/ Perfect Charging / Perfect Welding / Solar Energy
DeltaCon Stationary System
Operating Instructions
Resistance welding
EN-US
42,0426,0313,EA 002-29112018
2
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 familiarize yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features your Fronius product 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.
EN-US
Explanation of
Safety Instructions
DANGER!
Indicates an immediate danger.
► Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
► Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
► Minor injury or damage to property may result if appropriate precautions are not taken.
NOTE!
Indicates the possibility of flawed results and 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.
If you see any of the symbols depicted in the "Safety Rules," special care is required.
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Contents
Safety Instructions ..................................................................................................................................... 7
General ................................................................................................................................................. 7
Intended Use......................................................................................................................................... 7
Grid Connection .................................................................................................................................... 7
Environmental Conditions ..................................................................................................................... 8
Obligations of the Operating Company................................................................................................. 8
Obligations of Personnel....................................................................................................................... 8
Personal Protection and Protection of Others....................................................................................... 8
Danger from Toxic Gases and Vapors.................................................................................................. 9
Danger from Flying Sparks ................................................................................................................... 9
Risks from Mains Current and Welding Current ...................................................................................10
EMC Device Classifications .................................................................................................................. 10
EMC Measures ..................................................................................................................................... 10
EMF measures...................................................................................................................................... 11
Particular Hazard Areas........................................................................................................................ 11
Safety Measures at the Setup Location and During Transport ............................................................. 12
Safety Measures in Normal Operation.................................................................................................. 12
Maintenance and repair ........................................................................................................................ 13
Safety Inspection .................................................................................................................................. 13
Disposal ................................................................................................................................................ 13
Safety Symbols ..................................................................................................................................... 13
Backup .................................................................................................................................................. 14
Copyright............................................................................................................................................... 14
General Information 15
EN-US
General ...................................................................................................................................................... 17
Device Concept..................................................................................................................................... 17
Applications........................................................................................................................................... 17
Warning Notices on the Device............................................................................................................. 18
Information on the Dimensioning of the Welding System ..........................................................................20
General ................................................................................................................................................. 20
System components .................................................................................................................................. 21
General ................................................................................................................................................. 21
Overview of System Components......................................................................................................... 21
Operating controls, connections and mechanical components 23
DeltaCon Controller ................................................................................................................................... 25
Operating Controls, Connections and Mechanical Components, DeltaCon Controller......................... 25
EMERGENCY STOP connection diagram............................................................................................ 26
Mechanical components ............................................................................................................................ 27
Mechanical Components ...................................................................................................................... 27
Control Box Connections ...................................................................................................................... 29
Remote control
...................................................................................................................................................................
Foot-Operated Remote Control ............................................................................................................ 30
Commissioning 31
Before installation ...................................................................................................................................... 33
Measures to Ensure Safe Operation of the Device when Operating Personnel are Untrained ............ 33
Intended Use......................................................................................................................................... 33
Setup Regulations................................................................................................................................. 33
Grid Connection .................................................................................................................................... 33
Notes on System Cooling ..................................................................................................................... 34
Transformer Ground Conductor Connection......................................................................................... 35
Commissioning .......................................................................................................................................... 37
General ................................................................................................................................................. 37
Overview ............................................................................................................................................... 37
30
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Installing the Stationary Welding System.............................................................................................. 37
Setting Up the Lower Gun Arm ............................................................................................................. 38
Installing the DeltaCon Controller ........................................................................................................ 40
Connecting the DeltaCon Controller to the Grid ................................................................................... 41
Connecting the DeltaCon Controller to the Spot Welding Gun ............................................................. 42
Connecting the Cooling System............................................................................................................ 43
Connecting the Foot-Operated Remote Control ................................................................................... 44
Connecting the EMERGENCY STOP................................................................................................... 44
Troubleshooting and Maintenance 45
Troubleshooting ......................................................................................................................................... 47
General ................................................................................................................................................. 47
Troubleshooting .................................................................................................................................... 47
Service, maintenance and disposal ........................................................................................................... 48
General ................................................................................................................................................ 48
Maintenance Per Shift........................................................................................................................... 48
Weekly maintenance or 50,000 spots................................................................................................... 48
Monthly Maintenance or 200,000 Spots ............................................................................................... 48
Disposal ................................................................................................................................................ 48
Replace wearing parts ............................................................................................................................... 49
Wearing parts........................................................................................................................................ 49
Replacing the Electrode Shaft and Electrodes ..................................................................................... 49
Replacing the Current Line ................................................................................................................... 50
Calibrating the lower gun arm .................................................................................................................... 51
Calibrating the Lower Gun Arm............................................................................................................. 51
Appendix 55
Technical Data ........................................................................................................................................... 57
Special Voltage ..................................................................................................................................... 57
Transformer MFT 184 ........................................................................................................................... 57
DeltaCon Controller .............................................................................................................................. 57
DeltaCon stationary system .................................................................................................................. 58
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Safety Instructions
General The device has been manufactured using state-of-the-art technology and according to rec-
ognized safety standards. If used incorrectly or misused, however, it can cause
- serious or fatal injury to the operator or a third party
- damage to the device and other material assets belonging to the operating company
- inefficient operation of the device.
All persons involved in the commissioning, operation, maintenance, and servicing of the
device must
- be suitably qualified
- have knowledge of welding and
- have completely read and followed these Operating Instructions.
The Operating Instructions must always be at hand wherever the device is being used. In
addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device must
- must be kept in a legible state
- not be damaged/marked
- not be removed
- not be covered, pasted, or painted over.
EN-US
Intended Use
Before switching on the device, remedy any faults that could compromise safety.
Your personal safety is at stake!
The device is to be used exclusively for its intended purpose.
The device is intended exclusively for resistance spot welding (Process 21 as per DIN EN
ISO 4063).
Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose." The manufacturer is not responsible for any damage
resulting from improper use.
Proper use also means
- Reading and adhering to all instructions in the operating instructions
- Reading and adhering to all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work
The device is designed for operation in industrial and commercial environments.
The manufacturer shall not be liable for any damage resulting from use in a residential area.
The manufacturer shall also not be liable for faulty or incorrect work results.
Grid Connection Devices with a high output can influence the energy quality of the grid due to their current
consumption.
This may affect a number of device types in terms of:
- connection restrictions
- criteria regarding maximum permissible grid impedance
- criteria regarding the minimum required short-circuit power
*)
both at the interface with the public grid
See technical data
*)
*)
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In this case, the operator or the person using the device should check whether or not the
device is allowed to be connected, where appropriate through discussion with the power
supply company.
NOTE! Ensure secure grounding of the grid connection.
Environmental
Conditions
Obligations of the
Operating Company
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer accepts no liability for any damage
resulting from improper use.
Temperature range of the ambient air:
- 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 of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 1000 m (3280 ft.)
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations
and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section "Safety Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
Personal Protection and Protection of Others
All persons who are assigned to work with the device must do the following before beginning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and confirm
that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can occur
in one's absence.
You are exposed to hazards while handling the device, for example: Welding spatter
Wear suitable protective clothing when dealing with the device. The protective clothing
must have the following properties:
- Flame resistant
- Insulating and dry
- Covering the entire body and in good condition with no damage
- Cuffless pants.
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Protective clothing involves the following:
- Protecting eyes by wearing regulation-compliant safety glasses
- Wearing rigid, wet-insulating footwear
- Protecting hands with appropriate gloves (featuring electrical insulation, thermal protection, and protection against cutting injuries)
- Wearing ear protection to reduce noise exposure and protect against injury.
Keep persons, especially children, away during the operation of the devices and during the
welding process. If persons are in the vicinity, however:
- Instruct them about all hazards (risk of injury from flying sparks, welding fumes hazardous to health, noise exposure, possible hazard due to grid current or welding current, etc.)
- Provide suitable protective equipment, or
- Construct suitable protective walls and curtains.
EN-US
Danger from Toxic Gases and Vapors
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that may cause birth defects and cancer in some circumstances.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
- Do not breathe them in
- Extract them from the work area using appropriate equipment
Ensure that there is sufficient fresh air.
Use breathing apparatus with air supply if there is insufficient ventilation.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding fumes are:
- The metals used for the workpiece
- Coatings of the materials
- Additives (e.g., adhesive)
- Cleaning agents, degreasers, etc.
Consult the corresponding material safety data sheets and manufacturer's instructions for
the components listed above.
Danger from Flying Sparks
Keep flammable vapors (such as solvent vapors) away from the direct welding process.
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (35 ft.) from the welding process or
protected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through small cracks
and openings. Take appropriate measures to ensure that there is no risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums,
or pipes if these have not been prepared in accordance with corresponding national and
international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils, and the like are/
were stored. Residues pose a risk of explosion.
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Risks from Mains
Current and
Welding Current
An electric shock is life-threatening and may be deadly.
Do not touch voltage-carrying parts inside or outside of the device.
Ensure suitable personal protection with dry temporary backing or cover with sufficient insulation against the ground potential. The temporary backing or cover must completely
cover the entire area between the body and the ground potential.
All cables and leads must be secured, undamaged, insulated, and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned
cables and leads immediately.
Have the grid and device supply lead regularly inspected by an electrician to ensure that
the ground conductor is functioning properly.
Operate the device only on a grid with a ground conductor and a socket with a ground conductor contact.
Operating the device on a grid without a ground conductor and on a socket without a
ground conductor contact is considered gross negligence. The manufacturer is not responsible for any damage resulting from improper use.
Use suitable equipment to ensure that the workpiece is sufficiently grounded if necessary.
Switch off unused devices.
Before working on the device, switch off the device and remove the mains plug.
Secure the device to prevent the mains plug from being connected and switched on again
by applying a clearly legible and understandable warning sign.
After opening the device:
- discharge all electrically charged components
- ensure that all components are disconnected from the power supply
If work is needed on voltage-carrying parts, bring in a second person who will switch off the
main switch at the correct time.
EMC Device Classifications
EMC Measures In certain cases, even though a device complies with the standard limit values for emis-
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage grid.
EMC device classification as per the rating plate or technical data.
sions, it may affect the application area for which it was designed (e.g., when there is sensitive equipment at the same location, or if the site where the device is installed is close to
either radio or television receivers).
If this is the case, then the operating company is obliged to take appropriate action to rectify
the situation.
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Test and assess the immunity of equipment in the vicinity of the device in accordance with
national and international provisions. Examples of interference-prone equipment that could
be affected by the device:
- Safety devices
- Grid power lines, signal lines and data transfer lines
- EMC and telecommunications equipment
- Devices for measuring and calibrating
Supporting measures to avoid EMC problems:
1. Grid power supply
- If electromagnetic interference occurs despite a grid connection that complies
with regulations, take additional measures (e.g., use a suitable grid filter).
2. Welding power-leads
- Keep them as short as possible
- Route them close together (also to avoid EMF problems)
- Route them far from other lines
3. Equipotential bonding
4. Workpiece grounding
- If necessary, establish grounding using suitable capacitors
5. Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
EN-US
EMF measures Electromagnetic fields may cause health problems that are not yet known:
- Effects on the health of persons close by, e.g., those with pacemakers and hearing
aids
- Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of the device and the welding process
- Keep distances between welding cables and the head/torso of the welder as large as
possible for safety reasons
- Do not carry welding cables and hosepacks over one's shoulder or wrap them around
one's body or body parts
Particular Hazard
Areas
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
- Shafts
- Joints
Do not reach into rotating drive components.
Crush hazard, puncture hazard!
Do not put hands or other body parts between the electrodes or other moving parts.
Cut hazard!
Wear protective gloves when handling sharp objects.
Covers must only be opened/removed during maintenance and repair work.
During operation:
- Ensure that all covers are closed.
- Keep all covers closed.
Do not leave any parts or tools made from ferromagnetic materials lying around in the gun
window area. These could be accelerated during a welding procedure by the magnetic
field.
The powerful electromagnetic, high-frequency fields that occur when resistance welding
could seriously interfere with active and passive medical implants.
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During the welding process, your hands must be at least 40 cm away from the gun window,
and your head and torso at least 50 cm away.
Do not touch workpieces, electrodes, current lines and busbars during or after welding –
risk of burns.
Also wear regulation-compliant protective equipment when reworking workpieces and ensure that other persons are sufficiently protected.
Leave device components with a high operating temperature to cool before working on
them.
Special regulations apply in areas at risk of fire or explosion
- follow the appropriate national and international regulations.
Only use suitable load-carrying equipment from the manufacturer to transport devices by
crane.
Chains or ropes must be as close to perpendicular as possible.
All lifting equipment (belts, straps, chains, etc.) used in connection with the device or its
components must be checked regularly (e.g., for mechanical damage, corrosion, or changes due to other environmental influences).
The test interval and scope must, as a minimum, comply with the respective valid national
standards and guidelines.
The device must only be lifted at the marked points.
Safety Measures
at the Setup Location and During
Transport
A toppling device can be deadly! Set up the device securely on an even, solid surface.
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the workplace
is always clean and organized.
Only set up and operate the device in accordance with the degree of protection shown on
the rating plate.
When setting up the gun controller, ensure that there is an all-round clearance of 0.5 m
(1.6 ft.) to allow cooling air to circulate freely.
Wall-mounting is permitted.
Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.
Before transporting the device, always completely drain the coolant and dismantle components.
It is essential to conduct a visual inspection of the device to check for damage after it has
been transported but before it is commissioned. Have any damage repaired by trained service technicians before commissioning the device.
Safety Measures
in Normal Operation
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Only operate the device when all protection devices are fully functional. If the protection
devices are not fully functional, there is a danger of
- Injury or death to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the equipment
Safety devices that are not fully functional must be repaired before the device is switched
on.
Maintenance and
repair
Never bypass or disable protection devices.
Before switching on the device, ensure that no one can be put in danger.
- The device must be examined at least once a week for externally detectable damage
and functionality of the safety devices.
- Only use suitable coolants. Observe information from the cooling unit manufacturer.
- If there is damage due to use of unsuitable coolants, the manufacturer shall not be liable for this and all warranty claims are forfeited.
It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.
- Use only original spare 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 replaced 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.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
EN-US
Safety Inspection The manufacturer recommends that a safety inspection of the device be performed at least
every 12 months.
A safety inspection by a certified electrician is recommended:
- After changes
- After alterations
- After repair, service and maintenance
- At least every twelve months.
For the safety inspection, follow the appropriate national and international standards and
guidelines.
You can obtain more information about the safety inspection from your service center. The
service center will provide the necessary documents upon request.
Disposal To comply with the European Directive 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 your dealer or else taken to
the approved collection or recycling facilities in your area. Ignoring this European Directive
may have potentially adverse effects on the environment and your health!
Safety Symbols
Devices with the EU Declaration of Conformity satisfy the essential requirements of the
machinery directive and the low-voltage and electromagnetic compatibility directives (e.g.,
relevant product standards of the EN 62 135 series).
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Backup The user is responsible for backing up any changes made to the factory settings. The man-
ufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
Text and illustrations are technically correct at the time of going to print. The right to make
modifications is reserved. The contents of the operating instructions shall not provide the
basis for any claims whatsoever on the part of the purchaser. If you have any suggestions
for improvement, or can point out any mistakes that you have found in the operating instructions, we will be most grateful for your comments.
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General Information
General
EN-US
Device Concept
Applications The Fronius DeltaCon spot welding process is suitable for connecting two-sheet and multi-
sheet joints of all common coated and uncoated steels, as well as all common aluminum
alloys.
Main applications:
- Automotive and supply industry
- Domestic appliance industry
- Rail vehicle manufacturing
- Plant construction and mechanical engineering
- Aerospace industry
The particular flexibility and the ease of adjustment to complex tasks are typical of the
resistance welding system. This is due to
the sophisticated design of the spot welding
guns and the ease of controlling the work
processes.
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Warning Notices
on the Device
The device has safety symbols and a rating plate fitted. These safety symbols and the rating plate must not be removed or painted over. The safety symbols warn against operating
the equipment incorrectly, as this may result in serious injury and damage to property.
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Do not use the functions described here until you have fully read and understood the following documents:
- These Operating Instructions
- All Operating Instructions for system components, especially the safety
rules
Welding is dangerous. To ensure that this device can be used correctly and
safely, the following basic requirements must be met:
- Adequate automated welding qualifications
- Appropriate protective equipment
- Keep unauthorized people away from the welding process
Hazardous voltage!
The areas marked contain parts that carry high voltages. An electric shock can
be fatal.
- The relevant areas must not be opened by unauthorized personnel!
Risk of burns due to hot surfaces!
The marked parts, housing, or drives will heat up when operated for a longer
period of time. If touched, you could burn your hands or other parts of the
body.
- Avoid contact with these parts!
Danger from moving parts!
The device indicated has dangerous moving tools that can cause serious injury. Hands can be crushed, dragged in, cut or otherwise injured
- Avoid contact with these parts!
Lifting point for transport
The welding system can be transported by a forklift truck at the two points
marked with this sign.
Important! There are four suspension points on the switch cabinet for transportation by crane. These must only be used for the switch cabinet on its own,
and not when the stationary welding system is combined with the switch cabinet.
Danger for people with pacemakers!
Welding produces hazardous electromagnetic fields that pose a risk of death
for individuals with pacemakers.
- Seek advice from your doctor before staying in the immediate vicinity of
the system and the welding process.
- Keep as much distance as possible between power lines and your head
or body.
Danger from incorrect operation!
The DeltaSpot welding system must only be operated by a single individual!
EN-US
Risk of skin damage or burns from weldments!
Considerable residual heat can result from welding. Falling components can
cause serious foot injuries.
- Wear appropriate protective footwear!
Risk of eye injury!
- Wear suitable safety glasses!
Risk of cut injuries or burns from weldments!
Weldments get extremely hot during the welding process. If touched, you
could burn your hands or other parts of the body.
- Wear appropriate protective welding clothing!
Risk of cut injuries or burns from weldments!
Weldments get extremely hot during the welding process. If touched, you
could burn your hands or other parts of the body.
- Wear welding safety gloves for protection when inserting and removing
weldments!
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Information on the Dimensioning of the Welding
System
General
CAUTION!
Risk of damage to property due to excessive loads on the welding system.
► Check inverter and transformer for correct dimensioning for the respective application.
In order to avoid overloading the components in use, the load capacity of the inverter and
transformer must be adjusted to the respective application.
Load diagrams define the maximum permitted welding current depending on the duty cycle.
The operating points must be determined for both the transformer and the inverter. The
lower of the two values determined must be used for the application.
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System components
General
50 / 60 Hz
EN-US
3
Overview of System Components
Control unit MF inverter Welding unit
Structure of 1 kHz medium frequency direct current welding system
The 50/60 Hz mains AC voltage is converted into DC voltage via a bridge rectifier. The following transistorized H bridge switches the DC voltage on the welding transformer with a
frequency of 1 kHz. The welding current is rectified at the secondary terminal in the welding
transformer.
(3)
(2)
(1)
(4)
(4a)
Fronius Xplorer
(4b)
Transformer Rectifier
(5)
(1) Welding system
(2) Internal bus control cable
(3) Coolant supply
(4) DeltaCon controller
incl.
(4a) industry PC with Fronius Xplorer
and (4b) inverter
(5) Cooling network, cooling unit
21
22
Operating controls, connections and
mechanical components
DeltaCon Controller
Operating Controls, Connections and
Mechanical Components, DeltaCon Controller
(1)
(2a)
EN-US
(2b) (2d)(2c)
(2)
(3) (4) (5) (6) (7)
Item Name
(1) Main switch
(2) Media set (optional)
consisting of:
(2a) Country-specific socket
IMPORTANT! The socket is not internally cabled and must be supplied from the
outside.
(2b) DVI connection (OUT)
e.g., for connecting a monitor
(8)
(9)
(10)
(12)
(13)
(14)
(15)
(16)
(11)
(2c) Ethernet connection
(2d) USB port
(3)
(4)
Coolant connections for inverter (optional)
only available if an optional inverter is present in the DeltaCon controller
25
(5) Welding current (optional)
only available if an optional inverter is present in the DeltaCon controller
(6) Transformer signals (optional)
only available if an optional inverter is present in the DeltaCon controller
(7) Additional grounding
for combi control option
(otherwise strain-relief device)
(8) Power IN
grid power supply
(9) Power gun
power supply control box
(10) Network
(11) Bus robot
fieldbus for robots
(12) Bus gun
fieldbus for control box
(13) Strain-relief device for socket power supply (optional) **
(14) Resolver *
motor encoder
(15) Motor *
motor phases
(16) Emergency stop external
EMERGENCY STOP
EMERGENCY
STOP connection
diagram
* Only with combi control option available
** Only with media set option available
The socket for the EMERGENCY STOP X6 connection is assigned as follows:
Pin Description Pin Description Pin Description
A +24 V OUT F EMERGENCY
STOP_A2
B +24 V IN (EXT) G EMERGENCY
STOP_B1
C GND IN (EXT) H EMERGENCY
STOP_B2
D GND OUT I RESET_A1 N -
E EMERGENCY
STOP_A1
J RESET_A2
K-
L-
M-
26
Mechanical components
Mechanical Components
(11)
(10)
(9)
EN-US
(1)
(2)
(3)
(4)
(5)
(5)
(6)
(4)
(8)
(1) Upper arm
(2) Operating controls on the welding system
(3) Lamp
(4) Electrode shaft
(5) Electrode
(6) Clamping device for the electrode shaft
(7) Lower arm support
(8) Cooling water connection with flow sensors
(9) Adjustment screw for x-axis
(10) Adjustment screw for y-axis
(7)
(11) Control box
Not shown:
screen with holder
27
(22)
(21)
(23) (25)(24)
(20)
(19)
(18)
(17)
(16)
(15)
(14)
(13)
(12)
(2) Operating controls on the welding system (1) Upper arm
The side and front covers are not shown.
(12) Program selection button
(13) Close gun button
(14) Open gun button
(15) Reset Error button/indication
(16) OK Reference button/indication
(17) Emergency Stop button
(26)
(27)
(18) Rotary switch
Welding with current
Welding without current
Milling
(19) Emergency Stop connection
(20) Power IN connection
(21) Power OUT connection
(22) Lamp connection
(23) Bus IN connection
(24) Bus OUT connection
(25) Foot-operated remote control connection
(26) Main drive
(27) Flexible current line
28
Control Box Connections
(1)
(2)
(3)
(4)
No. Function
(5) Power IN connection
(6) Power OK LED
Lights up if the power supply is in place
(7) Memory connection
For the connection of a socket with installed DeviceID, on which the gun setup data
is saved.
(5)
(6)
(7)
(8)
(9)
(10)
No. Function
EN-US
(1) Flow sensor connection
Flow sensor
(2) Force sensor connection
Force sensor
(3) I sensor connection
Current sensor
(4) U sensor connection
Voltage sensor
(8) Link LED
off ... no connection
flashing ... active communication with the sensor box (data exchange)
illuminates ... connection available, no data exchange
(9) EC status LED (EtherCAT—connection to the sensor box)
off ... INIT mode
flashes sporadically ... SAFE OPERATIONAL mode
flashes slowly ... PRE-OPERATIONAL mode
flashes quickly ... BOOT mode (firmware update)
illuminates ... OPERATIONAL mode
(10) Bus IN connection
29
Remote control
Foot-Operated
Remote Control
(1) (2)
(1) Pedal
with two-position activation:
1st position:
Close gun, positioning
2nd position:
Welding
(2) TIG Multi Connector cable
TMC
30
Commissioning
Before installation
EN-US
Measures to Ensure Safe Operation of the Device
when Operating
Personnel are Untrained
Intended Use The welding system is intended solely for manual resistance welding. Any other use does
Setup Regulations
If untrained operating personnel are within range of the device, the entire system must be
shut down for the duration of access to this area and remain switched off to prevent unintentional start-up.
not constitute proper use. The manufacturer shall not be liable for any damage resulting
from such improper use.
Proper use also means
- Following all instructions in the Operating Instructions
- Complying with the inspection and maintenance work (see Service, Maintenance, and
Disposal)
WARNING!
Toppling or falling devices can be deadly.
► Ensure that all components are properly installed and secured.
NOTE!
The system operator is responsible for assembling the components of the resistance welding system.
Ensure that
► All connections are properly established
► All connection screws are secure
The manufacturer shall not be liable for any damage resulting from improper assembly of
the spot welding gun.
Grid Connection The devices are designed for the grid voltage stated on the rating plate. The fuse protection
required for the grid lead can be found in “Technical Data.” If mains cables or mains plugs
are not included with your version of the appliance, attach the appropriate mains cable or
mains plug in accordance with your country’s standards.
NOTE!
An under-dimensioned electrical installation can lead to serious damage.
The grid lead and its fuse protection should be designed to suit the inverter that is used.
The technical data on the rating plate should be followed. The ground conductor must also
be established in duplicate in the same cross section as the connection cable.
33
Observe the following points in relation to the electrical connection:
- The converters may not be operated in asymmetrical grids (one grid phase is grounded).
- The converters may only be operated in grounded grids, such as: TT or TN grids.
In non-grounded grids (e.g., IT grid) a separating transformer with secondary grounded midpoint must be used. Single-sided grounding of the intermediate circuit is not
permitted.
- A grid-side electrical fuse is required.
- Operation on systems with normal RCCBs is not permitted because residual currents
from the intermediate circuit may flow back into the grid via the ground without triggering the RCCB.
- If a residual current protection device is used on the network, then this must be suitable for operation with medium frequency systems with a direct current intermediate
circuit and a frequency of 1000 Hz. Check the relevant manufacturer’s specifications
in this regard. Comply with the respective valid regulations.
- Ensure that the grid voltage is within the permitted range.
The range information can be found in the technical data of the respective converter
and on the type plate of the converter.
Notes on System
Cooling
Prior to each start-up of the welding system, check the coolant supply and the cleanliness
of the coolant.
NOTE!
Insufficient cooling can cause damage to property.
Never operate the welding system without sufficient cooling. The manufacturer shall not be
liable for any damage resulting from insufficient cooling.
IMPORTANT!
We recommend that water-cooled components should be operated with flow controllers.
The switching point of the flow controller on a gun arm is approx. 4.0 l/min (1.0 gal./min).
Find the switching point of the flow controller on the transformer in the transformer data
sheet.
IMPORTANT!
The coolant supply temperature should be around 20°C (68°F).
The minimum flow amount is 16 l/min at 3 bar differential pressure.
34
Recommended coolant quality:
pH value 7 to 8.5
Hardness D
max
10 German degrees
12.5 English degrees (Clark degrees)
10.5 ppm CaCO3 (American degrees)
18 French degrees
Chloride max. 20 mg/l
Nitrate max. 10 mg/l
Sulfate max. 100 mg/l
Insoluble substances max. 250 mg/l
CAUTION!
Risk of short circuit due to condensate.
Insulate water-bearing components to prevent the formation of condensate. Observe information from the cooling unit manufacturer.
EN-US
Transformer
Ground Conductor Connection
Medium frequency transformers comply with rating 1.
NOTE!
For medium frequency transformers of rating 1, additional protective measures
must be provided between the primary and secondary circuits in case insulation
fails.
► Observe the national and international standards and guidelines. The system operator
is responsible for its implementation and functionality.
The medium frequency transformer is equipped with the additional "direct ground conductor connection" protective measure on delivery as follows:
- Removable ground conductor bridge (MPE) between secondary circuit of the medium
frequency transformer and ground conductor connection of the transformer
When implementing another valid protective measure:
Remove ground conductor bridge (MPE)
1
Permanently mark on the transformer that the ground conductor bridge (MPE) has
2
been removed.
DANGER!
Unacceptably high contact voltages possible due to compensating currents.
If compensating currents cannot be avoided with the "direct ground conductor connection":
► Use protective residual voltage or residual current devices that are suitable for opera-
tion on 1000 Hz medium frequency systems with a DC intermediate circuit!
The "direct ground conductor connection" protective measure may have a negative effect
on the welding quality due to possible compensating currents. In order to prevent this, a
ground-free operated secondary circuit is required in conjunction with another protective
measure as per EN 62135-1.
Check compensating currents (cross currents)
Compensating currents ("cross currents" as per EN 62135-1) are currents that flow during
a welding procedure in parallel to the target current path of "electrode - workpiece - electrode". These may occur if the workpiece has any kind of ground connection.
DANGER!
Compensating currents may render the "direct ground conductor connection" protection ineffective even if the MPE bridge is properly installed.
This means that lives will be put at risk if the insulation fails (primary/secondary circuit).
► If compensating currents cannot be avoided when using the "direct ground conductor
connection", then other protective measures must be installed as per EN 62135-1
35
Check MPE bridge
The test is required if the "direct ground conductor connection" protective measure is used.
DANGER!
Unacceptably high contact voltages possible.
A non-functional MPE bridge renders the "direct ground conductor connection" protective
measure ineffective. This means that lives will be put at risk if the insulation fails (primary/
secondary circuit).
► Only put the system with the "direct ground conductor connection" into operation if the
test did not identify any concerns.
36
Commissioning
EN-US
General
WARNING!
An electric shock can be fatal.
If the unit is connected to the grid during installation, there is a danger of serious injury and
damage to property.
► Only perform work on the device when it is disconnected from the power supply
WARNING!
Work performed incorrectly can cause serious injury and damage to property.
► The connection work may only be carried out by trained specialist personnel and in ob-
servance of the valid safety regulations.
► Follow the safety rules in the Operating Instructions.
Overview The commissioning includes the following steps:
- Installing the stationary welding system
- Setting up the lower gun arm
- Installing the DeltaCon controller
- Connecting the DeltaCon controller to the grid
- Connecting the welding system
- Connecting the cooling system
- Connecting the remote control
Installing the Stationary Welding
System
WARNING!
Toppling or falling objects may cause serious injuries and damage to property:
► Only install the welding system vertically.
► The installation surface must be able to safely support dead weights and permissible
live loads.
► Secure the welding system to the points provided on the floor with 4 heavy-duty an-
chors.
► Ensure that the method of attachment is adequate and suitable.
► Check the welding system for any damage at regular intervals.
1
1
1
1
1
Securing the welding system to the floor
1
37
Setting Up the
Lower Gun Arm
Depending on the application and the electrode being used, the lower gun arm can be
moved backwards by 170 mm and forwards by 50 mm:
170 mm
50 mm
IMPORTANT! Observe the tightening sequence when tightening the screws!
1 2
1
1
2
1
10x
2
2
38
3 4
3
4
10x 30 Nm
5
9
4
8
2
5 6
1
7
3
10
6
5
10x 70 Nm
5
9
4
8
2
1
7
3
10
6
EN-US
10x 50 Nm
5
9
4
8
2
6
1
7
3
10
6
1
39
Installing the DeltaCon Controller
The DeltaCon controller is installed standing on the ground in conjunction with the optional
mounting frame.
The optional mounting frame must be permanently screwed to the floor.
Ground installation with optional mounting frame
NOTE!
The DeltaCon controller weighs more than 80 kg.
► With manual installation, there must be at least two people to carry out the installation
work!
CAUTION!
Toppling or falling objects may cause serious injuries and damage to property.
► When installing the DeltaCon controller, screw it securely to the optional mounting
frame and then screw the mounting frame securely to the floor!
NOTE!
Screws, dowels, and other mounting materials are not included in the scope of delivery.
The system installer is independently responsible for selecting the correct screws, dowels,
and mounting materials.
40
Connecting the
DeltaCon Controller to the Grid
The DeltaCon controller is connected to the grid using a 4-pin cable (3 phases + ground).
When selecting the cable and connecting to the public grid, observe the national standards.
Attach cable lugs with a bore diameter of 8 mm to the individual cables
1
Open the DeltaCon controller
2
Remove the touch protection
3
7
4
Insert the cable and the additional grounding cable for the motor controller into the
DeltaCon controller from below
1
EN-US
8
5
2
9
4
1
6
3
5
6
3
Connect the phase conductor using a 6 mm
Allen key
Tightening torque = 20 Nm
Use a 13 mm wrench to connect the ground
conductor and the additional grounding cable for the motor controller to the ground
connection
Tightening torque = 30 Nm
Install touch protection
1
2
41
Connecting the
DeltaCon Controller to the Spot
Welding Gun
The connection between the DeltaCon controller and the welding system is established using interconnecting hosepacks.
DeltaCon controller connections Welding system/control box connec-
tions
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
V
U
UV
(8)
(3)
(4)
(1)
(2)
(8)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(3)
(5)
(1)
(2)
Item Color Name Connection to the
(1) Tur-
Bus signal Bus for control box Bus IN
(5)
(4)
DeltaCon controller
(6)
Connection to the
gun/control box
(7)
quoise
(2) Light
gray
Control box supply Control box power
supply
Power IN
(3) Black Transformer signal Transformer signal * Transformer measur-
ing signals
(4) Orange Motor cable ** Motor phase Connection, main
drive
(5) Green Motor encoder ** Motor encoder Motor encoder
(6) Green Coolant supply *** - Coolant supply
(7) Red Coolant return *** - Coolant return
42
Item Color Name Connection to the
DeltaCon controller
(8) Black Transformer cable Welding current *
Connection to the
gun/control box
Primary connection
transformer
U ... Phase
V ... Phase
... Grounding
* The connections are only established if the inverter option is present on the Del-
taCon controller.
** Only in the basic interconnecting hosepack.
*** The coolant hoses are connected to the external cooling system for the spot weld-
ing gun.
EN-US
Connecting the
Cooling System
NOTE!
Insufficient cooling can cause damage to property.
► Never operate the welding system without sufficient cooling. The manufacturer shall
not be liable for any damage resulting from insufficient cooling.
Connect coolant supply and return to the welding system distributor block
1
Establish coolant supply
2
1
43
Connecting the
Foot-Operated
Remote Control
1
1
Connecting the
EMERGENCY
STOP
1
Connect the plug of the EMERGENCY STOP cable from the welding system to the
1
1
DeltaCon controller
2
EMERGENCY
STOP
44
Troubleshooting and Maintenance
Troubleshooting
EN-US
General
WARNING!
Activities performed incorrectly can cause serious injury and damage to property.
► Troubleshooting, maintenance work, and services may only be performed by trained
specialist personnel.
WARNING!
An electric shock can be fatal.
Before opening the device
► Set power switch to - O - on the welding power supply
► Unplug the welding power supply from mains power
► Secure against anyone turning on power again
► Use a suitable measuring instrument to ensure that electrically charged components
(e.g., capacitors) are discharged
WARNING!
An inadequate ground conductor connection can cause serious injury and damage
to property.
The housing screws act as a ground conductor connection for grounding the housing.
► Never replace the housing screws with other screws without a reliable ground conduc-
tor connection.
Troubleshooting No welding current
Inverter OK, control unit OK
Cause: Welding power lead interrupted
Remedy: Check cables and connection contacts
Welding power too low
Cause: Defective contact points
Remedy: Check contact points
Cause: Diode defective
Remedy: Change welding transformer
Cause: Transformer supply too weak
Remedy: Establish transformer supply as per technical data
Temperature sensors trigger
Cause: Dimensioning error
Remedy: Dimension transformer correctly according to application
Cause: Coolant flow too low
Remedy: Ensure minimum flow amount as per technical data
47
Service, maintenance and disposal
General The spot welding gun only requires minimal service and maintenance under normal oper-
ating conditions. However, several points must be observed in order for the welding system
to remain operational for years to come.
For the maintenance intervals, the point in time that occurs first must always be used.
WARNING!
Activities performed incorrectly can cause serious injury and damage to property.
► Troubleshooting, maintenance work, and services may only be performed by trained
specialist personnel.
Maintenance Per
Shift
Weekly maintenance or 50,000
spots
Monthly Maintenance or 200,000
Spots
- Check the function of the Emergency Stop button
- Check cooling tube adjustment
- Check screws for secure fit
- Check plug connections for secure fit
- Check cabling for damage
- Check coolant quality (see section “Notes on System Cooling”)
- Clean spot welding gun with damp cloth
- Check wear of the current lines (maximum 15% wear)
- Clean cooling system using compressed air
- Flow monitoring:
- If there is no individual circuit monitoring using flow sensors, flow inspection on
gun arms, transformer, and power source using external flow sensors
- If there is individual circuit monitoring using flow sensors, check the LED display
of the flow sensors
- Check plug connections for corrosion
- Check the function of the main switch on the DeltaCon controller
Disposal Materials should be disposed of according to valid local and national regulations.
48
Replace wearing parts
Wearing parts - Electrode shaft, electrode
- Current line
EN-US
Replacing the
Electrode Shaft
and Electrodes
1 2
1
1
2
2
1
3
2
4x
NOTE!
When replacing the electrode shaft, ensure that the tip of the inner cooling tube is
approx. 2 - 5 mm away from the base of the cooling bore, in accordance with the
electrode used.
3 4
3
4
50 Nm
1
2
1
4x
49
Replacing the
Current Line
NOTE!
Check the current lines for wear on a weekly basis.
Replace the current lines if there is any more than 15% wear.
1
1
1
3
2
Loosen the screws, lift the cover, remove the cover
8x
2
2
3
*
* Left side panel not shown
2
2
2
2
1
4x
50
Calibrating the lower gun arm
Calibrating the
Lower Gun Arm
EN-US
y
z
x
z
y
x
IMPORTANT! Observe the tightening sequence when tightening the screws!
1 2
1
2
10x
2
4
8
1
10x 15 Nm
5
9
1
2
10
6
7
3
51
3 4
3
y
y
1
x
2
5 6
x
5
10x 50 Nm
4
10x 30 Nm
5
9
4
8
2
1
7
3
10
6
6
10x 70 Nm
5
9
4
8
2
7 8
1
7
3
10
6
7
1
5
9
4
8
2
1
7
3
10
6
8
1
z
z
4x
52
9
9
EN-US
50 Nm
1
4x
53
54
Appendix
Technical Data
Special Voltage For devices designed for special voltages, the technical data on the rating plate applies.
EN-US
Transformer MFT
184
Nominal capacity at 100% duty cycle 184 kVA
Grid voltage 500 V
Frequency 1000 Hz
Transformation ratio 38
Open circuit DC voltage U
Continuous DC current I
Primary continuous current I
Coolant amount > 10.0 l/min
Coolant temperature max. 30 °C (86 °F)
Pressure difference at 8.0 l/min (2.11 gal/
min)
Current sensing coil 150 mV/kA
Temperature monitor opener (transformer) 1 x 140 °C (284 °F)
Temperature monitor opener (rectifier) 1 x 80 °C (176 °F)
Insulation class F
Weight 32 kg (70.55 lb.)
Emissions class A *
* A device in emissions class A is not intended for use in residential areas in which
the power is supplied via a public low-voltage grid.
The electromagnetic compatibility may be influenced by conducted or radiated radio frequencies.
d0
2P
1P
12.6 V
14 kA
368 A
< 1.6 bar
DeltaCon Controller
Grid voltage 3 x 400 V
Grid frequency 50–60 Hz
Nominal current primary RMS 200 A
Cycle time 500 μs
Protection class IP 54
EMC device class A *
* A device in emissions class A is not intended for use in residential areas in which
the power is supplied via a public low-voltage grid.
The electromagnetic compatibility may be influenced by conducted or radiated radio frequencies.
57
DeltaCon stationary system
Power supply U
1N
400 V 3~ 50 Hz
Total weight (with transformer) 1500 kg
Gun force min. 1.5 kN
Gun force max. 7 kN
Throat height 440 mm
Throat depth 1400 mm
Coolant pressure drop 0.3 MPa
Gun arm coolant flow rate 4.0 l/min
Coolant flow rate 16.0 l/min
Protection class IP 20
EMC device class A
58
A
EU-KONFORMITÄTSERKLÄRUNG 2018
EU-DECLARATION OF CONFORMITY 2018
DÉCLARATION UE DE CONFORMITÉ, 2018
Wels-Thalheim, 2018-11-26
eingapmoc aLrerutcafunaMamriF eiD
FRONIUS INTERNATIONAL GMBH
Froniusstraße 1, A-4643 Pettenbach
erklärt in alleiniger Verantwortung,
dass folgendes Produkt:
DeltaCon Stationary System
Widerstandsschweißgerät
auf das sich diese Erklärung
bezieht, mit folgenden Richtlinien
bzw. Normen übereinstimmt:
Richtlinie 2014/35/EU
Elektrische Betriebsmittel
Niederspannungsrichtlinie
Richtlinie 2014/30/EU
Elektromag. Verträglichkeit
Richtlinie 2011/65/EU
RoHS
Richtlinie 2006/42/EG
Maschinenrichtlinie
Europäische Normen inklusive
zutreffende Änderungen
EN ISO 12100:2010
EN 60204-1:2006 (18.3-18.7)
EN 62135-1:2015
EN 62135-2:2015
Die oben genannte Firma hält
Dokumentationen als Nachweis der
Erfüllung der Sicherheitsziele und
die wesentlichen Schutzanforderungen zur Einsicht bereit.
Dokumentationsverantwortlicher:
(technische Dokumentation)
Ing. Josef Feichtinger
Günter Fronius Straße 1
- 4600 Wels-Thalheim
Hereby certifies on its sole
responsibility that the following
product:
DeltaCon Stationary System
Resistance welding device
which is explicitly referred to by this
Declaration meet the following
directives and standard(s):
Directive 2014/35/EU
Electrical Apparatus
Low Voltage Directive
Directive 2014/30/EU
Electromag. compatibility
Directive 2011/65/EU
RoHS
Directive 2006/42/EC
Machinery Directive
European Standards including
relevant amendments
EN ISO 12100:2010
EN 60204-1:2006 (18.3-18.7)
EN 62135-1:2015
EN 62135-2:2015
Documentation evidencing
conformity with the requirements of
the Directives is kept available for
inspection at the above
Manufacturer.
person responsible for documents:
(technical documents)
Ing. Josef Feichtinger
Günter Fronius Straße 1
A - 4600 Wels-Thalheim
se déclare seule responsable du fait
que le produit suivant:
DeltaCon Stationary System
Appareil de pointage par résistance
qui est l’objet de la présente
déclaration correspondent aux
suivantes directives et normes:
Directive 2014/35/UE
Outillages électriques
Directive de basse tension
Directive 2014/30/UE
Électromag. Compatibilité
Directive 2011/65/UE
RoHS
Directive 2006/42/CE
Directive aux machines
Normes européennes avec
amendements correspondants
EN ISO 12100:2010
EN 60204-1:2006 (18.3-18.7)
EN 62135-1:2015
EN 62135-2:2015
En tant que preuve de la satisfaction
des demandes de sécurité la
documentation peut être consultée
chez la compagnie susmentionnée.
responsable documentation:
(technique documentation)
Ing. Josef Feichtinger
Günter Fronius Straße 1
A - 4600 Wels-Thalheim
EN-US
2018
Member of Board
Chief Production Officer
DE German Deutsch EN English English FR French Française
ppa. T. Herndler, MAS
59
FRONIUS INTERNATIONAL GMBH
Froniusplatz 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
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Under http://www.fronius.com/addresses you will find all addresses
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