Fronius SpotWelding Operating Instructions Manual

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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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Autobackup-Ringbuffer-Size

The ring buffer size indicates how many backup files are stored in the entered location.

Autobackup-Starttime

A start time can be specified for the automatic backup. If a backup was not created upon

start-up in the last interval, one is created immediately. If a backup is already available,

the next one will be created at the specified time.

Docu directory

Directory where the documentation CSV data is saved.

If no value is provided, the function is disabled.

A simple path (e.g. k:\directory) or network path (e.g. \\file-server\share\directory) can be

set.

IMPORTANT! Do not save the welding documentation on the system drive ("c:\..."), as

this has a limited number of write cycles and relatively little memory.

Docu state monitoring

When this function is enabled, the system monitors whether the welding documentation

(CSV data, WeldCube, etc.) is functioning correctly.

Device id

A freely chosen device ID. The "device id" signal on the robot interface will be set to this ID

Power source (max. current)

The maximum available output current of the power source (see following section "Cal-

culating the maximum welding current")

Power source (target value before start signal)

For power sources that require an analogue set value and a digital current-start signal.

The analogue set value signal of 0 V to 10 V therefore corresponds to the power source

current range of 0 to the maximum current in kA.

When this setting is enabled, an analogue voltage value of 1.5 V is output shortly before

the digital current-start signal.

The analogue voltage value is raised to 1.5 V within the first 25 ms of the digital current-

start signal, unless this analogue value needs to be lower due to the welding program

specified by the user.

The size of the minimum current during the start pulse is calculated as follows:

Size of the start pulse [A] =

max. output current x

of the power source [A]

Transformer

x

ratio

Start pulse output signal (=

1.5 V)

10 V

Swap high/low bytes

Swap the high/low bytes on the fieldbus interface

Input signal filter time

The time in milliseconds to filter complex signals on the robot interface (e.g.: "program

number"). The values are only accepted once they have continued for the defined period.

Flow controller 4 (external)

Enables or disables the flow controller

Tape drive delay

The delay between opening of the welding gun and the forward movement of the tape

Actual values monitoring

Monitors the actual force and current values while welding. The values can be defined in

the relevant welding program on the "Actual values monitoring" tab.

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Spot welding sys-

tem configuration

- spot welding

gun

To configure the spot welding gun:

Access the system configuration from the Options menu

and switch to the "Gun" tab

Actual values monitoring error limit

The actual values monitoring error limit defines how many successive welds must violate

the defined actual values monitoring limits before an error is output.

If the parameter is set to "0", the function is disabled and no corresponding error is output.

A warning is always output.

Position in millimetres

When enabled, the actual and target positions are in millimetres. This setting affects the

output on the fieldbus interface and the "target position" signal on the input side of the

fieldbus interface.

Position precision

Defines the precision of the position specification in millimetres on the fieldbus interface

Sheet thickness precision

Defines the precision of the sheet thickness signals in millimetres on the fieldbus interface

Allow program changes in automatic mode

When enabled, program changes can also be carried out in automatic mode.

Use safety circuit

In addition to the emergency stop safety circuit, another safety circuit can be activated.

This function must be supported by the hardware (SpotWelding Control).

If the safety circuit is interrupted, all drives are stopped and error "E2.23" is output. This

error is filtered out in the logbook. On closing the safety circuit an error reset is performed

and the drives are initialised.

Compensation drive position precision

Defines the precision of the position signals of the compensation drive on the fieldbus in-

terface (1 mm / 0.1 mm / 0.01 mm)

Compensation drive target position in manual mode

Defines the distance travelled by the compensation drive in a manual welding process

(e.g. via DeltaRemote). This parameter is only used in the "Position" compensation mode

during manually started welding operations.

Main drive teach position

The "Learn teach position" function searches for the sheet with minimum force, and then

moves to a position defined in the system configuration as the "Main drive teach position"

plus the identified sheet thickness. The "Acknowledge teach position" function must then

be performed.

Prestroke force

To set the prestroke closing force on DeltaCon stationary systems

As such the prestroke can also be used for manual cap milling.

Sheetthickness recalibration warning limit

To set the number of welding operations following which a recalibration warning for sheet

thickness monitoring should be output.

Sheetthickness recalibration error limit

To set the number of welding operations following which a recalibration error for sheet

thickness monitoring should be output.

Gun type

Select the gun type

Power source (current correction factor)

Correction factor to compensate for tolerances

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Transformer (max. current)

Define the maximum available current of the built-in welding transformer. (see following

section "Calculating the maximum welding current").

Transformer (transmission ratio)

The input/output transmission ratio of the welding transformer (see following section "Cal-

culating the maximum welding current").

Tape length (movable arm), (fixed arm)

Define length of the process tape that is used. If the defined length is used up, error

"E0.26" or "E0.27" is output. When the tape length counter is reset, it is initialised with

these values.

Tape length warning (movable arm), (fixed arm)

Individually adjustable tape length warning. When the remaining welding spots reach the

value defined here, warning "W0.0" or "W0.1" is output.

Tape cover plate monitoring (Tape cover plate monitoring)

If a cover on the tape spool device is not closed, an error is output in automatic mode and

a warning in manual mode.

Electrode service life (movable arm), (fixed arm)

Define the service life of the electrode. After the specified number of welding spots, an

error message (2.10 "electrode service life movable arm" or 2.11 "electrode service life

fixed arm") is output

Electrode service life warning (movable arm), (fixed arm)

Individually adjustable warning (electrodes must be changed soon) appears before the

actual "electrode service life" error.

Force sensor characteristic curve

Characteristic curve of the force sensor. Set automatically during calibration (see "Cali-

brating the force sensor")

Force controller P-factor

The P-factor of the force controller influences the speed and stability of the force build-

up. Higher values allow the force to build up quicker but could make the force controller

unstable (oscillation tendency). Enter 0 to use a safe default value, or enter the value de-

termined when the force controller was calibrated.

Actual welding current conversion factor

The actual welding current value signal is read directly from the power source via a 10 V

analogue input. To allow conversion into kiloamperes, the correct conversion factor must

be specified.

Example:

Power source max. = 0.6 kA (corresponds to 10 V)

Transformer ratio = 1:44

Actual welding current conversion factor = 0.6 x 44 / 10 = 2.6

Electrode speed

The electrode speed can be defined in mm/s. The speed of the main drive is then adjust-

ed during the external position specification to ensure the gun arms open or close at a

constant speed. An electrode speed of 0 means that the linearization function is deacti-

vated.

Flow controller 1 (transformer)

Enables or disables the flow controller on the spot welding gun

Flow controller 2 (movable arm)

Enables or disables the flow controller on the spot welding gun

Flow controller 3 (fixed arm)

Enables or disables the flow controller on the spot welding gun

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Calculating the

maximum weld-

ing current

The maximum available welding current is calculated from the product of the maximum

current of the power source "power source (max current)" and the transmission ratio of the

welding transformer "transformer (transmission ratio)". If the calculated maximum welding

current is higher than the maximum permitted current of the welding transformer and an

attempt is made to weld a profile that exceeds the maximum current of the transformer,

error "E0.22" is output.

For example:

Maximum power source current: 800 A

Transformer ratio: 1:55

Maximum welding transformer current: 24 kA (see "Technical data of welding transformer")

Calculated maximum welding current: 800 A * 55 = 44 kA

Since the maximum permitted current of the welding transformer is less than the calculated

maximum welding current, if an attempt is made to weld above 24 kA, error "E0.22" is out-

put.

Manual and auto-

matic backup

A manual backup can be executed or an automatic backup can be scheduled.

The manual backup is started via the "Tools  Backup" menu. The spot welding gun and

data to be backed up can be selected in the dialog box.

The settings for the automatic backup can be defined in the system configuration (see the

section "SpotWelding system configuration").

Option: E-Set Brakes (Option: E-set brakes)

With certain gun types, the main and compensation drives can be equipped with motor

brakes if required. If the spot welding gun supports this option, it must be enabled here.

Measurement system

Enables or disables the measurement system on the spot welding gun

If the parameters are enabled, the actual values from the measurement system on the

spot welding gun are supplied.

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Worksheets

Overview work-

sheet

Gun-relevant information about current settings is displayed in the worksheet overview

(Overview):

- serial number, gun number, article number, base type

- Interface

- Program number, spot number, part number, part item number

- Actual gun code, expected gun code

- Electrode distance1) in millimetres

(the position must be calibrated for this to be displayed - see section "Setting position

calibration")

- Main drive connecting rod position1) displayed in the form of "Degrees to top dead

center"

- Working point

The working (operating) point must be in the range of 10-15° for DeltaSpot systems.

- Sheet thickness1)

(calibration of the sheet thickness monitoring must be carried out for this to be dis-

played)

The Overview also provides information about the current consumption values and can be

used to reset the counter for

- Process tapes1)

here, in addition to resetting, the tape length can be adjusted in order to make correc-

tions

- Electrode service life (electrode replacement)

- Lubrication cycle1)

- Tip dressing2)

- Total and current spot count

The spot count can be reset to 0 at any time.

- Stepper - spot count

- Stepper - current adjustment

Explanation of footnotes:

1) DeltaSpot systems only 2) DeltaCon systems only

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Example: Overview worksheet for a DeltaSpot system

Overview worksheet

(1) Indicates the length of the process tape remaining

(2) Indicates the number of welding spots that are still possible

The robot interface allows a simultaneous reset of the tape length counters or of the elec-

trode service life counters of both gun arms. However, tape length counters and electrode

service life counters cannot be reset simultaneously.

Reset counter button (Reset):

Press the button to reset the counter. This is possible even when the spot weld-

ing gun is switched off or undocked. Resetting the process tape counter and

electrode service life counter allows the spot welding gun to be selected.

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Operator work-

sheet

The Operator worksheet is only visible to users with certain rights.

On this tab, the spot welding gun can be controlled directly with Xplorer.

Operator worksheet - Service

Operator worksheet - Welding

"Activate" button

activates the function in Xplorer, does not work if a remote control is connected

to the spot welding gun

"Service" button

opens the window with the service functions

"Welding" button

opens the window with the welding functions

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Programs work-

sheet

Programs worksheet

"Error Reset" button

resets a fault that has occurred. Compensation drive and main drive are moved

back to the starting position. The next time welding is started, and before the

spot welding gun is closed, the tape is automatically moved forward, provided

current was flowing before the error occurred.

"Reference" button

moves drives to home position

"Process tape Backward/Forward" buttons

moves the process tape backwards and forwards

"Open spot welding gun" button

opens the spot welding gun

"Close spot welding gun" button

closes the spot welding gun

"Program selection" button

selects a program

Weld ON / OFF

Welding with or without current

Create/edit program button (Change)

Click to select program preview in the worksheet and press the "Program Editor"

button to open.

Shortcut: Enter key

Delete program button (Delete)

Click on the program to select it and press this button to delete it

Shortcut: Delete key

Export program to data carrier button (Export)

Select the required program and press the button to save it to a file.

"Import" button

Opens a program saved as a file

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Status worksheet The Status worksheet contains all the current warnings and faults related to the spot weld-

ing gun.

Status worksheet

The current warning and error number will appear on the right next to the symbols.

Copy program button (Copy)

Select the required program and press the button to save to the clipboard.

Shortcut: Ctrl + C

Paste program button (Paste)

Click to select the required position and press the button to paste a previously

copied program. In a dialogue window, it can be specified whether the names

and comments from the old program are to be retained.

Keyboard shortcut: Ctrl + V

Check program button (Check)

Press the button to check one or more programs. After selecting the transformer

in question, the delay necessary between each weld to avoid damaging the

transformer diodes is displayed.

FILTER

Option to filter the programs displayed by:

- Program number

- Spot number

- Program name

- Comments

- Materials

System Stop symbol

Operation cannot be resumed until the problem has been rectified

Warning symbol

Ignoring a warning can result in the system stopping

!

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Logbook work-

sheet

The Logbook worksheet records all of the following events, together with the associated

user:

- Status changes (errors, warnings), including gun code, spot number and program

number

- Program changes

- Configuration changes

- Stepper changes

- Electrode resets (gun code, gun arm, number of welds, number of welds still possible)

- Length of process tape resets (gun code, gun arm, length of process tape used, length

of process tape not used)

-

The display of the various changes can be filtered.

There is a limited number of logbook entries that can be displayed.

A note will be displayed when the limit for the selected period is reached.

Clicking the "Show more" button will double the limit.

Logbook worksheet

Any time period for the logbook entries display can be selected in the date selection fields.

Details symbol

Opens a detailed view of the selected logbook entry. A program comparison

function (of the old and new program) is opened when programs are changed.

The details of a logbook entry can also be displayed by double-clicking on the

relevant entry.

Export symbol

Logbook entries can be exported using this function. CSV (plain) exports all log-

book entries. CSV (set/reset) exports only status changes (existing errors/warn-

ings are not shown twice). Only currently displayed logbook entries are exported.

Top 10 symbol

Opens a top 10 view of errors/warnings within a specified period (everything/30

days/7 days).

Status filter symbol

Errors/warnings that occur frequently can be entered here. Entered errors/warn-

ings are not recorded in the logbook

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Fronius SpotWelding Operating Instructions Manual

Fronius SpotWelding Operating Instructions Manual

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