FRO­NIUS DeltaSpot User manual

Operating Instructions
Spare Parts List
Resistance welding gun
GB
42,0426,0050,EN 022007
DeltaSpot

ud_fr_st_et_00493 012004
Dear Reader
Thank you for choosing Fronius - and congratulations on your new, technically high-
grade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.
Please also take special note of the safety rules - and observe them! n this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.
Introduction

I
Safety rules
DANGER!
WARNING!
CAUTION!
„NOTE!“ indicates a risk of flawed results and possible damage to the
equipment.
NOTE!
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 opera-
tor,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing
the device must
- be suitably qualified,
- have sufficient knowledge of resistance welding and
- read and carefully follow these operating instructions as well as the
operating instructions for all system components.
The operating instructions must always be at hand wherever the device is
being used. In addition to the operating instructions, generally applicable and
local regulations regarding accident prevention and environmental protection
must be made available and observed.
General remarks
Important!
„DANGER!“ indicates immediate and real danger. If it is not avoided, death
or serious injury will result.
„WARNING!“ indicates a possibly dangerous situation. eath 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.
„Important!“ indicates tips for correct operation and other particularly useful
information. It does not indicate a potentially damaging or dangerous situati-
on.
If you see any of the symbols depicted in the „Safety rules“, special care is
required.

II
The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the welding process described in the
rating plate.
Utilisation for any other purpose, or in any other manner, shall be deemed to
be „not in accordance with the intended purpose“. The manufacturer shall
not be liable for any damage resulting from such improper use.
Utilisation in accordance with the “intended purpose” also comprises
- reading all operating instructions carefully and following them thoroughly
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and servicing work.
The device must not be used for the following applications:
- thawing out pipes
- charging batteries/accumulators
- starting engines
The device is designed for use in industry and the workshop. The manufac-
turer accepts no responsibility for any damage caused through use in living
quarters.
The manufacturer likewise accepts no liability for inadequate or incorrect
results.
Utilisation in
accordance wit
„intended purpo-
se“
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!
General remarks
(continued)
Operation and/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.
Surrounding temperature:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- for 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 2000 m (6500 ft)
Environmental
conditions

III
The operator undertakes to allow only such people to work with the device
who:
- are familiar with the fundamental instructions regarding safety and
accident prevention, and have been instructed how to use the device
- have read and understood the „Safety rules“ section and warning notices
in these operating instructions, and then signed them to confirm this
- 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
t e operator
Before using the device, all persons instructed to do so undertake to:
- follow the basic instructions regarding safety at work and accident
prevention
- read the „Safety rules“ section and warning notices in these operating
instructions, and sign them to confirm that they have understood them
and will follow them.
Before leaving the work area, ensure that no-one or nothing can come to any
harm in your absence.
Obligations of
personnel
Protecting
yourself and
ot ers
Anyone involved with welding exposes themself to numerous risks e.g.:
- flying sparks, hot pieces of metal flying around
- hazardous electromagnetic fields, which risk the lives of those using
cardiac pacemakers
- risk of electrocution from mains current and welding current
- greater noise pollution
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
- harmful welding smoke and gases

IV
The smoke produced during welding contains harmful gases and vapours.
This smoke contains substances which may, under certain circumstances,
cause birth defects or cancer.
Keep face away from welding smoke and gases.
Smoke and hazardous gases,
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Make sure the area is well ventilated.
Otherwise, a protective mask with air supply must be worn.
If there is any doubt about whether the extraction system is powerful enough,
then the measured toxic emission values should be compared with the
permissible limit values.
The following components are responsible, amongst other things, for the
welding smoke’s degree of toxicity:
- 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.
Danger from
toxic gases and
vapours
Keep all persons, especially children, out of the working area while any
devices 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 arc, injury from
sparks, inhaling welding smoke, noise, possible danger from mains or
cutting current, etc),
- provide suitable protective equipment or
- erect suitable safety screens/curtains.
Protecting
yourself and
ot ers
(continued)
Protective clothing refers to a variety of different items. Operators should
- protect eyes and face from UV rays, heat and sparks with regulation
protective visor with filter.
- wear regulation protective goggles with side protection behind the safety
visor.
- wear solid footwear that provides insulation even in wet conditions
- protect the hands with suitable gloves (electrically insulated and providing
protection against heat).
Insulated ear protectors should be worn to reduce the harmful effects of
noise and to prevent injury.

V
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 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.
o not carry out welding on containers which are being or have been used to
store gases, propellants, mineral oils or similar products. Residues pose an
explosive hazard.
Danger from
flying sparks
Risks from mains
current and
welding current
An electric shock can be fatal. Every electric shock is potentially life threate-
ning
o 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 ba-
cking or cover must extend over the entire area between the body and the
earth or ground potential.
All cables and leads must be complete, undamaged, insulated and adequate-
ly dimensioned. Loose connections, scorched, damaged or inadequately
dimensioned cables and leads must be repaired/replaced immediately .
Have the mains and device supply checked regularly by a qualified electrici-
an to ensure the PE conductors are 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 to be gross negligence. The
manufacturer 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.
Wear a safety harness if working at great heights.

VI
Warning, electromagnetic field Electromagnetic fields may pose as yet
unknown risks to health.
It is the operator’s responsibility to ensure that no electromagnetic interfe-
rence occurs in electrical and electronic devices.
If electromagnetic interference is detected, the operator is obliged to take
action 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 components
- power, signal and data transfer lines
- computer and telecommunications devices
- measuring and calibrating devices
- the health of neighbouring persons
Precautions against EMC problems:
a) Mains supply
- if electromagnetic interference arises despite correct mains connection,
additional measures are necessary (e.g. use a suitable line filter).
b) Welding leads
- should be as short as possible
- allow them to run closely together
- keep them far from other leads
c) Potential equalisation
EMC measures
If the following instructions are ignored, meandering welding flows can
develop with the following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to P.E. conductors
- amage to device and other electrical equipment
Meandering
welding flows
Risks from mains
current and
welding current
(continued)
Before working on the device, switch it off and disconnect it from the mains
supply.
Attach a clearly legible and easy-to-understand warning sign to the device to
prevent anyone from reconnecting it to the mains and switching it on again.
After opening the device:
- discharge all components that are electrically charged
- ensure that all components in the device are de-energised.
If work on live parts cannot be avoided, appoint a second person to switch off
the main switch at the right moment.

VII
d) Earthing the workpiece
- If necessary, establish earth connection using suitable capacitors.
e) Screening, if necessary
- screen off other devices nearby
- screen 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 can have serious health conse-
quences for the affected person.
Persons with pacemakers must not remain in the immediate vicinity of
welding operations.
g) Prohibited to persons with metal implants:
Persons with metal implants may not work with a resistance welding
device and must not remain in the vicinity when welding is being carried
out.
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 metal parts:
You should not be carrying watches or metal parts: Watches can be
damaged when operating resistance welding devices.
EMC measures
(continued)
Keep hands, hair, clothing and tools away from moving parts, for example:
- Cogs
- Rollers
- Shafts
-Arms
o not reach into rotating drive parts
anger of crushing
o not place hands or other body parts between the welding electrodes
anger of shearing
Wear safety gauntlets when handling sharp edged objects.
Covers and side panels may only be opened/removed while maintenance or
repair work is being carried out.
uring operation
- ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
Specific azar-
dous areas

VIII
Specific azar-
dous areas
(continued)
Use only suitable load-carrying equipment 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.
anger of scalding from escaping steam. Switch off cooling unit before
detaching water feed or return lines.
Special provisions apply in areas at risk of fire or explosion - observe rele-
vant national and international regulations.
Never touch the workpiece, electrodes or process tape during or after wel-
ding - risk of burns.
Welding residues can jump off cooling work pieces. 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 pro-
tected.
Welding electrodes, process tape and other parts with a high operating
temperature must be allowed to cool down before handling.
Safety measures
at t e installation
location and
during transport
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 requirements.
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 a gap of 0.5 m (1.6 ft.) all round
so that cooling air can enter and exit unhindered.
When transporting the device, observe the relevant national and local guideli-
nes 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, and before commissioning, you MUST carry out
a visual inspection to check whether it has been damaged in any way. Any
damage must be repaired by trained service personnel before commissio-
ning takes place.

IX
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 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 endange-
red.
- Check the device at least once a week for obvious damage and 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 ac-
cepts no liability. In addition, all warranty claims are forfeited.
- Check the coolant level before you start to weld while the system is still
cool.
Safety measures
in normal mode
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).
o not carry out any modifications, alterations, etc. 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.
Maintenance and
repair
The operator is obliged to arrange a safety inspection of the device at least
once every 12 months.
A safety inspection must be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed and after any conversions
- after repair, care and maintenance
- at least every twelve months.
For safety inspections, follow the appropriate national and international
standards 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 re-
quire.
Carrying out a
safety inspection

X
evices with the CE mark satisfy the fundamental requirements of the low-
voltage and electromagnetic compatibility directive.
Safety
evices with the CSA test mark satisfy the requirements of the relevant
standards in Canada and the USA.
The user is responsible for the safekeeping of any changes made to the
factory settings. The manufacturer accepts no liability for any deleted perso-
nal settings.
Data protection
Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of going to
print. Subject to change without notice. The contents of the operating instruc-
tions shall not provide the basis for any claims whatever on the part of the
purchaser. We are grateful for any suggestions for improvement and for
drawing our attention to any errors in these instructions.
Copyrig t
o not dispose of this device with normal domestic waste!
To comply with the European irective 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 facility Any device that you no longer
require must be returned to our agent, or find out about the approved collec-
tion and recycling facilities in your area.
Ignoring this European irective may have potentially adverse affects on the
environment and your health!
Disposal

1
Contents
General remarks ........................................................................................................................................... 3
Principle ................................................................................................................................................... 3
Device concept......................................................................................................................................... 3
Areas of utilisation .................................................................................................................................... 3
Scope of supply ........................................................................................................................................ 4
Information for dimensioning the welding plant ........................................................................................ 4
System components ...................................................................................................................................... 6
General remarks ...................................................................................................................................... 6
Overview of system components ............................................................................................................. 7
Delta Control connections ........................................................................................................................ 8
Controls and connections .............................................................................................................................. 8
General remarks ...................................................................................................................................... 8
DeltaControl controls ................................................................................................................................ 8
Welding transformer connections .......................................................................................................... 10
Welding gun connections ........................................................................................................................ 11
Mechanical components ........................................................................................................................ 12
Delta Remote control ............................................................................................................................. 14
DeltaRemote Plus remote control .......................................................................................................... 15
Before commissioning ................................................................................................................................. 17
General remarks .................................................................................................................................... 17
Utilisation in accordance with „intended purpose“ .................................................................................. 17
Machine set-up regulations .................................................................................................................... 17
Mains connection ................................................................................................................................... 17
Guidelines for system cooling ................................................................................................................ 18
Transformer PE conductor connection ................................................................................................... 18
Commissioning ........................................................................................................................................... 19
General remarks .................................................................................................................................... 19
Connecting DeltaControl ........................................................................................................................ 19
Connecting the welding gun ................................................................................................................... 20
Connecting to cooling water supply ........................................................................................................ 20
Threading up process tape .................................................................................................................... 21
Move to reference point ......................................................................................................................... 22
Sheet thickness correction ..................................................................................................................... 23
DeltaSpot resistance spot welding .............................................................................................................. 25
General remarks .................................................................................................................................... 25
Process tape consumption ..................................................................................................................... 25
Holder adjustment .................................................................................................................................. 26
Influence of the process tape on the welding process ........................................................................... 27
Holder control / Fronius Xplorer .................................................................................................................. 28
General remarks .................................................................................................................................... 28
System overview .................................................................................................................................... 28
Configuring DeltaSpot ............................................................................................................................ 29
Calibrating welding guns ........................................................................................................................ 31
Overview of options ................................................................................................................................ 31
Program options ..................................................................................................................................... 32
Status options......................................................................................................................................... 33
Diagnosis view ....................................................................................................................................... 34
Creating welding parameters in program editor .......................................................................................... 35
Opening program editor ......................................................................................................................... 35
Symbols used in program editor ............................................................................................................ 35

2
Creating current/force profile ................................................................................................................. 36
Editing current/force profiles .................................................................................................................. 36
Exiting program editor ............................................................................................................................ 36
Program presettings ............................................................................................................................... 37
Signal description ........................................................................................................................................ 38
General remarks .................................................................................................................................... 38
Description of signal inputs .................................................................................................................... 38
Description of signal outputs .................................................................................................................. 39
Data in process image, inputs ................................................................................................................ 39
Data in process image, outputs .............................................................................................................. 40
Signal waveform .......................................................................................................................................... 41
Move to reference point ......................................................................................................................... 41
Start welding with external position specification ................................................................................... 41
External position check .......................................................................................................................... 42
Reset error ............................................................................................................................................. 42
Replace wearing parts ................................................................................................................................. 43
General remarks .................................................................................................................................... 43
Instructions for storing and assembling process tapes .......................................................................... 43
Loading new process tape ..................................................................................................................... 44
Adjusting process tape brake ................................................................................................................. 46
Replacing electrodes .............................................................................................................................. 46
Adjusting holder arms ............................................................................................................................ 48
Troubleshooting........................................................................................................................................... 49
General remarks .................................................................................................................................... 49
Troubleshooting ..................................................................................................................................... 49
Description of error signals .................................................................................................................... 50
Description of warning signals ............................................................................................................... 52
Care, maintenance and disposal ................................................................................................................. 53
General remarks .................................................................................................................................... 53
Every start-up ......................................................................................................................................... 53
Every time you change an electrode ...................................................................................................... 53
Disposal ................................................................................................................................................. 53
Technical Data ............................................................................................................................................. 54
Special voltages ..................................................................................................................................... 54
TR-Unit ................................................................................................................................................... 54
DeltaSpot welding gun............................................................................................................................ 55
Spare parts lists
Fronius worldwide

3
General remarks
Principle The DeltaSpot resistance spot welding system is a revolutionary system in spot welding
technology. The newly developed system with continuous process tapes
allows you to welded steel, galvanised sheet and aluminium and to mix materials such
as steel plate with aluminium. The process tapes protect the electrodes and the materi-
als to be joined and prevent spattering.
The continuous advance of the process tape enables spot welds of equally high quality
to be produced throughout several shifts.
The result is previously unmatched precision in the welding process, exact quality control
and maximum service life for the electrodes.
Device concept
This new 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
welding guns, and the easily controlled operating procedures.
The system also enables every single spot weld within an ongoing production run to be
detected and analysed.
The optional integration of the quality assurance system „QMaster“ allows continuous
monitoring of the ongoing process. Welding faults can therefore be recognised quickly,
thereby reducing costly subsequent quality checks.
Areas of utilisati-
on
The DeltaSpot spot welding process is designed for joining two or more sheets of stan-
dard coated or uncoated steels and all standard aluminium alloys. It is also ideal for
welding different combinations and thicknesses of materials (Usibor, CrNi, etc.).
Main application areas:
- Automobile and component supply industry
- Domestic appliances industry
- Aircraft construction
- Plant, machine and container construction, steel engineering
Fig.1 X-welding gun

4
Information for
dimensioning the
welding plant
To prevent components from being overloaded, it is necessary to define the load capaci-
ty 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 is calculated as follows:
CAUTION! Overloading the welding plant may result in damage to property.
Check the inverter and the transformer are configured correctly for the re-
spective application.
X =
t1 x 100
T
t1Duty time, welding time
T Duration
X On-time t1
T
Scope of supply System is supplied with:
- Holder main body x 500 + arms, sandwich design
- Medium frequency transformer (1000 Hz) water-cooled
- Holder drive
- Servo-electric holder adjustment
- Holder control
- Industrial PC for graphical display of control functions (Fronius Xplorer)
- DeltaRemote remote control
- DeltaRemote plus remote control (optional)
- Quality assurance system (optional)
- Process tape
- Electrodes, water-cooled
- Guide bushes
- Elastomer springs

5
0
5000
10000
15000
20000
25000
30000
110 1004,5
On-time X in %
Welding current (A)
Example:
The welding time is 180 ms and cycle time is 4 s
The on-time is accordingly ED = t1/ T x 100 % = 0.18 s / 4 s x 100 % = 4.5 %
Transformer limiting
Welding time: 50 Per (1s)
Welding time: 20 Per (400 ms)
Welding time: 10 Per (200 ms)
17.8 kA
Information for
dimensioning the
welding plant
(continued)
Fig.2 Diagram for dimensioning the welding gun

6
System components
General remarks Using the medium frequency technique the weight of the welding transformer can be
significantly reduced.
Reaching a greater operating frequency with medium frequency welding can result in a
significant reduction of the weight and volume of the welding transformer.
Control unit
50 / 60 Hz
3
+
MF-inverter Transformer
commutator
Welding
apparatus
Fig. 3 Construction of 1 kHz medium frequency DC welding system
The 50/60 Hz AC mains voltage is converted to DC voltage via a bypass rectifier. The
transistorised H-bridge circuit transfers the direct current to the welding transformer at a
frequency of 1 kHz. The welding current is rectified in the welding transformer.