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Fronius DeltaSpot G2, Operating Instructions And Spare Parts List

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Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

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Perfect Welding

 / Solar Energy

42,0426,0242,EN 012-09052019

DeltaSpot
Stationary welding system

Operating Instructions
Spare parts list

Resistance welding

EN

Summary of Contents for DeltaSpot G2

Page 1: ...e free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0242 EN 012 09052019 DeltaSpot Stationary welding system Operating Instructions Spare parts list Resistance welding EN ...

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Page 3: ... 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 ...

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Page 5: ...imensioning 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 ...

Page 6: ...s 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 6...

Page 7: ...e 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 no...

Page 8: ...eople 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 ...

Page 9: ...et 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...

Page 10: ...es 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 a...

Page 11: ...ing 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 nation...

Page 12: ...efficient 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 infor...

Page 13: ...pean 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 electromag...

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Page 15: ...General information ...

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Page 17: ...pliances 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...

Page 18: ...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 dut...

Page 19: ... 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 s...

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Page 21: ...rom the wire feeder and the welding process Danger of death from electrical voltage The areas bearing this symbol contain parts under high voltage An electric shock can be fatal The areas concerned must not be opened by unauthorised personnel Risk of injury from hot surfaces The parts housing or drives carrying this symbol get hot when in use for a long time If touched they can cause burns to hand...

Page 22: ...vice or any welding that is in progress Maintain as large a distance as possible between the power cables and the head torso Risk due to incorrect operation The DeltaSpot welding system may only be operated by one person at a time Risk of skin injuries or burns due to weldments High levels of residual heat may be generated when welding Falling compo nents can cause severe injuries to feet Wear app...

Page 23: ...tal led vertically The mounting surface must be able to safely withstand dead weights and per mitted loads Units bolted to the floor must be secu red with four heavy duty anchors see manufacturer s installation instructions at the points provided for this purpose 1 An adequate and suitable fastening method must be used Check the device for possible damage at regular intervals ...

Page 24: ...o the welding transformer at a frequen cy of 1 kHz The welding current is rectified in the welding transformer System compo nents overview Overview of system components Control unit MF inverter Welding unit 3 50 60 Hz Transformer Rectifier GunControl 0 1 Higher level control e g SPS field bus gun control cooling unit cooling network welding system spot welding gun Inverter Fronius Xplorer coolant ...

Page 25: ...Control elements and connections ...

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Page 27: ...quipment incorrectly can cause serious injury and damage Do not use the functions described until you have thoroughly read and understood the fol lowing documents these operating instructions all the operating instructions for the system components especially the safety rules GunControl 110 230 controls No Function 1 Main switch to switch on the gun controller 2 keylock switch mode only with C gun...

Page 28: ...ND EXTERNAL OUT N RESET_B1 P RESET_B2 X3 Coolant flow controller connection socket for connecting the coolant flow controller Pin assignment A 24 V output for flow controller B Flow controller feedback signal C GND for flow controller X4 Digital power source connection socket for connecting digital power source signals Pin assignment A GND GunControl B 24 V Start welding C Welding current on off D...

Page 29: ... incorrectly can cause serious injury and damage The design of external operating equipment or Emergency Stop actuators must comply with applicable national and international standards X6 Analogue power source connection socket for connecting analogue power source signals Assign ment Colour Connection cable A Yellow pin secondary voltage welding transformer B Green pin secondary voltage welding tr...

Page 30: ...al PC Key ext Plug for optional external keylock switch F1 Power supply fuse 10 A T F2 48 V fuse 8 A F F3 GunControl bus coupler 24V supply fuse 3 15 A T F4 DeltaSpot spot welding gun 24V supply fuse 1 A T F5 Keylock switch fuse 1 A T F6 External 24 V power supply fuse 1 A T F7 Welding voltage measurement fuse 1 A T ...

Page 31: ...former connec tions Welding transformer connections No Function 1 Transformer primary connection for transformer power supply 2 Transformer measuring signal connection for connection of welding control 3 Coolant flow connection 4 Coolant return connection 1 2 3 4 ...

Page 32: ...Main drive 3 Tape spool device for holding used and unused process tape 4 Controls on the welding system 5 Hydraulic height adjustment of movable arm 6 Electrode shaft 7 Height adjustment of fixed arm 8 Cooling water connection with flow watchdogs 1 3 7 8 2 3 4 6 5 ...

Page 33: ...hat have occurred None of the controls on the front of the remote control will work unless one of the two en abling buttons on the back is pressed at the same time If neither of the enabling buttons is pressed while in manual mode the safety circuit will be broken and the drives will stop 1 Open and close spot welding gun switch for manually opening and closing the spot welding gun 2 Process tape ...

Page 34: ...un and C gun will be simulated without current but with a prede fined force profile Welding after pressing the RUN button 32 welding will begin using a welding program with predefined parameters 10 Left right enabling buttons IMPORTANT Always check the enabling button before switching on the remote control Unless one of the enabling buttons is pressed at the same time the con trols on the front of...

Page 35: ...Start up ...

Page 36: ......

Page 37: ... 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 The spot welding gun is designed exclusively for resistance welding Any use above and beyond this purpose is deemed improper The manufacturer shall not be liable for any damage resulting from such improper use Proper use also includes complying with a...

Page 38: ...pply side is required Operation on systems with normal residual current circuit breakers is not permitted as fault currents could flow back from the intermediate circuit via the earth to the mains without the residual current circuit breaker being triggered If you use a fault current protection device on the power supply side this must be de signed for operation with medium frequency systems with ...

Page 39: ...tween the primary and sec ondary power circuits National and international standards and guidelines must be observed The plant operator is responsible for the implementation and operation of the system The medium frequency transformer is supplied with the additional safety feature of a di rect PE conductor connection as follows PE conductor bridge MPE between the secondary circuit of the medium fr...

Page 40: ...ctioning MPE bridge renders the direct PE conductor connection safety meas ure ineffective A failure of insulation primary secondary circuit can therefore be life threatening Do not start a system with direct PE conductor connection if the check revealed any prob lems ...

Page 41: ...age All connections must be made by trained and qualified personnel in compliance with the relevant safety regulations Note the safety rules in the operating instructions Connecting the remote control 1 Establishing the coolant connec tions NOTE Inadequate cooling can cause material damage Never operate the welding system without adequate cooling The manufacturer shall not be liable for damage cau...

Page 42: ...42 Threading the process tape Threading the process tape at the top 2 3 4 5 6 3 4 5 6 7 ...

Page 43: ...43 EN Threading the process tape at the bottom 7 8 9 10 8 9 10 11 ...

Page 44: ... stay within the working area of the robot NOTE Please note that the integrated Emergency Stop function in the robot control directly affects the RemoteControl Pro To determine the position of the gun arm after switching on the system the gun arm must be fully opened A sensor detects the homing position and releases the gun for the welding process RemoteControl Pro functions After switching on the...

Page 45: ...Spot welding ...

Page 46: ......

Page 47: ...nes that start up automatically can cause serious injury and damage In addition to these operating instructions the safety rules issued by the manufacturer of the robot and welding systems must also be observed For your personal safety ensure that all protective measures have been taken and will remain in place for the duration of your stay within the working area of the robot Process tape con sum...

Page 48: ...of process tape results in additional resistances being generated between the electrodes and the workpiece The welding current required is much lower than with con ventional spot welding due to the increased efficiency The lower welding current and the type of alloy used in the process tape provide controlled heat input and control over the position and shape of the weld nugget 2 2 3 ...

Page 49: ...als material thicknesses and different process tapes Example a process tape with higher resistance R1 R2 Material resistances of the electrode R3 R4 Contact resistances between electrode and process tape R5 R6 Material resistances of process tape R7 R8 Contact resistances between process tape and workpiece R9 R10 Material resistances of the workpiece R11 Contact resistance from workpiece to workpi...

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Page 51: ...Troubleshooting and maintenance ...

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Page 53: ...ease note the follow ing recommended environmental conditions for storage Store process tapes only in the original packaging vacuum packed The temperature in the storage location should not exceed 35 C 95 F When loading a new process tape note the following Do not remove process tapes from their packaging until they are required Wear oil and grease free gloves Dust and dirt free environment Do not...

Page 54: ...ing de vice 4 5 CAUTION Danger of serious material damage resulting from ejection of process tape due to incorrect closing of holders and process tape spooling device Before commissioning make sure that all parts are correctly closed and intact Never use a spot welding gun with defective closures 1 2 3 4 3 sec 5 ...

Page 55: ...oo slack 2 Process tape brake slack turn in direction Process tape brake too tight turn in direction 3 Process tape brake slack turn in direction Process tape brake too tight turn in direction 4 IMPORTANT If the spring is noticeably compressed when feeding the process tape then the pro cess tape brake is too tight Procedure for process tape brakes that are too loose 1 Turn the screw anti clockwise...

Page 56: ...ion 2 Manually feed in a short section of process tape 3 Check that the process tape brake is set correctly If not repeat steps 1 and 2 Replacing elec trodes Switch off the coolant supply CAUTION Danger of burns from hot coolant Before changing the electrodes turn off the coolant supply 1 2 3 4 1 3 4 5 6 ...

Page 57: ...o ensure that the electrode is held se curely Adjusting the gun arms IMPORTANT After replacing an electrode check that the electrodes are aligned with each other If necessary adjust the gun arm IMPORTANT Only loosen the hexagon bolts step 1 do not remove them You will not be able to adjust the arm if the screws are removed Upper gun arm 1 2 7 8 1 2 ...

Page 58: ...58 3 4 Lower gun arm 1 2 3 3 4 1 2 3 ...

Page 59: ...age Cause Welding lead break Remedy Check leads and contacts Insufficient welding power Cause Faulty contacts Remedy Check contacts Cause Defective diode Remedy Replace the welding transformer Cause Transformer supply too weak Remedy Ensure transformer supply complies with technical data Temperature sensors trip Cause Dimensioning error Remedy Dimension transformer correctly for the application Ca...

Page 60: ...ompensation for the required applications operating range 10 15 from top dead centre Check tape transport brake setting Check wear on tape guide caps tape must not be in contact with the electrode during tape feed Check that the tape spooling device lock is firmly seated When welding with adhesive clean the tape feed mechanism with a detergent rec ommended by the adhesive manufacturer General visu...

Page 61: ...eck the individual circuits check the LED indicators of the flow sensors Check plug connections for corrosion After250 000spot welds Lubricate the main drive via the grease nipple with 1 5 cm of KPF2N 30 DIN 51502 lu bricant mineral oil soap based lithium with EP additives and MoS2 Item number of lubri cant 40 0009 0132 Disposal Dispose of in accordance with the applicable national and local regul...

Page 62: ...temperature max 30 C 86 F max 30 C 86 F Differential pressure at 8 0 l min 2 11 gal min 1 6 bar 1 bar Current measuring coil 150 mV kA 150 mV kA Temperature monitor NC transformer 1 x 140 C 284 F 1 x 150 C 284 F Temperature monitor NC rectifier 1 x 80 C 176 F 1 x 80 C 176 F Insulation class F F Weight 29 kg 63 9 lb 20 kg 44 1 lb Power supply U1N 400 V 3 50 Hz Power supply U2N 230 V 1 50 Hz Gun wei...

Page 63: ...Appendix ...

Page 64: ...F5 F6 F4 F7 HOWD RQWURO HOWD RQWURO 9 GunControl 110V 230V 3 4 8 V 1 5 A 2 4 V 5 A 㻮 㻱 㻯 㻷 㻴 㻻 㻲 㻲 㻮㻷 㻡㻝 㻝㻜 1 SROLJ SROLJ 7 9 7 9 7 9 7 9 7 9 7 9 VSHFLI OHQJWK VSHFLI OHQJWK 7 9 LHOGEXV 1RSHQ HYLFH1HW 3URILEXV QWHUEXV 17 DVW FDUG FDUG 4 300 011 ...

Page 65: ...chpaket 5m 70mm Verbindung Schlauchpaket 10m 70mm Verbindung Schlauchpaket 20m 70mm JUHHQ UHG 7DE 7DE 7DE 7DE VSHFLI OHQJWK VSHFLI OHQJWK VSHFLI OHQJWK VSHFLI OHQJWK VSHFLI OHQJWK VSHFLI OHQJWK 9 PPÕ 9 PPÕ VSHFLI OHQJWK VRFNHW 3 PPÕ 3 PPÕ PPÕ 3 PPÕ PPÕ 3LQV LQFO 3LQV 4 051 001 4 051 002 4 051 003 4 051 004 4 051 005 4 051 006 ...

Page 66: ...66 DRPDS1 0 RemoteControl PRO VSHFLI OHQJWK 4 300 006 ...

Page 67: ...sistance welding device which is explicitly referred to by this Declaration meet the following directives and standard s Directive 2006 42 EC Machinery Directive Directive 2004 108 EC Electromag compatibility Directive 2006 95 EC Low Voltage Directive European Standards including relevant amendments EN ISO 12100 EN 62135 1 EN 62135 2 2008 Documentation evidencing conformity with the requirements o...

Page 68: ...RNATIONAL GMBH Vorchdorfer Straße 40 A 4643 Pettenbach Austria E Mail sales fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and locations ...

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