FRO­NIUS DeltaSpot User manual

/ Battery Charging Systems / Welding Technology / Solar Electronics
42,0426,0050,EN 001-02042012
DeltaSpot Operating Instructions
Spare parts list
Resistance welding
EN

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1
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.

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3
EN
Contents
Safety rules ................................................................................................................................................ 5
Explanation of safety symbols .............................................................................................................. 5
General ................................................................................................................................................. 5
Proper use ............................................................................................................................................ 6
Environmental conditions...................................................................................................................... 6
Obligations of the operator.................................................................................................................... 6
Obligations of personnel ....................................................................................................................... 7
Protecting yourself and others .............................................................................................................. 7
Danger from toxic gases and vapours .................................................................................................. 7
Danger from flying sparks ..................................................................................................................... 8
Risks from mains current and welding current...................................................................................... 8
Meandering welding flows..................................................................................................................... 9
EMC measures ..................................................................................................................................... 9
Specific hazards.................................................................................................................................... 10
Safety measures at the installation location and during transport ........................................................ 11
Safety measures in normal operation ................................................................................................... 12
Maintenance and repair ........................................................................................................................ 12
Safety inspections................................................................................................................................. 13
Disposal ................................................................................................................................................ 13
Safety symbols...................................................................................................................................... 13
Data protection...................................................................................................................................... 13
Copyright............................................................................................................................................... 13
General information 15
General ...................................................................................................................................................... 17
Principle ................................................................................................................................................ 17
Device concept ..................................................................................................................................... 17
Application areas .................................................................................................................................. 17
Scope of supply .................................................................................................................................... 17
Information for dimensioning the welding system .................................................................................18
System components .................................................................................................................................. 19
General ................................................................................................................................................. 19
System components overview .............................................................................................................. 19
Control elements and connections 21
DeltaControl ............................................................................................................................................... 23
General ................................................................................................................................................. 23
DeltaControl control elements............................................................................................................... 23
DeltaControl connections...................................................................................................................... 23
EMERGENCY STOP connection diagram............................................................................................ 25
Welding transformer and spot welding gun................................................................................................ 27
Welding transformer connections ......................................................................................................... 27
Welding gun cooling water connections................................................................................................ 27
Spot welding gun current connections .................................................................................................. 27
Mechanical components ............................................................................................................................ 28
X-gun mechanical components............................................................................................................. 28
C-gun mechanical components ............................................................................................................ 30
Remote control........................................................................................................................................... 32
DeltaRemote remote control ................................................................................................................. 32
DeltaRemote Plus remote control ......................................................................................................... 32
Start-up 35
Before commissioning................................................................................................................................ 37
General ................................................................................................................................................. 37
Proper use ............................................................................................................................................ 37
Setup regulations .................................................................................................................................. 37
Mains connection .................................................................................................................................. 37

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Guidelines for system cooling ............................................................................................................... 37
Transformer PE conductor connection ................................................................................................. 38
Start-up ...................................................................................................................................................... 40
General ................................................................................................................................................. 40
Connecting DeltaControl....................................................................................................................... 40
Connecting the spot welding gun.......................................................................................................... 41
Connecting the cooling water supply .................................................................................................... 41
Connecting Bosch PSI 6xxx.000 power source .................................................................................... 41
Loading the process tape for the X-gun................................................................................................ 43
Loading the process tape for the C-gun - upper holder ........................................................................ 44
Loading the process tape for the C-gun - lower holder......................................................................... 46
Move to reference point ........................................................................................................................ 47
Sheet thickness correction.................................................................................................................... 48
Adjusting sheet thickness correction..................................................................................................... 48
Spot welding 53
DeltaSpot resistance spot welding............................................................................................................. 55
General ................................................................................................................................................. 55
Process tape consumption.................................................................................................................... 55
Welding gun adjustment ....................................................................................................................... 55
Effect of the process tape on the welding process ...............................................................................57
Troubleshooting and maintenance 59
Replace wearing parts ............................................................................................................................... 61
General ................................................................................................................................................. 61
Instructions for storing and loading process tapes................................................................................ 61
Load new process tape ........................................................................................................................ 61
Reloading process tape C-gun ............................................................................................................. 63
Adjusting the process tape brake.......................................................................................................... 65
Replacing electrodes ............................................................................................................................ 66
Calibrating holder arms......................................................................................................................... 67
Calibrating the C-gun arm..................................................................................................................... 68
Troubleshooting ......................................................................................................................................... 70
General ................................................................................................................................................. 70
Troubleshooting .................................................................................................................................... 70
Care, maintenance and disposal ............................................................................................................... 71
General ................................................................................................................................................ 71
Maintenance to be carried out daily or each time the tape is changed................................................. 71
Weekly maintenance or after every 50000 spots.................................................................................. 71
Weekly maintenance or after every 200000 spots................................................................................ 71
After 250,000 spot welds ...................................................................................................................... 71
Disposal ................................................................................................................................................ 72
Technical data............................................................................................................................................ 73
Special voltages.................................................................................................................................... 73
TR unit .................................................................................................................................................. 73
DeltaSpot spot welding gun .................................................................................................................. 73
Appendix 75
Spare parts list: DeltaSpot ......................................................................................................................... 76

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EN
Safety rules
Explanation of
safety symbols
If you see any of the symbols depicted in the "Safety rules", special care is required.
General
DANGER! indicates immediate and real danger. If it is not avoided, death or se-
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. If it is 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.
It does not indicate a potentially damaging or dangerous situation.
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 operat-
ing 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
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is be-
ing used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident preven-
tion and environmental protection.
All safety and danger notices on the device
- must be kept in a legible state
- must not be damaged/marked
- must not be removed
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the
section headed "General remarks" in the operating instructions for the device.
Before switching on the device, remove any faults that could compromise
safety.
Your personal safety is at stake!

6
Proper use
Environmental
conditions
Obligations of the
operator
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
- studying and obeying all safety and danger notices carefully
- carrying out all the specified 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 re-
sults.
Operation or storage of the device outside the stipulated area will be deemed
as not in accordance with the intended purpose. The manufacturer shall not
be liable for any damage resulting from such improper use.
Ambient 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)
Ambient air: free from dust, acids, corrosive gases and substances, etc.
For use at altitudes above sea level: up to 1000 m (3280 ft)
The operator undertakes only to allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety and acci-
dent prevention, and have been instructed 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.

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EN
Obligations of
personnel
Protecting your-
self and others
Danger from toxic
gases and va-
pours
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 work area, ensure that people or property cannot come to
any harm in your absence.
Persons involved with welding expose themselves to numerous risks, e.g.:
- flying sparks and hot pieces of metal
Anyone working on the workpiece whilst welding is taking place must wear
suitable protective clothing with the following properties:
- flame-resistant
- insulating and dry
- covers the whole body, is undamaged and in good condition
- safety helmet
- trousers with no turn-ups
Welding apparel refers to a variety of different items. Operators should:
- protect eyes and face from UV rays, heat and sparks using a protective
visor and regulation filter.
- wear regulation protective goggles behind the protective visor.
- wear stout footwear that provides insulation even in wet conditions.
- protect the hands with suitable gloves (electrically insulated and providing
protection against heat).
- 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 devic-
es are in operation or welding is in progress. If, however, there are people in
the vicinity,
- make them aware of all the dangers (risk of dazzling by the arc, injury
from flying sparks, harmful welding fumes, noise, possible risks from
mains current and welding current, etc.),
- provide suitable protective equipment or
- erect suitable safety screens/curtains.
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances,
cause birth defects or cancer.
Keep your face away from welding fumes and gases.
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.
If this cannot be provided, a protective mask with an air supply must be worn.

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Danger from fly-
ing sparks
Risks from mains
current and weld-
ing current
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
- 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 process.
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 alternatively covered with a checked cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small
gaps or openings. Take appropriate precautions to prevent any danger of in-
jury 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 ac-
cordance 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.
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
dimensioned. Loose connections, scorched, damaged or inadequately dimen-
sioned cables and leads must be repaired/replaced immediately.

9
EN
Meandering weld-
ing flows
EMC measures
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. The manufac-
turer shall not be liable for any damage resulting from such improper use.
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 anyone 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.
If the following instructions are ignored, meandering welding flows can devel-
op with the following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to PE conductors
- Damage to device and other electrical equipment
Warning, electromagnetic field Electromagnetic fields may pose as yet un-
known risks to health.
It is the operator's responsibility to ensure that no electromagnetic interference
occurs in electrical and electronic devices.
If electromagnetic interference is detected, the operator is obliged to take ac-
tion to rectify the situation.
Check for possible problems, and check and evaluate neighbouring devices'
resistance to interference according to national and international require-
ments:
- Safety features
- power, signal and data transfer lines
- IT and telecommunications devices
- measuring and calibrating devices
- the health of neighbouring persons

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Specific hazards
Supporting measures for avoidance of EMC problems:
a) mains supply
- if electromagnetic interference arises despite correct mains connec-
tion, additional measures are necessary (e.g. use of a suitable line
filter).
b) 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
c) Equipotential bonding
d) Earthing the workpiece
- If necessary, establish an earth connection using suitable capacitors.
e) Shielding, if necessary
- shield off other nearby devices
- shield off entire welding installation
f) Prohibited to persons with pacemakers:
The strong magnetic fields generated by resistance welding will interfere
with the function of pacemakers. This may cause considerable damage to
the health of the affected persons. Persons with pacemakers must not re-
main in the immediate vicinity of welding operations.
g) Prohibited to persons with metal implants:
Persons with metal implants must not work with a resistance welding de-
vice and must not be in the immediate vicinity when welding is in
progress.
h) You should not be carrying magnetic or electronic data carriers:
Magnetic electronic data carriers can be damaged by the magnetic fields
generated by resistance welding.
i) You should not be carrying watches or pieces of metal. Watches can be
damaged when operating resistance welding devices.
Stay out of the working area of the robot
The operating company must incorporate the device into a higher-level safety
system if the installation location is within a secured area that has to be ac-
cessed when setup and maintenance work is carried out. In this case meas-
ures must be implemented 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:
- Cogs
- Rollers
-Shafts
- Joints
Do not reach into rotating drive components.

11
EN
Safety measures
at the installation
location and dur-
ing 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.
- keep all covers and side panels closed.
Never touch the workpiece, electrodes or process tape during or after welding
- risk of burns.
Welding residues can jump off cooling workpieces. The specified protective
equipment must therefore also be worn when reworking workpieces, and
steps must be taken to ensure that other people are also adequately protect-
ed.
Welding electrodes, process tape and other parts with a high operating tem-
perature 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 discon-
necting coolant flow or return lines.
Use only suitable load-carrying equipment supplied by the manufacturer when
transporting devices by crane.
- Hook chains and/or ropes onto the suspension points provided on the
load-carrying equipment.
- Chains/ropes must be at the smallest angle possible to the vertical.
A device that topples over can easily kill someone. Place the device on a solid,
level surface.
Special regulations apply in rooms at risk of fire or explosion
- observe relevant national and international regulations.

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Safety measures
in normal opera-
tion
Maintenance and
repair
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.
When transporting the device, observe the relevant national and local guide-
lines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transportation.
Before transporting the device, allow coolant to drain completely and detach
components.
After transporting the device, the device must be visually inspected for dam-
age before commissioning. Any damage must be repaired by trained service
technicians before commissioning the device.
Only operate the device when all protection devices are fully functional. If the
protection devices are not fully functional, there is a risk of
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operat-
ing company,
- 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 proper
functioning of safety devices.
- Use only appropriate coolant. Note the cooling unit manufacturer's in-
structions.
- If damage results from using a different coolant the manufacturer accepts
no liability. In addition, all warranty claims are forfeited.
- Check the coolant level before you start to weld while the system is still
cool.
It is impossible to guarantee that bought-in parts are designed and manufac-
tured to meet the demands made on them, or that they satisfy safety require-
ments. Use only original replacement and wearing parts (also applies to
standard parts).
Do not carry out any modifications, alterations, etc. to the device without the
manufacturer's consent.
Components that are not in perfect condition must be changed 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.

13
EN
Safety inspec-
tions
Disposal
Safety symbols
Data protection
Copyright
The manufacturer recommends that a safety inspection of the device is per-
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.
For safety inspections, follow the appropriate national and international stand-
ards and directives.
Further details on safety inspections can be obtained from your service centre.
They will provide you on request with any documents you may require.
To comply with the European Directive 2002/96/EC on Waste Electrical and
Electronic Equipment and its implementation as national law, electrical equip-
ment that has reached the end of its life must be collected separately and re-
turned to an approved recycling facility. 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 Directive may have po-
tentially adverse affects on the environment and your health!
Devices with the CE marking satisfy the essential requirements of the low-volt-
age and electromagnetic compatibility directive (e.g. relevant product norms
from the EN 60 974 series).
Devices with the CSA test mark satisfy the requirements of the relevant stand-
ards in Canada and the USA.
The user is responsible for the safekeeping of any changes made to the fac-
tory settings. The manufacturer accepts no liability for any deleted personal
settings.
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 basis for any claims whatsoever on the part of the pur-
chaser. 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.

14

General information

17
EN
General
Principle The DeltaSpot resistance spot welding system is a revolution in spot welding technology.
The system with continuous process tapes allows you to weld steel, galvanised sheets and
aluminium and to join dissimilar materials such as steel plate and aluminium. The process
tapes protect the electrodes and the materials to be joined and prevent spattering. Another
advantage of DeltaSpot is the additional process heat that is produced from the electrical
resistance of the process tape. The required current quantity can be reduced and energy
consumption lowered significantly.
The continuous advance of the process tape enables spot welds of equally high quality to
be produced.
The result is previously unmatched precision in the welding process, exact quality control
and maximum service life for the electrodes.
Device concept This resistance welding system features
outstanding flexibility and is well able to
cope with challenging jobs. This reason is
thanks to the well thought out design of the
spot welding guns, and the easily controlled
operating procedures.
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
- Domestic appliances industry
- Railway vehicle industry
- Plant, machine and steel engineering
Scope of supply System is supplied with:
- Spot welding gun
- Medium frequency transformer (1000 Hz) water-cooled
- Gun control
- Fronius Xplorer
- DeltaRemote remote control
- DeltaRemote plus remote control (optional)
- Process tape
- Electrodes, water-cooled

18
Information for di-
mensioning the
welding system
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.
The duty cycle (D.C.) is calculated as follows:
D.C. = (t1x 100) / T
t1Duty time, welding time
T Cycle time
D.C. duty cycle
Example:
welding time is 180 ms and the cycle time is 4 s
The duty cycle is therefore:
D.C. = (t1x 100) / T = (0.18 s x 100 %) / 4 s = 4.5 %
and the maximum welding current is 17.8 kA
Diagram for dimensioning the spot welding gun
CAUTION! Overloading the welding system may result in damage to property.
Check the inverter and the transformer are configured correctly for the respective
application.
t1
T
100
Duty cycle X in %
Welding current (A)
4,5 10
1
30000
25000
20000
17,8 kA
15000
10000
5000
0
Transformer limiting
Welding time: 50 Per (1 s)
Welding time: 20 Per (400 ms)
Welding time: 10 Per (200 ms)