Fronius DeltaSpot Operating Instructions/Spare Parts List Download Page 3 | Manualshive

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EN

Dear reader,

Introduction

Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.

Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.

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Summary of Contents for DeltaSpot

Page 1: ...Battery Charging Systems Welding Technology Solar Electronics 42 0426 0050 EN 001 02042012 DeltaSpot Operating Instructions Spare parts list Resistance welding EN...

Page 2: ...0...

Page 3: ...h 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...

Page 4: ...2...

Page 5: ...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 ov...

Page 6: ...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...

Page 7: ...r 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 invol...

Page 8: ...e 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 ran...

Page 9: ...sor 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 elec...

Page 10: ...e 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 no...

Page 11: ...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 i...

Page 12: ...lants 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 e...

Page 13: ...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 Specia...

Page 14: ...arty 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...

Page 15: ...at 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...

Page 16: ...14...

Page 17: ...General information...

Page 18: ......

Page 19: ...ity 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 tha...

Page 20: ...calculated as follows D C t1 x 100 T t1 Duty 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 t1 x 100 T 0 18 s x...

Page 21: ...stem The 50 60 Hz AC mains voltage is converted to DC voltage via a bypass rectifier The tran sistorised H bridge circuit transfers the DC voltage to the welding transformer at a frequen cy of 1 kHz T...

Page 22: ...20...

Page 23: ...Control elements and connections...

Page 24: ......

Page 25: ...n your unit that are not described in these operating instructions or vice versa Certain illustrations may also differ slightly from the actual control elements on your device but these control elemen...

Page 26: ...he robot installation panel Pin configuration A 24 V output for flow controller B Flow controller feedback signal C GND for flow controller X4 Digital power source connector for connecting digital pow...

Page 27: ...ge The de sign of external operating equipment or Emergency Stop actuators must com ply with valid national and international standards X6 Analogue power source connector for connecting analogue power...

Page 28: ...24 V START SIGNAL NC NC A B C D E E F K2 K2 A1 A2 A1 A2 K1 11 12 14 K1 21 22 24 K2 31 32 34 G H J K L M N GND extern A B C D 24 V FLOW Controller GND A B Q x5 START Extern X3 Anschluss Durchfluss berw...

Page 29: ...ansformer power supply 5 Ground strap 6 Connection pin Welding gun cooling water connections Connections for cooling water No Function 1 Cooling water flow connection on moving gun arm 2 Cooling water...

Page 30: ...s 3 Process tape securing device prevents process tape from unrolling by itself 4 Process tape brake 5 Process tape spooling device with drive to hold used process tape 6 Electrode shaft 7 Spring 8 Pr...

Page 31: ...r adjusting to different sheet thicknesses 14 Console with transformer and control box Welding gun adjustment 15 Welding gun adjustment to compensate for component tolerances or positional differences...

Page 32: ...r distribution block 4 Process tape holder for holding the process tape 5 Main drive 6 Process tape spooling device with drive to hold used process tape 7 Sheet thickness correction for adjusting to d...

Page 33: ...31 EN Welding gun adjustment 11 Welding gun adjustment to compensate for component tolerances or positional differences 12 Welding gun adjustment drive 11 12...

Page 34: ...reload process tape manual spot welding within predefined parameters reset faults that have occurred WARNING Machines that start up automatically can cause serious injury and damage In addition to the...

Page 35: ...weld In manual mode program 0 is tested automatically 5 Move to reference point key to define a reference point before starting the welding operation 6 Reference point LED lights up as soon as the ref...

Page 36: ...34...

Page 37: ...Start up...

Page 38: ......

Page 39: ...nforms to national standards Guidelines for system cooling The cooling liquid supply the purity of the coolant and the differential pressure in the cool ing water system must always be checked before...

Page 40: ...witching point of a flow controller on a gun arm is approx 4 0 l min 1 0 gal min The switching point of a flow controller on a transformer can be found in the transformer data sheet IMPORTANT The flow...

Page 41: ...safety measure ineffective even if the MPE bridge is installed correctly A failure of insulation primary secondary circuit can therefore be life threatening If compensating currants cannot be avoided...

Page 42: ...s connected to the mains electricity supply during installation there is a high risk of very serious in jury and damage Disconnect from the power supply before carrying out any work on the device WARN...

Page 43: ...ot welding gun Establish a CAN connection between the PC and the CAN connector 1 Plug DeltaSpot welding gun 2 main connector into connection X1 1 Flow controller connection upper lower gun arm and wel...

Page 44: ...I O module ZFMMPX HSFFO XIJUF CSPXO QJOL HSFZ 9 ZFMMPX HSFFO 1 3 4 5 PS5 EA Disk 1 9 9 9 9 9 9 9 9 4USBOE 9 9 POUSPM MJOF JOWFSU N QJO POUSPM MJOF JOWFSU N QJO GPS QPXFS TPVSDF 4UBSU XFMEJOH 8JUI XJU...

Page 45: ...oading the proc ess tape for the X gun Place the robot in the change position tip sideways so that the process tape cannot fall out during operation 1 Bus Manuel 1 2 2 1 2 3 3 1 2 3 4 1 5 2 3 4 1 6 2...

Page 46: ...oc ess tape for the C gun upper hold er Place the robot in the change position tip sideways so that the process tape cannot fall out during operation 1 2 3 click 8 click 5 9 1 Bus Manuel 1 2 2 1 1 2 3...

Page 47: ...45 EN 1 6 1 2 3 7 1 1 8 1 9 1 2 10 1 11 11...

Page 48: ...oading the proc ess tape for the C gun lower holder Place the robot in the change position tip sideways so that the process tape cannot fall out during operation 1 1 2 1 2 3 3 3 1 2 4 1 5 5 3 4 2 1 4...

Page 49: ...welding systems must also be observed For your personal safety ensure that all protective measures have been taken and will re main in place for the duration of your stay within the working area of th...

Page 50: ...The closed position depends on the thickness of the sheets being welded Detail showing welding gun drive in the X gun opera ting range 1 Operating range 10 15 from top dead centre 2 0 10 top dead cent...

Page 51: ...49 EN X gun Open sheet thickness correction completely C gun Open sheet thickness correction completely Click on Start button 1 1 2 3 2 3 4...

Page 52: ...ontrol The spot welding gun closes until the electrodes are at a predefined distance Hold the workpiece to be welded between the electrodes X gun Adjust the sheet thickness correction until both elec...

Page 53: ...outside the defined operating range Fronius Xplorer 4 will issue a warning signal The warning is listed in the status worksheet Operating point is outside the defined operating range Enter the offset...

Page 54: ...52...

Page 55: ...Spot welding...

Page 56: ......

Page 57: ...eously In this case one of the gun arms usually makes contact with the component first and stops the closing process The second gun arm continues to close until it also comes into contact with the com...

Page 58: ...f welding gun adjustment is deactivated the gun arm is fixed when you switch on the sys tem During the welding process the electrode force is applied via the other gun arm while the fixed gun arm func...

Page 59: ...lding Weld nugget formation with multi sheet joints 1 Weld nugget formation when using different materials material thicknesses and the same process tape alloys 2 Weld nugget formation when using diff...

Page 60: ...58...

Page 61: ...Troubleshooting and maintenance...

Page 62: ......

Page 63: ...nel in compliance with the relevant safety regulations Note the safety rules in the operating instruc tions IMPORTANT Check electrodes for wear and replace if necessary each time a new proc ess tape i...

Page 64: ...n point is reeled onto the tape reeling de vice 1 Bus Manuel 1 2 2 1 2 3 3 1 1 4 1 5 2 1 6 1 2 2 7 CAUTION Danger of serious material damage resulting from ejection of process tape due to incorrect cl...

Page 65: ...1 1 2 3 9 2 1 4 click 3 5 10 1 2 3 click 11 11 CAUTION Risk of injury from springiness of spooled process tape To avoid in juries caused by the process tape springing back hold the end of the tape fir...

Page 66: ...4 1 5 2 1 6 2 2 1 7 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 su...

Page 67: ...n Process tape brake slack turn in direction Process tape brake too tight turn in direction 2 1 4 click 3 5 10 IMPORTANT The process tape must fit snugly but not be under tension A tensioned process t...

Page 68: ...rew clockwise half a turn direction 2 Manually feed in a short section of process tape 3 Check that the process tape brake is correctly set If not repeat steps 1 and 2 Replacing elec trodes Move the r...

Page 69: ...ushing in the new electrode to ensure that the electrode is held securely IMPORTANT After changing an electrode check that the electrodes are aligned with each another If necessary calibrate the gun a...

Page 70: ...TANT After changing an electrode check that the electrodes are aligned with each another If necessary calibrate the gun arm 1 1 2 2 2 IMPORTANT Only loosen the hexagon bolts step 1 do not remove them...

Page 71: ...69 EN 3 11 Nm 3 4 4 5 5 5 6 24 Nm 6...

Page 72: ...ttings current too high or incorrect tape type Remedy Correct parameter settings clean electrodes and reload process tape check tape type and replace if necessary Cause No coolant flow Remedy Ensure c...

Page 73: ...Check cooling pipe setting Check ease of movement location and contamination of tape guide rollers Check that screws are firmly seated Check that plug connections are firmly seated Check cables for d...

Page 74: ...72 Disposal Dispose of in accordance with the applicable national and local regulations...

Page 75: ...r 1 x 80 C 1 x 80 C Insulation class F F Weight 29 kg 20 kg Spot welding gun C70 C300 X350 X500 X750 Gun force 6 kN 8 kN 7 kN 5 kN 3 kN Cooling water quantity head arm 4 0 l min 1 06 gal min 4 0 l min...

Page 76: ...8 kg 59 1 lb Installation kit 130 kVA X Gun 4 100 555 22 4 kg 49 4 lb Installation kit 130 kVA C Gun 4 100 593 25 3 kg 55 8 lb 130 kVA MF transformer 42 0411 0032 20 0 kg 44 1 lb 250 kVA MF transforme...

Page 77: ...Appendix...

Page 78: ...peciales ver la hoja adjunta PB Em caso de vers es especiais vide a folha anexa 130kVA 42 0411 0032 42 0411 0059 250kVA 42 0201 2500 43 0009 0059 42 0201 3454 C 43 0004 2815 42 0201 3457 42 0201 3462...

Page 79: ...50 Elektrode Expo R 70 Elektrode R 40 Elektrode R 70 Elektrode Expo R 100 16mm Elektrode R 20 A 43 0004 2926 16mm B 42 0001 6051 44 3000 0068 MS 42 0404 0383 A B 42 0402 0252 42 0001 3678 X500 X750 44...

Page 80: ...2 0001 6051 44 3000 0068 DE Bei Sonderausf hrungen siehe Beiblatt EN In the case of special versions see insert FR En cas des constructions sp ciales voir notice IT In caso di versioni speciali vedere...

Page 81: ...0138 Z SB50 PKS1 43 0001 1251 44 3000 0124 BE2 0201 2556 43 0001 1233 43 0001 1253 42 0402 0233 44 3000 0056 Z 43 0011 0054 42 0403 0139 42 0201 2026 43 0001 1251 44 3000 0139 BE2 0201 2556 43 0001 12...

Page 82: ...1 2 M22x1 5I 1 2 M22x1 5I 90 42 0001 3676 42 0001 3658 40 0001 0479 42 0407 0273 42 0401 1080 42 0401 0874 42 0300 2787 42 0401 1036 42 0001 3713 42 0201 2879 42 0001 3652 42 0001 3712 42 0001 3739 X...

Page 83: ...018 0060 41 0018 0036 4 060 152 43 0004 2951 43 0004 2866 41 0018 0049 4 300 002 4 300 004 KL 1408 KL 1408 KL 2408 KL 4001 KL 3061 KL 9010 CAN 48V 15A 24V 5A 41 0007 0176 41 0007 0160 41 0007 0160 41...

Page 84: ...1 A 4600 Wels Austria Tel 43 0 7242 241 0 Fax 43 0 7242 241 3940 E Mail sales fronius com www fronius com www fronius com addresses Under http www fronius com addresses you will find all addresses of...

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