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.