............................................................................................... 47
Effect of the process tape on the welding process ............................................................................... 48
Troubleshooting and maintenance 51
Replacing wearing parts and consumables ............................................................................................... 53
General ................................................................................................................................................. 53
Instructions for storing and loading process tapes................................................................................ 53
Reloading the process tape ................................................................................................................. 53
Adjusting the process tape brake.......................................................................................................... 55
Replacing electrodes ............................................................................................................................ 56
Adjusting the gun arms ......................................................................................................................... 57
Troubleshooting ......................................................................................................................................... 59
General remarks ................................................................................................................................... 59
Troubleshooting .................................................................................................................................... 59
Care, maintenance and disposal ............................................................................................................... 60
General ................................................................................................................................................ 60
Maintenance to be carried out daily or each time the tape is changed................................................. 60
Weekly maintenance or after every 50,000 spots.................................................................................60
Monthly maintenance or after every 200,000 spots .............................................................................. 60
After 250,000 spot welds ...................................................................................................................... 61
Disposal ................................................................................................................................................ 61
Technical data............................................................................................................................................ 62
Special voltages.................................................................................................................................... 62
MF transformer ..................................................................................................................................... 62
DeltaSpot stationary welding system .................................................................................................... 62
Appendix 63
Spare parts list: DeltaSpot G2 ................................................................................................................... 64
  ................................................................................................................................................... 67

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EN
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.
All persons involved in commissioning, operating, maintaining and servicing the device
must:
- be suitably qualified,
- have sufficient knowledge of welding and
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being used. In
addition to the operating instructions, attention must also be paid to any generally applica-
ble and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- 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" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
Proper use The device is to be used exclusively for its intended purpose.
The device is intended solely for the purposes of spot welding.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.
Proper use also includes:
- carefully reading and following all the instructions given in the operating instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and servicing work.
The device is designed for use in industry and the workshop.
The manufacturer likewise accepts no liability for unexpected or incorrect results.
Environmental
conditions
Operation or storage of the device outside the stipulated area will be deemed as not in ac-
cordance with the intended purpose. The manufacturer shall not be held liable for any dam-
age arising from such usage.
Ambient air temperature range:
- during operation: + 5 °C to + 40 °C (41 °F to 104 °F)
- during transport and storage: - 25 °C to + 55 °C (- 13 °F to 131 °F)
Relative humidity:
- up to 50 % at 40 °C (104 °F)
- up to 90 % at 20 °C (68 °F)

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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. Due to conducted and radiated emissions, it may be
difficult to ensure electromagnetic compatibility in these areas.
Obligations of the
operator
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the section "safety
rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
- 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 workplace, ensure that people or property cannot come to any harm in
your absence.
Protecting your-
self and others
Anyone working with the device exposes themselves to numerous risks e.g.: Weldingspat-
ter
Suitable protective clothing must be worn when working with the device. The protective
clothing must have the following properties:
- flame-resistant,
- insulating and dry,
- covers the whole body, is undamaged and in good condition,
- trousers with no turn-ups.
Protective clothing refers to a variety of different items. Operators should:
- protect their eyes with the specified safety goggles;
- wear stout footwear that provides insulation even in wet conditions;
- protect their hands by wearing suitable gloves (electrically insulated, heat-proof, pro-
tection from cut injuries);
- wear ear protection to reduce the harmful effects of noise and to prevent injury.
Keep all persons, especially children, out of the working area while any devices are in op-
eration or welding is in progress. If, however, there are people in the vicinity,
- make them aware of all the dangers (risk of dazzling by arc, injury from sparks, inhal-
ing welding smoke, noise, possible danger from mains or cutting current, etc.);
- provide suitable protective equipment or
- erect suitable safety screens/curtains
Danger from toxic
gases and va-
pours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances, cause birth de-
fects or cancer.
Keep your face away from welding fumes and gases.

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EN
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.
The following components are responsible, amongst other things, for the degree of toxicity
of welding fumes:
- Metals used for the workpiece,
- Coating of the process tapes,
- Coatings of the materials,
- Additives (e.g. adhesive),
- Cleaners, degreasers, etc.
The relevant material safety data sheets and manufacturer's specifications for the listed
components should therefore be studied carefully.
Flammable fumes (e.g. solvent fumes) should be kept away from the direct welding pro-
cess.
Danger from fly-
ing sparks
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (35 ft) away from the welding process, or
covered with an approved 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. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or near sealed
tanks, vessels or pipes unless these have been prepared in accordance with the relevant
national and international standards.
Do not carry out welding on containers that are being or have been used to store gases,
propellants, mineral oils or similar products. Residues pose an explosive hazard.
Risks from mains
current and weld-
ing current
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
Make sure that you and others are protected with an adequately insulated, dry temporary
backing or cover for the earth or ground potential. This temporary backing or cover must
extend over the entire area between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately dimen-
sioned. Loose connections, scorched, damaged or inadequately dimensioned cables and
leads must be repaired/replaced immediately.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the
ground conductor is functioning properly.
The device must only be operated on a mains supply with a ground conductor and a socket
with a ground conductor contact.

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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.
Switch off unused devices.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent any-
one from plugging the mains plug back in and switching it on again.
After opening the device:
- discharge all live components.
- ensure that all components in the device are de-energised.
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
EMC measures Warning, electromagnetic field. Electromagnetic fields may cause as yet unknown dam-
age to health.
It is the operator's responsibility to ensure that no electromagnetic interference occurs in
electrical and electronic devices.
If electromagnetic interference is found to be occurring, the owner/operator is obliged to
take all necessary measures to prevent this interference.
Check for possible problems, and check and evaluate neighbouring devices' resistance to
interference according to national and international requirements:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
- Health of persons in the vicinity
Supporting measures for avoidance of EMC problems:
a) Mains supply
- If electromagnetic interference arises despite the correct mains connection, addi-
tional measures are necessary (e.g. use of a suitable line filter).
b) Equipotential bonding
c) Earthing the workpiece
- If necessary, establish an earth connection using suitable capacitors.
d) Shielding, if necessary
- Shield other devices nearby
- Shield the entire welding installation
e) Persons with pacemakers:
The powerful magnetic fields that occur during resistance welding can interfere with
the functioning of pacemakers. This may cause considerable damage to the health of
the affected persons. Persons with pacemakers must not remain in the immediate vi-
cinity of welding operations.
f) Persons with metal implants:
Persons with metal implants must not work with a resistance welding device and must
not be in the immediate vicinity when welding is in progress.
g) Do not have any magnetic or electronic data carriers about your person:
Magnetic or electronic data carriers may be damaged by the magnetic fields generat-
ed by resistance welding.
h) Do not have any watches or pieces of metal about your person. Watches can be dam-
aged when operating resistance welding devices.

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EN
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.
In addition to these operating instructions, the robot manufacturer's safety rules must also
be observed.
Keep hands, hair, clothing and tools away from moving parts. For example:
- Rollers
- Shafts
- Arms
Do not reach into rotating drive components.
Risk of entrapment!
Do not place hands or other body parts between the welding electrodes or other moving
parts.
Risk of cutting!
Wear safety gloves when handling sharp objects and process tape.
Covers and side panels may only be opened or removed for as long as maintenance or
repair work is being carried out.
During operation:
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
Never touch the workpiece, electrodes or process tape during or after welding - risk of
burns.
Welding residue may be ejected from cooling workpieces. The specified protective equip-
ment must therefore also be worn when reworking workpieces, and steps must be taken
to ensure that other people are also adequately protected.
Welding electrodes, process tape and other parts with a high operating temperature must
be allowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.
Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting cool-
ant flow or return lines.
Use only suitable load-carrying equipment supplied by the manufacturer when transporting
devices by crane.
- Hook chains or ropes onto all suspension points provided on the load-carrying equip-
ment.
- Chains and ropes must be at the smallest angle possible to the vertical.
All lifting accessories (straps, handles, chains, etc.) used in connection with the device or
its components must be tested regularly (e.g. for mechanical damage, corrosion or chang-
es caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.
Safety measures
at the installation
location and dur-
ing transport
A device that topples over can cause life-threatening injuries. Place the device on a solid,
level surface.

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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.
When setting up the gun control, ensure there is an all-round clearance of 0.5 m (1.6 ft.)
so that cooling air can flow in and out unhindered.
When transporting the device, observe the relevant national and local guidelines and ac-
cident prevention regulations. This applies especially to guidelines regarding the risks aris-
ing during transport.
Before transporting the device, allow coolant to drain completely and detach components.
After transporting the device, the device must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before com-
missioning the device.
Safety measures
in normal opera-
tion
Only operate the device if all of its protection devices are fully functional. If the protection
devices are not in full working order, 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.
Any safety devices that are not functioning properly must be repaired before switching on
the device.
Never bypass or disable protection devices.
Before switching on the device, ensure that no one is likely to be endangered.
- Check the device at least once a week for obvious damage and the proper functioning
of safety devices.
- Use only appropriate coolant. Note the information provided by the manufacturer of
the cooling system.
- If damage results from using a different coolant the manufacturer accepts no liability.
In addition, all warranty claims are forfeited.
Commissioning,
maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufac-
turer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at least
once every 12 months.

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EN
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.
Further details on safety inspections can be obtained from your service centre. They will
provide you, on request, with any documents you may require.
Disposal 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 facil-
ity. Any device that you no longer require must be returned to your dealer, or find out about
the approved collection and recycling facilities in your area. Ignoring this European Direc-
tive may have potentially adverse affects on the environment and your health!
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directive (e.g. relevant product standards from the EN 62 135 se-
ries).
Devices with a CE declaration of incorporation satisfy the essential requirements of the
low-voltage and electromagnetic compatibility directive (e.g. relevant product standards
from the EN 62 135 series).
Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We reserve the
right to make changes. The contents of the operating instructions shall not provide the ba-
sis for any claims whatsoever on the part of the purchaser. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the instructions, we will
be most grateful for your comments.

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General information

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EN
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. A further advantage of DeltaSpot is the extra
process heat resulting from the electrical resistance of the process tape. The required am-
perage can be reduced and the energy requirement significantly lowered.
The continuous advance of the process tape enables spot welds of equally high quality to
be reproduced.
The result is previously unmatched precision in the welding process and maximum service
life for the electrodes.
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.).
Main application areas:
- Automotive and component supply industry
- Household appliances industry
- Railway vehicle construction
- System and plant construction
- Aerospace industry
Information for di-
mensioning the
welding system
CAUTION!
Overloading the welding system may result in damage to property.
Check the inverter and the transformer are configured correctly for the respective applica-
tion.
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.
Load capacity diagrams define the maximum permitted welding current in relation to the
duty cycle.
Operating points need to be defined both for the transformer and for the inverter. The lower
of the two values should be used for the application.
Calculating the maximum permitted welding current for the transformer
Calculating the maximum diode duty cycle
-Due to the lower heat capacity of the diodes, the maximum permitted duty cycle
is determined using the "welding spot to welding spot" time (welding cycle time).
-If the application uses current times or welding cycle times of different lengths, al-
ways use the longest current time and shortest welding cycle time
-Important! If the longest current time is greater than two seconds, the duty cycle
of the diode should be set to 100 %.
DC_Diodes = longest current time/shortest welding cycle time x 100 %
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Example:
(1) Welding current axis
(2) Time axis
Longest current time = 500 ms
/shortest welding cycle time = 2500 ms
DC_Diodes = 500 ms/2500 ms x 100 % =
20 %
Calculating the maximum transformer duty cycle
-Since the transformer has a higher heat capacity, the maximum permitted duty
cycle is calculated on the basis of the welding cycle with a maximum integration
time of one minute
DC_Transf = (number of welds x current time for each welding spot/integration time)
x 100 %
Example:
(1) Welding current axis
(2) Time axis
Number of welds = 1 x 10 spots
current time per welding spot = 600 ms
integration time = 60 s
DC_Transf = (1x10 spots x 600 ms/60000
ms) x 100 % = 10 %
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):
-Find the transformer load diagram
-Mark a vertical line on the diagram for the diode duty cycle (DC_Diodes)
-Search for a diode characteristic that corresponds to the longest current time for
each welding spot and read off the current at the intersection with the vertical line
for the diode duty cycle -> I_max_Diodes
-Draw a vertical line on the diagram for the transformer duty cycle (DC_Transf)
-Read off the current at the intersection with the vertical line for the transformer
duty cycle -> I_max_Transf
Calculating the maximum permitted inverter current
Calculating the maximum semiconductor duty cycle
-Due to the limited heat capacity of the semiconductors, the maximum permitted
duty cycle is determined using the "current time to welding cycle time" period.
-If the application uses current times or welding cycle times of different lengths, al-
ways use the longest current time and shortest welding cycle time
DC_Inverter = current time/welding cycle time x 100 %
Example:
500 ms
2500 ms
(1)
(2)
2
10 spots
60 s
(1)
(2)
600 ms
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EN
(1) Welding current axis
(2) Time axis
Current time = 400 ms
Welding cycle time = 2000 ms
DC_Inverter = 400 ms/2000 ms x 100 % =
20 %
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
(DC_Inverter)
-Multiply the primary current read off by the transformation ratio of the transformer
(e.g. 38) -> I_max_Inverter
Calculating the maximum permitted welding current
The maximum permitted welding current is the lowest of the three calculated currents
for the diodes (I_max_Diodes), transformer (I_max_Transf) and inverter
(I_max_Inverter)
Warning notices
on the device
The device is fitted with safety symbols and a rating plate. The safety symbols and rating
plate must not be removed or painted over. The safety symbols warn against operating the
equipment incorrectly, as this may result in serious injury and damage.
400 ms
2000 ms
(1)
(2)
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