Amada WELTOUCH CY-210D Operation Manual
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Amada WELTOUCH CY-210D Operation Manual

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WELTOUCH
®
CY-210D
OPERATION MANUAL
AA04OM1188253-04

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Summary of Contents for Amada WELTOUCH CY-210D

  • Page 1 WELTOUCH ® CY-210D OPERATION MANUAL AA04OM1188253-04...
  • Page 2 CY-210D Preface Thank you for purchasing our WELTOUCH CY-210D. We have developed a low-priced constant-current resistance control featuring the powerful functions essential in our advanced technological age. The 3-stage power-on function and upslope and downslope functions will be particularly helpful in various manufacturing fields.

  • Page 3: Table Of Contents

    CY-210D Contents 1. Special Notes .......................... 1-1 (1) Safety Precautions ..............................1-1 (2) Precautions for Handling ............................1-4 (3) On Disposal ................................1-4 2. Features ........................... 2-1 3. Name and Function of Each Section ..................3-1 (1) Front Panel ................................3-1 (2) Rear Panel ................................

  • Page 4: Special Notes

    CY-210D 1. Special Notes (1) Safety Precautions Prior to use, read these “Safety CAUTION Precautions” carefully to gain a full understanding of the proper method of use. Indicates a risk of physical injury or damage to product if precautions are not correctly ...
  • Page 5 CY-210D WARNING Do not insert your fingers or hands between the electrodes. When welding, keep your fingers and hands away from the electrodes. Do not touch any welded part or electrode during welding or just after completion of welding. The welded parts of a workpiece, electrodes, and the arm are very hot. Do not touch them;...
  • Page 6 CY-210D CAUTION Always use a terminal cover. Touching the terminal block directly may result in electric shock. Be sure to fit the block with a cover. Connect the cables securely. Improper connection of a cable may result in fire or electric shock. Use proper tools (wire strippers, pressure wire connectors, etc.) for terminal treatment of the connecting cables.

  • Page 7: Precautions For Handling

    CY-210D (2) Precautions for Handling Install the Controller securely on a firm and level surface, to ensure that it will not fall. Do not install the Controller in the following locations: Damp areas (where the humidity is above 90%), areas where chemicals are handled, dusty areas, areas near a high noise source, areas where water may condense, areas exposed to large amounts of vibration or shock, and areas where temperatures are above 45C or below 0C Clean the exterior of the Controller using a soft, dry cloth or one slightly dampened with water.

  • Page 8: Features

    CY-210D 2. Features The WELTOUCH CY-210D is a constant/alternating-current resistance weld control with a 15-schedule setting function. It is controlled by a microcomputer, allowing it to be applied to all types of welding. Due to the plating-layer treatment by the pre-stage current, heat treatment by the post-stage current, etc., splashing is prevented, the welding tip is protected from overheating, and an ideal welding current can be set.

  • Page 9: Name And Function Of Each Section

    CY-210D 3. Name and Function of Each Section (1) Front Panel ⑦ State indicator ⑧ Weld ON/OFF key ② Cycle setter/indicator ± keys Indicator CYCLES ON/OFF W.POWER ERROR START WELD READY CAUTION STEP END PULSATION MONITOR COUNT SQUEEZE COOLⅠ SLOPEⅠ COOLⅡ...

  • Page 10: Rear Panel

    CY-210D ⑦ State indicator Indicates the current state of the CY-210D for confirmation. ⑧ Weld ON/OFF key [WELD] Turns welding on and off. Each time this key is pressed, welding is turned on and off alternately. If this key is turned on, the LED at the upper left comes on; if this key is turned off, the LED goes off.

  • Page 11: Internal Block Diagram

    CY-210D (3) Internal Block Diagram Welding transformer Welding head Welding power Thyristor Toroidal coil (For detection of the secondary constant current) (For detection of the primary constant current) Turn-on pulse Transformer for generation synchronization Waveform Waveform amplification reproduction Turn-on angle command Primary Secondary...

  • Page 12: Connection

    CY-210D 4. Connection (1) Basic Configuration 1) The general system configuration of the CY-210D is as follows: Example) Combination with a welding robot ① CY-210D The body of the constant-current resistance welding control. Connect AC power to it. ② Thyristor contactor (Option) Connects a welding power source to this device.

  • Page 13: Connection Of Power Source

    CY-210D (2) Connection of Power Source 1) Connect the power source to the power-supply terminal block mounted on the rear panel. ① Connect the thyristor contactor to the power-supply terminal block on the rear panel of CY-210D, as shown below. ②...

  • Page 14: Installation Method For The Current-Detecting Coil

    CY-210D (3) Installation Method for the Current-Detecting Coil 1) Installation Method for a Toroidal Coil ① Install the toroidal coil to the secondary side of the welding transformer. If only one welding head is used, install the toroidal coil as shown below: Primary side Welding transformer Toroidal coil...
  • Page 15 CY-210D When two or more welding heads weld at a time  The current of only one circuit is kept constant in this case. Primary side Welding transformer Toroidal coil Welding head Fig.3 Connector method for toroidal coil (3) ② Set dip switch DSW1-(2) to the OFF position (see page 4-7). ③...
  • Page 16 CY-210D ④ Checking for breakage and short-circuiting of the toroidal coil Breakage of and shorts in the toroidal coil can be checked using a tester, as the toroidal coil has the internal resistance shown in Fig. 5. (Keep in mind that the internal resistance changes depending on the type of toroidal coil.) Toroidal coil Internal resistance MB-400L...

  • Page 17: Selecting Of Functions

    CY-210D (4) Selecting of Functions Functions are set using dip switches on the printed-circuit board. [DANGER! High Voltage] When removing the cover and setting the dip switches on the board, confirm that the welding power and control power are turned off to ensure safety. 1) Initial setting of dip switches Factory default setting of dip switches DSW1 DSW 1...
  • Page 18 CY-210D 3) Explanation of functions of dip switches  Selects the constant-current control or source-voltage ① DSW1-(1) fluctuation compensation control. OFF: Constant-current control Source-voltage fluctuation compensation control  In constant-current control mode (DSW1-(1): OFF) ② DWS1-(2) OFF: Constant-current control method with secondary-current feedback Constant-current control method with primary-current feedback...
  • Page 19 CY-210D  Makes settings so that the power will or will not be supplied again ⑥ DSW1-(6) when the lower current limit is detected or no current flows. OFF: Re-power-on---OFF Re-power-on---ON If this dip switch is set to OFF, power is not supplied again. If it is set to ON, current increased by 5% is supplied (see 4) on page 5-7).
  • Page 20 CY-210D  Selects a schedule No. ⑪ DSW2-(3) OFF: Starts with external schedule No. Starts with schedule No. on panel If this dip switch is set to OFF, a schedule No. is selected and operation starts upon the reception of start signal [START 1, 2, 4, and/or 8] from outside.

  • Page 21: Input Method For Start Signals

    CY-210D (5) Input Method for Start Signals 1) When the operation is started in the 15-schedule start mode and the parity check of the start signal is not performed (when DSW1-(4) is set to OFF). Select up to 15 schedules by inputting the four signals of Start 1, Start 2, Start 4, and Start 8 in Binary Format.
  • Page 22 CY-210D 2) When operation is started in the 15-schedule start mode and the parity check of the start signal is performed (when DSW1-(4) is set to ON) Select up to 15 schedules by inputting the four signals of Start 1, Start 2, Start 4, and Start 8 in Binary Format and Start P (parity).

  • Page 23: Interface

    CY-210D 5. Interface (1) External Input and Output Signals GROUND- Interior of CY-210D Ground the E terminal (grounding) of CY-210D in common with the grounding of the contactor. Change the connection in accordance with the welding power source: 240 V or 480 V. If 480 V is connected to the 240-V Welding power source terminal, the transformer in the timer will...
  • Page 24 CY-210D WELD ON OPTION HOLD END RY1-RY4: G6B1114P 24 V DC (OMRON) ERROR STEP END INTERLOCK/WELD No. ERROR +24 V DC OUT (100 mA Max) +24 V DC IN (Terminals 33 and 34 are shorted when delivered.) COIL Connection of toroidal coil (Secondary constant-current control) or CT (Primary constant-current control) 1) Explanation of external input and output signals...
  • Page 25 CY-210D Pin No. Name Description Common terminal for Pins 20 and 21 INTERLOCK/WELD No. SET input terminal Input the interlock signal to this terminal when the INTERLOCK interlock function is selected. Input a workpiece /WELD No. SET confirmation signal, which is on if the workpiece is set and off if it is removed, when the weld-count monitor function is selected.

  • Page 26: Timing Chart

    CY-210D (2) Timing Chart 1) Timing chart of basic operation START 1,2,4,8 Start input VALVE 1,2 Weld force output Welding current WELD ON Power on output HOLD END Holding-finish output (When a caution concerning (When an error is detected) the current is output) ERROR Error output (When the last step is completed)
  • Page 27 CY-210D 2) Timing chart of repeating function operation (when DSW2-(1) is set to ON) START 1,2,4,8 Start input VALVE 1,2 Weld force output Welding current HOLD END Holding-finish About 200ms About 200ms output OFF: Off T1: Time from when the start signal [START1,2,4,8] is turned on (rising edge of the first input signal) until the valve signal [VALVE1,2] is turned on (60 ms max.) T2: Time from the Hold is finished until the holding finish signal [HOLD END] is...
  • Page 28 CY-210D 3) Timing chart of interlock function operation (when DSW2-(2) is set to OFF) When the welding is performed at the same timing, the voltage of the welding power supply decreases and the welding current fluctuates. In such a case, this function keeps the welding from being performed while the interlock input signal [INTERLOCK/WELD No.SET] is turned on.
  • Page 29 CY-210D 4) Timing chart of weld counter function operation (when DSW2-(2) is set to ON) (Example of counting of 4 welds) Welding WELD COUNT INTERLOCK/ WELD NO.SET Interlock input INTERLOCK/ WELD NO.ERROR Interlock output Welding WELD COUNT INTERLOCK/ WELD NO.SET Interlock input INTERLOCK/ WELD NO.ERROR...
  • Page 30 CY-210D 5) Timing chart of re-power-on function operation (when DSW1-(6) is set to ON) START 1,2,4,8 Start input VALVE 1,2 Weld force output Welding current cycles (When the re-power-on current is less than the lower limit setting) ERROR Error output HOLD END Holding-finish output T1: Time from when the start signal [START1,2,4,8] is turned on (rising edge of...

  • Page 31: Operation Method

    CY-210D 6. Operation Method (1) Basic Operation (1) Turn on the control power switch. If the control power switch [POWER] on the rear is turned on, the control power is supplied to the device. All LEDs light up for 2 to 3 seconds to indicate that self-diagnosis is being performed.
  • Page 32 CY-210D (5) Input the start signal to start welding. If the start signal [START 1,2,4,8] is W.POWER ERROR START input, the red [START] LED lights READY CAUTION STEP END All indicators go out, and “-” lights up to indicate the currently executed process. The weld sequence is indicated clearly.

  • Page 33: Setting Of Schedule Data

    CY-210D (2) Setting of Schedule Data (1) Setting of Schedule No. SCHEDULE Press the [NUMBER] key so that a schedule No. can be input. Use the [+] / [–] keys to select the schedule No. to be set. NUMBER (2) Setting of timer CYCLE Indicator PULSATION...
  • Page 34 CY-210D (3) Setting of maximum current VALVE No. 1) Press the VALVE [No.] key to enter the Valve No. setting mode. Use the [+] / [–] keys to set the valve No. First, input 1. VALVE Press the [CURR.I] and [CURR.II] CURRENT keys at the same time, then use the [+] / [–] keys to input the maximum welding current...

  • Page 35: Setting Of Monitor

    CY-210D When the source-voltage fluctuation compensation control is used  Set the current as a %. When the current is set to 99.9%, such a current as flows, in a reference 50° welding machine having a 50° power-factor angle, at 50° firing angle 150° will flow; when set to 00.0%, at a 150°...
  • Page 36 CY-210D (2) Setting of current monitor (Effective only in constant-current control mode) 1) Press the [HIGH] key to enter the setting MONITOR mode. 2) Use the [+] / [–] keys to set the upper limit of COND. the current monitor (setting range: 0% to HIGH ANGLE 49%).
  • Page 37 CY-210D (4) Indication of conduction angle, and upper and lower limits of monitored currents Upon completion of the weld cycle, the monitor indicates the conduction angle and the upper/lower limit of the monitored current. MONITOR COND. HIGH ANGLE 1) Indication of conduction angle of Current I Press the [CURR.I] and [COND.

  • Page 38: Setting By Mode No

    CY-210D (4) Setting by Mode No. The setter/indicator of the data/counter are explained below. VALVE DATA MODE 0: STEPPER COUNT 1: STEPPER UP RATE 2: TOTAL COUNT 3: WELD COUNT 4: WORK COUNT 5: TURN RATIO STEP SELECT 6: ±%WINDOW ON/OFF 7: MODE SWITCH Press the [SELECT] key, and use the [+] / [–] keys to select the mode (0 to 7).
  • Page 39 CY-210D Current Set current (Io) Stepper count Step No. Ni: Stepper count (0-9999) Si: Stepper-up rate (50-200%) For example, if the set current is 8.0 kA, the step No. is 3, and the stepper up rate of stepper No. 3 is 105%, the welding current is as follows: Stepper rate step...
  • Page 40 CY-210D 3) Reset method Press the [SELECT] key, and set the mode to “2” using the [+] / [–] keys. Press the [COUNT RESET] key; the total counter is reset. (3) Mode 3: Weld counter [3: WELD COUNT] (1 schedule) This counter operates only while DSW2-(2) is set to ON.
  • Page 41 CY-210D (5) Mode 5: Setting the turn ratio of the transformer [5: TURN RATIO] (One setting for each Valve No.) When the primary constant-current control is selected, set the turn ratio of the transformer to be used. Set the mode No. to 5. (Setting turn ratio of transformer) Set the Valve No.
  • Page 42 CY-210D  When two secondary outputs are used independently: Primary input voltage Turn ratio Secondary output voltage Number of Secondary Welding transformer secondary circuits side Primary When two outputs are used simultaneously side Turn ratio When only one output is used Turn ratio (6) Mode 6: Setting of ±% WINDOW ON/OFF [6: ±% WINDOW ON/OFF] Determine if the upper and lower limits of the current monitor for Current I, Current...
  • Page 43 CY-210D Data: 1 Welding mode for high-tension material (only when DSW1-(1) is set to OFF) This is the mode for the quick rise of current applied to the high-tensile steel plate with a high initial resistance. The control method of Weld I to III is the constant-current control. This mode is suitable for welding of the high-tensile steel plate.

  • Page 44: Setting Of Maximum Current

    CY-210D (5) Setting of Maximum Current Set the maximum current of the welder to be used. If it is unknown, set it by the following procedure. ① Maximum current: 10.0 kA ② Weld I, II: ③ Weld III: ④ Current III: Desired current (10.0 kA maximum) Turn on the power.

  • Page 45: Maintenance

    CY-210D 7. Maintenance (1) Replacement of Battery The life of the lithium battery installed in the control is five years. Accordingly, replace it five years after you purchase this device. Model Lithium battery CR 2450 [ Warning ] ① When replacing the lithium battery, be sure to turn off the main power in order to prevent electric shock.

  • Page 46: Replacement Of Fuses

    CY-210D (2) Replacement of Fuses The printed circuit board in this device has two fuses to protect the device. If one is blown, check for what caused it to blow, and replace it in accordance with the following procedure. Model Fuse (φ6.4 1A) FGB0 250V 1A PbF Fuse (φ10.3 1A)

  • Page 47: Specifications

    CY-210D 8. Specifications (1) Standard Specifications 1) Welding power source: The voltage depends on the specification. See (2) Specification Chart. 220, 230, 240, 380 V AC -25% + 10%, 50/60 Hz 400, 415, 440, 460, 480 V AC -25% + 10%, 50/60 Hz (The voltage is set at shipment.) 2) Control power source: The voltage depends on the specification.
  • Page 48 CY-210D 5) WELD II time: 00-99 cycles, 15 schedules 6) COOL II time: 00-99 cycles, 15 schedules 7) WELD III time: 00-99 cycles, 15 schedules 8) SLOPE II time (downslope included in WELD III time): 00-99 cycles, 15 schedules 9) HOLD time: 00-99 cycles, 15 schedules 10) OFF time in Repeating function: 00-99 cycles, 15 schedules...
  • Page 49 CY-210D 13) Setting range of the maximum-conduction-angle monitor 1 - 180 degrees (if set to 0, the monitor is turned off), 15 schedules If the monitored conduction angle exceeds the set angle, an error signal [ERROR] is output. If the conduction angle is set to "000", the monitor does not check the conduction angle.
  • Page 50 CY-210D 8.Specifications...
  • Page 51 CY-210D 20) External input signals PROGRAM.LOCK: If a closed-contact signal is input, programming is locked. START 1,2,4,8,P: Five types of start signals - START 1, 2, 4, 8, and P (parity) - are available. A 4-bit input terminal is installed. Fifteen schedules can be selected using binary signals.

  • Page 52: Specification Chart

    CY-210D 25) Dimensions and mass 122 mm (H) x 355 mm (W) x 250 mm (D), 4.5 kg 26) Accessories 1) Fuse (spare): φ6.4, 1 A, φ10.3, 1 A: 1 pc. each 2) Operation manual: 1 copy (2) Specification Chart Control Model No.

  • Page 53: Data Out Function (Option)

    CY-210D (3) Data Out Function (Option) Data out function (option) is for outputting the monitor data via RS-485. As to whether the function is equipped on your device or not, see (2) Specification Chart. 1) Data out Data is output when dip switch DSW2-(5) in the control is ON and DSW2-(1) is OFF (Pulsation).
  • Page 54 CY-210D ①: Start No. ②: Monitor the current value of WELD 1. ③: Monitor the conduction angle of WELD 1. ④: Deviation of the WELD 1 current. If the current is larger than the current setting, “+” is displayed; if the current is smaller than the setting, “-” is displayed.

  • Page 55: Outline Drawing

    CY-210D (4) Outline Drawing (Unit: mm) 8.Specifications...

  • Page 56: Schedule Data Table

    CY-210D 9. Schedule Data Table 9.Schedule Data Table...
  • Page 57 CY-210D 9.Schedule Data Table...

  • Page 58: Error Indication And Countermeasures

    CY-210D 10. Error Indication and Countermeasures MODE DATA Each error code blinks in the “DATA” area on the panel. Error Code Contents Countermeasures Self-diagnosis error Because the backup battery is dead, the program data is lost. Replace the battery and input the schedule again. Start input error A parity check error of the start input was detected.

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