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DeltaCon X-gun
DeltaCon C-gun
DeltaCon Controller
Operating Instructions
Resistance welding
EN-US
42,0426,0272,EA 003-22112019
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Table of contents
Safety Instructions ..................................................................................................................................... 5
Explanation of Safety Instructions......................................................................................................... 5
General ................................................................................................................................................. 5
Intended Use......................................................................................................................................... 5
Grid Connection .................................................................................................................................... 6
Environmental Conditions ..................................................................................................................... 6
Obligations of the Operating Company................................................................................................. 6
Obligations of Personnel....................................................................................................................... 7
Personal Protection and Protection of Others....................................................................................... 7
Danger from Toxic Gases and Vapors.................................................................................................. 7
Danger from Flying Sparks ................................................................................................................... 8
Risks from Mains Current and Welding Current ................................................................................... 8
EMC Device Classifications .................................................................................................................. 9
EMC Measures ..................................................................................................................................... 9
EMF measures...................................................................................................................................... 9
Particular Hazard Areas........................................................................................................................ 9
Safety Measures at the Setup Location and During Transport ............................................................. 10
Safety Measures in Normal Operation.................................................................................................. 11
Commissioning, Maintenance and Repair ............................................................................................ 11
Safety Inspection .................................................................................................................................. 11
Disposal ................................................................................................................................................ 11
Safety Symbols ..................................................................................................................................... 11
Backup .................................................................................................................................................. 12
Copyright............................................................................................................................................... 12
EN-US
General Information 13
General ...................................................................................................................................................... 15
Device Concept..................................................................................................................................... 15
Application Areas .................................................................................................................................. 15
Information on the Dimensioning of the Welding System .......................................................................... 16
General ................................................................................................................................................. 16
System components .................................................................................................................................. 17
General ................................................................................................................................................. 17
Overview of System Components......................................................................................................... 17
Options.................................................................................................................................................. 18
Operating controls, connections and mechanical components 19
DeltaCon Controller ................................................................................................................................... 21
Operating Controls, Connections and Mechanical Components, DeltaCon Controller......................... 21
EMERGENCY STOP connection diagram............................................................................................ 22
Spot Welding Guns .................................................................................................................................... 23
C-Gun Connections .............................................................................................................................. 23
X-Gun Connections............................................................................................................................... 24
Control Box Connections ...................................................................................................................... 25
Mechanical Components ...................................................................................................................... 26
Commissioning 27
Before installation ...................................................................................................................................... 29
General ................................................................................................................................................. 29
Measures for the safe operation of the device in conjunction with untrained operating personnel....... 29
Intended Use......................................................................................................................................... 29
Setup Regulations................................................................................................................................. 30
Grid Connection .................................................................................................................................... 30
Notes on System Cooling ..................................................................................................................... 31
Transformer Ground Conductor Connection.........................................................................................31
Commissioning .......................................................................................................................................... 33
General ................................................................................................................................................. 33
3
Overview ............................................................................................................................................... 33
Installing the DeltaCon Controller ........................................................................................................ 33
Connecting the DeltaCon controller to the grid ..................................................................................... 34
Connecting the DeltaCon Controller to the Spot Welding Gun ............................................................. 36
Connecting the Cooling System............................................................................................................ 38
Connecting the EMERGENCY STOP...................................................................................................38
Troubleshooting and Maintenance 39
Troubleshooting ......................................................................................................................................... 41
General ................................................................................................................................................. 41
Troubleshooting .................................................................................................................................... 41
Service, maintenance and disposal ........................................................................................................... 42
General ................................................................................................................................................ 42
Weekly maintenance or 50,000 spots................................................................................................... 42
Monthly maintenance or 200,000 spots ................................................................................................ 42
Disposal ................................................................................................................................................ 42
Replace wearing parts ............................................................................................................................... 43
Wearing parts........................................................................................................................................ 43
Replacing electrode cap and electrode shaft, C-gun ............................................................................ 43
Replace current line - C-gun ................................................................................................................. 44
Replacing electrode cap and electrode shaft, X-gun ............................................................................ 45
Replace current line - X-gun ................................................................................................................. 46
Calibrating Gun Arms................................................................................................................................. 47
Calibrating Gun Arms, C-gun................................................................................................................ 47
Calibrating Gun Arms, X-gun ................................................................................................................ 48
Adjust fixed gun arms ........................................................................................................................... 50
Appendix 51
Technical Data ........................................................................................................................................... 53
Special Voltage ..................................................................................................................................... 53
MF Transformer .................................................................................................................................... 53
Spot welding gun .................................................................................................................................. 54
DeltaCon Controller .............................................................................................................................. 54
DeltaQ Inverter...................................................................................................................................... 55
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Safety Instructions
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.
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.
Before switching on the device, remedy any faults that could compromise safety.
Your personal safety is at stake!
Intended Use
The device is to be used exclusively for its intended purpose.
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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 accepts no liability for any damage
resulting from improper use.
Intended use also means
- Reading and adhering to all instructions in the Operating Instructions
- Carefully reading and obeying all safety instructions and danger notices
- Carrying out all the specified inspection and maintenance 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
*)
*)
Environmental
Conditions
*)
both at the interface with the public grid
See technical data
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.
IMPORTANT! Ensure secure grounding of the grid connection!
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 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.)
Obligations of the
Operating Company
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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
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.
EN-US
Personal Protection and Protection of Others
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.
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.
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.
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Consult the corresponding material safety data sheets and manufacturer's instructions for
the components listed above.
Keep flammable vapors (such as solvent vapors) away from the direct welding process.
Danger from Flying Sparks
Risks from Mains
Current and
Welding Current
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.
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.
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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.
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
- IT and telecommunications equipment
- Devices for measuring and calibrating
EN-US
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. Lines
- Keep them as short as possible
- Route them close together (also to avoid EMF problems)
- Route them far from other lines
3. Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
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
Particular Hazard
Areas
Do not linger in the operating area of the robot
The operating company must integrate the device into a superordinate safety system if the
installation location is in a secured area that needs to be accessed for preparatory or maintenance work. In this case, it must also be ensured that the entire system is shut down for
the duration of access to this area and remains switched off to prevent unintended operation, e.g., as a result of a control error.
In addition to these Operating Instructions, the safety rules of the robot manufacturer must
be followed.
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Keep hands, hair, loose clothing, and tools away from moving parts, such as:
- Shafts
- Joints
Do not reach into rotating drive components.
Crush 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 touch workpieces and electrodes 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.
Safety Measures
at the Setup Location and During
Transport
Only use suitable load-carrying equipment from the manufacturer to transport devices by
crane.
Chains or ropes must be the smallest angle possible from vertical.
All lifting equipment (belts, buckles, chains, etc.), which is used in association 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 at least comply with the respective valid national standards and guidelines.
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.
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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
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.
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.
EN-US
Commissioning,
Maintenance and
Repair
Safety Inspection The manufacturer recommends that a safety inspection of the device be performed at least
It is impossible to guarantee that externally procured parts are designed and manufactured
to meet the demands made on them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any alterations, installations, or modifications to the device without
first obtaining the manufacturer's permission.
- Components that are not in perfect condition must be changed immediately.
- When ordering, specify the exact name and part number according to the Spare Parts
List, as well as the serial number of your device.
every 12 months.
A safety inspection by a certified electrician is recommended
- after changes,
- after alterations,
- after repair, service and maintenance,
- at least every 12 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
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Devices with the CE mark satisfy the essential requirements of the low-voltage and electromagnetic compatibility directives (e.g., relevant product standards of the EN 62 135 series).
Devices with the EU declaration of incorporation satisfy the essential requirements of the
low-voltage and electromagnetic compatibility directives (e.g., relevant product standards
of the EN 62 135 series).
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.
For integration in a company network or similar, the operator must install a firewall or other
suitable anti-virus protection in order to avoid damage caused by malware.
The manufacturer shall not be liable for losses due to malware.
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
Device Concept
EN-US
DeltaCon C-gun DeltaCon X-gun
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.
Application Areas The 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
15
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
and the pulse duration.
The operating points must be determined for both the transformer and the inverter. The
lower of the 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)
(6)
(7)
(1) Spot welding gun, welding system
(2) Internal bus control cable
(3) Coolant supply
(4) Controller DeltaCon
incl.
(4a) industry PC with Fronius Xplorer
(4b) Inverter
(5) Fieldbus
(6) Higher-level control (e.g., PLC)
(7) Cooling network, cooling unit
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