Amada WELTOUCH CT-110E Operation Manual
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Amada WELTOUCH CT-110E Operation Manual

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WELTOUCH
®
CT-110E
OPERATION MANUAL
OM1211284
CT-110E-E01-202309

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Summary of Contents for Amada WELTOUCH CT-110E

  • Page 1 WELTOUCH ® CT-110E OPERATION MANUAL OM1211284 CT-110E-E01-202309...
  • Page 2 CT-110E Preface Thank you for purchasing our product. This operation manual describes the proper method of operation, as well as precautions for its use. If you have  any questions concerning operation of the controller, read this operation manual. Read this operation manual carefully to ensure the proper use of all functions. Keep this operation manual in a ...

  • Page 3: Table Of Contents

    CT-110E 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

    CT-110E 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 CT-110E 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 CT-110E 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

    CT-110E (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

    CT-110E 2. Features The WELTOUCH CT-110E 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...

  • Page 9: Name And Function Of Each Section

    CT-110E 3. Name and Function of Each Section (1) Front Panel ① Schedule No. setter/indicator [SCHEDULE] Calls a No. to input a schedule and indicates the schedule No. ① Schedule No. ② State indicator SCHEDULE NUMBER setter/indicator Indicates the current state of the CT-110E for confirmation.

  • Page 10: Rear Panel

    CT-110E ⑨ Weld-force key [SQUEEZE] Each time this key is pressed, the LED at its upper left comes on and goes off alternately. While the LED is lit up, the weld-force mode is selected and the weld force is applied while the start signal [START1,2,4,8] is turned on; however, the weld current does not flow.

  • Page 11: Internal Block Diagram

    CT-110E (3) Internal Block Diagram Welding transformer Welding head Welding power Thyristor Toroidal coil (For detection of the secondary constant current) (For detection of primary constant current) Turn-on pulse Transformer for generation synchronization Waveform Waveform amplification reproduction Turn-on angle command Primary Secondary Source-voltage...

  • Page 12: Connection

    CT-110E 4. Connection (1) Basic Configuration 1) The general system configuration of the CT-110E is as follows: Example) Installation to stationary welder ① CT-110E The body of the constant-current resistance welding control. Connect Control power to it. ① ② Toroidal coil (Option) Installed to the stationary welding electrode arm.

  • Page 13: Connection Of Power Source

    CT-110E (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 CT-110E, as shown below. ②...

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

    CT-110E (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 CT-110E 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 CT-110E 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

    CT-110E (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 Dip switches Factory default setting of dip switches...
  • Page 18 CT-110E (3) Explanation of the functions of dip switches ① DSW1-(1): Selects the constant-current control or source-voltage fluctuation compensation control. OFF: Constant-current control Source-voltage fluctuation compensation control ② DWS1-(2): Selects the primary current or secondary current to be detected in the constant-current control mode. If a coil is connected for full-wave detection in the source-voltage fluctuation compensation control mode, set this dip switch properly.
  • Page 19 CT-110E ⑦ DSW1-(7): Selects the length of time for which the holding finish signal is to be output. OFF: Output of the holding-finish-signal level Output of the holding-finish-signal pulse If this dip switch is set to OFF, the holding finish signal [HOLD END] is output for approximately 0.2 seconds, or while the start signal is being input.
  • Page 20 CT-110E ⑫ DSW2-(4): Selects start in 4-schedule start mode or 15-schedule start mode upon reception of an external start signal. OFF: 15-schedule start mode 4-schedule start mode If this dip switch is set to OFF, 15 schedules made by combining start signals [START 1, 2, 4, and/or 8] are selected.

  • Page 21: Input Method For Start Signals

    CT-110E (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 DSW-1(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 CT-110E 2) When the operation is started in the 15-schedule start mode and the parity check of the start signal is performed (when DSW-1(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

    CT-110E 5. Interface (1) External Input and Output Signals Ground the E terminal (grounding) of CT-110E 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 terminal, the transformer in the timer will The voltages for this device are indicated burn out.
  • Page 24 CT-110E 1) Explanation of external input and output signals Description Name Ground the E terminal (grounding) in common with the grounding Ｅ of the contactor. G1,K1,G2,K2 Connect to each gate terminal of the contactor (thyristor). The voltage for this equipment are indicated on the terminal block seal, check the voltage and connect properly.
  • Page 25 CT-110E connect to the solenoid valve. Outputs AC or DC 24V from the valve number VALVE 1 (4: VALVE1, 5: VALVE2) selected VALVE 2 from the start input until the end of HOLD. Common terminal. Connected to 0V side of the internal power supply (24V DC).
  • Page 26 CT-110E Pin No. Name Description WELD ON output terminal (Open collector) The output signal depends on the position of internal dip switch DSW1-(3). When the dip switch DSW1-(3)is ON: The signal is output while the power is turned on (Weld I, II, III). Connect to the flicker device. WELD ON When the dip switch DSW1-(3) is OFF: The signal is output output from the start of (WELD...
  • Page 27 CT-110E 2) Connection of input signals Wire according to the using PLC(programmable logic contoroller) to be used by referring to ① to ④ . Since terminals 33 and 34 are short-circuited at shipment, remove the short-circuit wire in the cases of ①, ③, and ④.
  • Page 28 CT-110E ③When connecting to a PNP current output type device (when using an external power supply) Connect the 0V side of the external power supply DC24V to terminal 34. ④When connecting to a device with NPN open collector output (when using an external power supply) Input the + side of the external power supply DC24V to terminal 34.

  • Page 29: Timing Chart

    CT-110E (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 30 CT-110E 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 OF: 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 31 CT-110E 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/COUNT RESET] is turned on.
  • Page 32 CT-110E 4) 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 33: Operation Method

    CT-110E 6. Operation Method (1) Basic Operation 1) Turn on the control power switch. If the control power switch [POWER] on the front is turned on, control power is supplied to the machine. When it is turned on, all LEDs light up for 2-3 seconds while self-diagnosis is performed.
  • Page 34 CT-110E 4) Press the [WELD] key to start welding. ON/OFF If the weld ON/OFF key [WELD] at the lower right is pressed to start welding, WELD the green LED to the upper left of the key lights up. The green [READY] LED lights up (when the weld ON/OFF signal [WELD ON/OFF] is turned on).
  • Page 35 CT-110E 6) Upon completion of welding, the measured value is indicated. ① The green [MONITOR DISPLAY] LED lights up, and the measured value that is the welding result is indicated. MONITOR DISPLAY The measured value of the item, the green LED of which is lit, is shown on the indicator CURRENT MONITOR...

  • Page 36: Setting Of Schedule Data

    CT-110E (2) Setting of Schedule Data 1) Setting of schedule No. Press the SCHEDULE [NUMBER] key SCHEDULE NUMBER and select a schedule No. Schedule No. key 2) Setting of timer CYCLES/ CURRENT ① Press the -> key to select an item to be set.
  • Page 37 CT-110E 3) Setting of the maximum current ① Press the [HIGH] and [LOW] MONITOR keys at the same time, then input the maximum welding current (maximum secondary DEG. current) using the [+] / [-] keys. COND. HIGH Setting range of max. current: ANGLE 5 - 80 kA CURR.

  • Page 38: Setting Of The Monitor

    CT-110E b. When the source-voltage fluctuation compensation control is used 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 a 50° thyristor firing angle will flow;...
  • Page 39 CT-110E 2) Setting of the current monitor (Effective only in constant-current control mode) ① Press the [HIGH] key to enter the MONITOR setting mode. ② Set the upper limit of the current DEG. monitor using the [+] / [-] keys (setting range: 0 - 49%).
  • Page 40 CT-110E 4) Indication of the conduction angle and monitored current MONITOR Upon completion of the weld cycle, the monitor indicates the conduction angle and DEG. monitored current. COND. HIGH ANGLE CURR. (WELD 1) Indication of the conduction angle of Weld 1 ①...

  • Page 41: Setting By Mode No

    CT-110E (4) Setting by Mode No. The setter/indicator of the data/counter are explained below. MODE ① Press the [SELECT] key, and select the mode MODE DATA (0 - 7) using the [+] / [-] keys. Note: If DSW2- (7) is set to ON, select the mode from 0 to 9.
  • Page 42 CT-110E ② Operation If the number of weld counts for each step No. reaches the set value, the step No. is increased by 1 and the current is increased by the set stepper-up rate. Upon completion of the last step, the red [STEP END] LED lights up and the step-end signal [STEP END] is turned on.
  • Page 43 CT-110E (3) Mode 3: Weld counter [3: WELD COUNT] (1 schedule) ① Setting method for preset value (Setting of the weld counter) Set the mode No. to 3. Set the preset value of the weld counter in the data setter. ②...
  • Page 44 CT-110E ③ Reset method 1) Reset of the work count. When the interlock function is turned on (DSW2-(2): ON) a. Press the [SELECT] key and set the mode to "4" using the [+] / [-] keys. b. Press the [COUNT RESET] key; the Work counter is reset. 2) Reset of the work count.
  • Page 45 CT-110E Examples of the turn ratio of the transformer • When only one secondary output is provided: Welding transformer Primary input voltage Primary Secondary = 44 Turn ratio = Secondary output voltage • When two secondary outputs are connected in parallel: Welding transformer Secondary Primary input voltage...
  • Page 46 CT-110E (6) Mode 6: Setting of: ±% WINDOW ON/OFF [6: ±% WINDOW ON/OFF] Determine whether the upper and lower limits of the current monitor for Current I, Current II, and Current III should be judged. Set the mode No. to 6. (Setting of ±% WINDOW ON/OFF) Set ±% WINDOW ON/OFF in the data setter.

  • Page 47: Setting Of The Maximum Current

    CT-110E (8) Mode 8: Setting of the constant-current correction value for Interval G1 (only when DSW2-(7) is set to ON) Adjust the constant-current correction value when the control is connected to a welder of the single-phase rectifier type and the welding current rises abnormally and overshoots or does not rise quickly enough.

  • Page 48: Current Calibration Method

    CT-110E (6) Current Calibration Method Though the CT-110E is properly factory-adjusted, the control current may vary over time. The control-current value may also change due to a current sensor and its installation. In such a case, the difference between controls used and the control current values can be adjusted using the properly calibrated Weld Checker, according to the following procedures.

  • Page 49: Maintenance

    CT-110E 7. Maintenance (１) Replacement of Fuses The printed circuit board in this device has two fuses to protect the device. If one is blown, check for the cause, and replace it in accordance with the following procedures. (Note) Both fuses use the same fuse, which is different from CT-110D and earlier.

  • Page 50: Specifications

    CT-110E 8. Specifications (1) Standard Specifications (1) Welding power source: The voltage depends on the specification. See (2) Specification Chart. 220V/230V/240V/380V AC -25% +10%, 50/60 Hz 400V/415V/440V/460V/480V AC -25% +10%, 50/60 Hz (Voltage set at time of shipment) (2) Control power source: The voltage depends on the specification.
  • Page 51 CT-110E ⑤ Weld II (W2) time: 00 - 99 cycles, 15 schedules ⑥ Cool II (C2) time: 00 - 99 cycles, 15 schedules ⑦ Weld III (W3) time: 00 - 99 cycles, 15 schedules ⑧ Slope II (S2) time (Downslope included in time of Weld 3): 00 - 99 cycles, 15 schedules ⑨...
  • Page 52 CT-110E (14) Setting range of the transformer turn ratio: 1.0 to 199.9 (15) Current stepper-up ① Preset Step No.: 1 - 9 Step count: 0 - 9999, 1 schedule Stepper-up rate: 50 - 200%, 1 schedule ② Operation If the number of weld counts for each step No. reaches the set value, the step No.
  • Page 53 (19) Error outputs To output an error signal [ERROR] when an error is detected or the "Check current" signal is indicated Contents Detection period Operation Reset Holding-finish output Alarm output Indication on panel Remarks 1 Self-diagnosis error Cannot start Reset error Not turned on ERROR When the power is...
  • Page 54 CT-110E (20) External input signals ① PROGRAM.LOCK: If a closed-contact signal is input, programming is locked. ② 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 55: Specification Chart

    CT-110E ① Fuse (spare): 2 pc. ② Fittings: 1 set (2) Specification Chart Control Model No. Welding power Valve Data out Toroidal power CT-110E- source output function coil source 00-00 100V 220V 440V 100V Available MB-400L or 00-01 120V 240V 480V 24V DC Available...

  • Page 56: Data Out Function (Option)

    CT-110E (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) on the control is ON and DSW2-(1) is OFF (Pulsation).
  • Page 57 CT-110E Starts with the character "M". Space code "20H" between each piece of data. Ends with CR code "0DH". 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, “+”...

  • Page 58: Outline Drawing

    CT-110E (4) Outline Drawing 1) CT-110E (Unit: mm) Fittings set M5 Rubber cushion: 4 pcs. M5 Sems, 5 x 12: 4 pcs. M5 Washer: 8 pcs. M5 Nut: 8 pcs. M5 Spring: 8 pcs. Fittings (Upper and lower): 2 pcs. 8.Specifications...
  • Page 59 CT-110E 2) Detail Drawing of Fitting 8.Specifications 8-10...

  • Page 60: Schedule Data Table

    CT-110E 9. Schedule Data Table 9.Schedule Data Table...
  • Page 61 CT-110E 9.Schedule Data Table...

  • Page 62: Error Indication And Countermeasures

    CT-110E 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 Schedule data is different from the time of programming. Check all settings. If it appears again after initialization, repair is required.

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