FRONIUS SpotWelding Bedienungsanleitung
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42,0426,0111,EN 007-10102019
SpotWelding gun controller Operating Instructions
Resistance welding
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Contents
General 7
Gun control/Fronius Xplorer....................................................................................................................... 9
General ................................................................................................................................................. 9
Setting automatic time synchronisation ................................................................................................ 9
Changing the default input language .................................................................................................... 10
SpotWelding system configuration........................................................................................................ 10
Spot welding system configuration - spot welding gun ......................................................................... 12
Calculating the maximum welding current ............................................................................................ 14
Manual and automatic backup .............................................................................................................. 14
Worksheets ................................................................................................................................................ 15
Overview worksheet.............................................................................................................................. 15
Operator worksheet .............................................................................................................................. 17
Programs worksheet ............................................................................................................................. 18
Status worksheet .................................................................................................................................. 19
Logbook worksheet............................................................................................................................... 20
Diagnostic worksheet............................................................................................................................ 21
Actual values worksheet (optional) ....................................................................................................... 22
SpotWelding.Configurator.......................................................................................................................... 24
General ................................................................................................................................................. 24
SpotWelding.Configurator overview...................................................................................................... 24
DeltaQ, Harms & Wende inverter .............................................................................................................. 26
General ................................................................................................................................................. 26
Operation 27
Settings in the system configuration .......................................................................................................... 29
General ................................................................................................................................................. 29
Setting the actual values monitoring ..................................................................................................... 29
Reversing the byte sequence on fieldbus interfaces ............................................................................ 30
Short-term storage of welding operations ............................................................................................. 31
Two-stage welding start ........................................................................................................................ 32
Configurable limits for sheet thickness monitoring................................................................................ 32
Calibrating the spot welding gun components ........................................................................................... 33
General ................................................................................................................................................. 33
Calibrating the position limit .................................................................................................................. 34
Calibrating the force sensor .................................................................................................................. 34
Calibrating the force controller .............................................................................................................. 35
Calibrating the main drive position........................................................................................................ 35
Calibrating the compensation drive position ......................................................................................... 37
Sheet thickness compensation ............................................................................................................. 37
Calibrating the sheet thickness monitoring ........................................................................................... 38
Calibrating the current........................................................................................................................... 39
Calibrating the Harms & Wende Sinius inverter.................................................................................... 40
Measurement system calibration .......................................................................................................... 41
Assigning a gun code................................................................................................................................. 43
General ................................................................................................................................................. 43
Gun replacement procedure ................................................................................................................. 43
Carrying out the firmware update............................................................................................................... 45
Carrying out the firmware update for the motor controller .................................................................... 45
Carrying out the CAN firmware update ................................................................................................. 45
Creating the stepper function..................................................................................................................... 48
General ................................................................................................................................................. 48
Stepper editor ....................................................................................................................................... 48
Creating the stepper function................................................................................................................ 49
Stationary system with welding gun adjustment: Adjusting the tripod ....................................................... 50
Stationary system with welding gun adjustment: Adjusting the tripod .................................................. 50
Restore Device ID...................................................................................................................................... 51
Storage of gun type data on device ID memory.................................................................................... 51
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Restore Device ID................................................................................................................................. 51
Creating welding parameters in program editor......................................................................................... 52
Opening the program editor .................................................................................................................. 52
Symbols used in the Program Editor .................................................................................................... 52
Creating the current/force profile .......................................................................................................... 53
Editing the current/force profile ............................................................................................................. 54
Program Editor - Parameters ................................................................................................................ 55
Program Editor - Actual values monitoring ........................................................................................... 56
Program Editor - Notes ......................................................................................................................... 57
Setting the sheet thickness monitoring ................................................................................................. 57
Recording the sheet thickness.............................................................................................................. 58
Bus systems 61
Bus systems............................................................................................................................................... 63
General ................................................................................................................................................. 63
CANopen ................................................................................................................................................... 64
Topology ............................................................................................................................................... 64
Default parameter settings.................................................................................................................... 64
Interface card ........................................................................................................................................ 64
Pin assignment ..................................................................................................................................... 64
DeviceNet .................................................................................................................................................. 65
Topology ............................................................................................................................................... 65
Default parameter settings.................................................................................................................... 65
Interface card ........................................................................................................................................ 65
Pin assignment ..................................................................................................................................... 65
Profibus...................................................................................................................................................... 66
Default parameter settings.................................................................................................................... 66
Interface card ........................................................................................................................................ 66
Pin assignment ..................................................................................................................................... 66
Interbus ...................................................................................................................................................... 67
Topology ............................................................................................................................................... 67
Default parameter settings.................................................................................................................... 67
Interface card ........................................................................................................................................ 67
Pin assignment ..................................................................................................................................... 67
Digital I/O interface (Version 1.6)............................................................................................................... 68
Outputs ................................................................................................................................................. 68
CANopen bus coupler........................................................................................................................... 68
Inputs .................................................................................................................................................... 69
ProfiNet ...................................................................................................................................................... 70
ProfiNet requirements ........................................................................................................................... 70
Installing the ProfiNet driver.................................................................................................................. 70
Activating the real-time adapter ............................................................................................................ 70
Activating the ProfiNet card .................................................................................................................. 72
Ethernet/IP ................................................................................................................................................. 73
Ethernet/IP requirements ...................................................................................................................... 73
Installing the Ethernet/IP driver............................................................................................................. 73
Activating the real-time adapter ............................................................................................................ 73
Activating the Ethernet/IP card ............................................................................................................. 75
Setting the cycle time............................................................................................................................ 75
CAN over EtherCAT................................................................................................................................... 77
CAN over EtherCAT requirements........................................................................................................ 77
Preparing a network interface ............................................................................................................... 77
Activating the CAN over EtherCAT option in the Configurator.............................................................. 79
Interfaces 81
SpotWelding interface signal description ................................................................................................... 83
Description of signal inputs ................................................................................................................... 83
Description of signal outputs................................................................................................................. 84
DeltaSpot 1.6 interface .............................................................................................................................. 88
Inputs .................................................................................................................................................... 88
Outputs ................................................................................................................................................. 88
Process data length .............................................................................................................................. 89
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DeltaSpot 1.8 interface .............................................................................................................................. 90
Inputs .................................................................................................................................................... 90
Outputs ................................................................................................................................................. 90
Process data length .............................................................................................................................. 91
DeltaSpot 1.10 interface ............................................................................................................................ 92
Inputs .................................................................................................................................................... 92
Outputs ................................................................................................................................................. 92
Process data length .............................................................................................................................. 93
DeltaSpot 3.1 interface .............................................................................................................................. 94
Inputs .................................................................................................................................................... 94
Outputs ................................................................................................................................................. 94
Process data length .............................................................................................................................. 96
DeltaCon interface (7th axis) 1.0 ............................................................................................................... 97
Inputs .................................................................................................................................................... 97
Outputs ................................................................................................................................................. 97
Process data length .............................................................................................................................. 98
SpotWelding interface signal waveform..................................................................................................... 99
Moving to the home position ................................................................................................................. 99
External position check ......................................................................................................................... 99
Welding start-up with external position specification ............................................................................ 100
Resetting errors .................................................................................................................................... 100
Deactivating actual value monitoring when welding without current..................................................... 100
Docking ................................................................................................................................................. 101
DeltaSpot signal waveform example..................................................................................................... 102
DeltaCon signal waveform example ..................................................................................................... 103
Troubleshooting and maintenance 105
Troubleshooting ......................................................................................................................................... 107
General ................................................................................................................................................. 107
Exporting inverter log files..................................................................................................................... 107
Description of error signals ................................................................................................................... 107
Description of warning signals .............................................................................................................. 118
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General
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Gun control/Fronius Xplorer
General The DeltaSpot and DeltaCon gun controller is accessed with the Fronius Xplorer through
an existing company network. This allows for remote maintenance, central monitoring and
documentation of all connected equipment.
Welding parameters are created using the program editor in Fronius Xplorer.
You will find further details about Fronius Xplorer in the Fronius Xplorer Operating Instruc-
tions.
If the Fronius Xplorer does not support all the functions made available through the server,
a note will be displayed to update the Fronius Xplorer:
NOTE!
As a result of firmware and software updates, you may find that there are functions
available on your device that are not described in these Operating Instructions, or
vice versa.
Certain illustrations may also differ slightly from the actual elements displayed on your user
interface. These elements function in exactly the same way.
For the firmware version DeltaSpot.Control 3.2, the control computer supports:
- Windows 8
- User name: "Admin", Password: "blizzard"
- User name: "User", Password: "user"
IMPORTANT! .Net-Framework 4.6.1 is required for firmware versions starting from Del-
taSpot.Control 4.0.
DeltaSpot.Control 4.0 firmware versions and higher can therefore no longer be run on a
Windows XP operating system.
The name "SpotWelding.Control" is generally used for firmware versions from 4.1.75 or
higher.
Setting automat-
ic time synchroni-
sation
In the operating system you can set automatic time synchronisation on the control comput-
er:
- Log in as an administrator, login = Admin
- Double click on the clock in the taskbar
(Windows 8: simply click once and then select "Change date and time settings")
- Open the Internet time tab
- Enable the "Automatically synchronise with an Internet Time Server" function
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Changing the de-
fault input lan-
guage
The default input language (keyboard layout) of the user account "User" and the login
screen can be changed by means of a batch file. If you run this batch file as administrator,
the default input language of the administrator user account will also be enabled for the
user account "User" and for the login screen.
To change the default input language:
Log in to Windows as "Admin"
Open the Control Panel and select the required default input language (under "Region
and Language")
Right click on the batch file at "C:\Tools\sync-international-settings.bat"
Restart the computer
SpotWelding sys-
tem configuration CAUTION!
Incorrect inputs can have serious consequences for material and equipment.
► The spot welding gun may only be configured by trained specialist personnel. The
manufacturer will not be held liable for damage caused by incorrect settings.
IMPORTANT!
Configuration changes and calibration can only be carried out in manual mode on
DeltaSpot systems.
Spot welding gun configuration only applies to the gun controller that is currently selected.
To configure the spot welding gun:
Access the system configuration from the Options menu
The menu items displayed may vary depending on the spot welding gun.
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Name
Give a name to the spot welding gun (to identify it in Fronius Xplorer)
Location (company), (plant), (hall), (cell)
Enter the name of the company and location of the spot welding gun. The names entered
are copied to Fronius Xplorer as a path and displayed in the folder structure.
Autobackup
An automatic backup can be specified. "Off / Daily and Weekly" are available as intervals.
Enter the path where the backup files are to be saved under "directory".
Docu directory
It is possible to set the path for automatically documenting the system adjustments. Nor-
mal paths (e.g. "k:\directory") and network paths (e.g. "\\file-server\share\directory") can
be specified.
Entering a path is sufficient to enable the system adjustment documentation. If no path is
entered, the system adjustment documentation is disabled.
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