Car-O-Liner CTR9 Instruction Manual Download Page 117

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CTR9 Car-O-Liner

Group

49023, EN - rev. 4,

2020-01

117

Essential parts list

Item

Description

Capacitor

D1,D2,D3

Rectifier diode

D4,D5

Welding diode

D6,D7,D8,D9

LED

D10,D11

Bi-Color LED

Contactor

Water pump

Fan for water cooler

USB connector

R1,R2

Resistors

SW1

Trigger button

SW2

Main switch

SW3

Thermal switch for over temperature protection

SW4

Reset switch

Transformer

Power supply

U2,U4

Control Board

Inverter

Control panel and display

Pressure sensor

U10

Proportional valve

U11

3/2 Valve

Summary of Contents for CTR9

Page 1: ...49023 rev 4 2020 01 EN CTR9 Spot welder Instruction Manual...

Page 2: ...l carefully to become familiar with the proper operation of the spot welder CTR9 It is recommended that you use your authorized Car O Liner Distributor for maintaining and servicing your products Neve...

Page 3: ...9001 2008 and ISO 14001 2004 accredited organisation Below an example of how the EC Declaration of Conformity for the CTR9 is outlined A signed and dated copy of the EC Declaration of Conformity incl...

Page 4: ...ng of cooling liquid 31 3 8 Draining the cooling system 32 3 9 C Tong transformer gun 33 3 9 1 Rotating the C Tong gun 34 3 9 2 Rotating the C Tong handle 36 3 10 C Tong accessories electrode yokes 37...

Page 5: ...ogger PC software 80 6 8 Turning off cooling water when changing electrodes 81 6 9 User settings 82 6 10 Multi function gun settings 83 6 10 1 Installing the multi function gun 84 6 10 2 Fitting the m...

Page 6: ...Dismantling and Salvage 111 10 Technical Specifications 112 10 1 208V 112 10 2 230V 113 10 3 400V 114 10 4 460V 115 11 Electrical diagram 116 12 Spare Parts and Accessories 118 12 1 Multi Function Gun...

Page 7: ...e welding electrodes together automatically when triggered Electrode force is an important ingredient in a good resistance weld The pressure setting is visible in the control panel display and can be...

Page 8: ...tion 208 V 5 10 50 60 Hz 3 phase 230 V 5 10 50 60 Hz 3 phase 400 V 5 10 50 60 Hz 3 phase 460 V 5 10 50 60 Hz 3 phase The actual voltage and frequency is stated on the name plate see section 1 3 Markin...

Page 9: ...rking The name plates are located at the front of the welder unit and on the right side of the C Tong Figure 1 3 Examples of CTR9 name plates Name plate for CTR9 208V art no 49081 Name plate for CTR9...

Page 10: ...e precedence over individual responsibili ties or local regulations Great effort has been placed on the design and manufacture of the CTR9 so that it will comply with all applicable safety aspects for...

Page 11: ...that is required for problem free use or optimal use of the welder In addition to the safety signs illustrated in section 2 3 Safety signs the following warnings and important notices appear in the m...

Page 12: ...efore servicing cleaning or maintenance Risk for electrical shock WARNING Ground Fault Circuit Interrupter GFCI must be used WARNING Don t remove any covers when cleaning the welder Risk for electrica...

Page 13: ...d this angle When the balancer suspension rope is fully extended do not pull the hanging C Tong any further The welder might tip causing personal injuries or material damage WARNING To avoid the risk...

Page 14: ...network IMPORTANT Read this manual carefully to become familiar with the proper operation of the welder Do not neglect to do this as improper handling may result in personal injury and damage to the...

Page 15: ...riendly way IMPORTANT All straight electrodes have an inner tube that must be fitted to provide sufficient cooling IMPORTANT It is not possible to start welding before cooling water pump flow is turne...

Page 16: ...agent must be used If the machine is used in temperatures below 10 C a higher concentration of High Tech Protection Fluid must be used IMPORTANT It is the responsibility of the owner to ensure that t...

Page 17: ...Art no 99786 WARNING All electrical connections must be made by a qualified electrician Disconnect the supply before performing any service or installation work Art no 43720 WARNING Appropriate protec...

Page 18: ...Group AB CTR9 18 49023 EN rev 4 2020 01 2 3 1 Placement of safety signs The safety signs are placed as follows Figure 2 1 Placement of safety signs Art no 43712 Art no 43720 Art no 99786 Art no 46002...

Page 19: ...Tong is used The electrodes become hot if the C Tong is used frequently which may affect the quality of the weld nuggets The overheat protection is in two levels The power transformer is monitored by...

Page 20: ...makers heart defibrillators insulin pump and other similar implants are not allowed to work on resistance spot welding ma chines Always remember that this type of machine produces powerful magnetic fi...

Page 21: ...e only replaced by identical parts Electromagnetic interferences may be reduced by performing regular maintenance on the complete installation keeping welding cables as short as possible shielding whe...

Page 22: ...ure that the equipment has been installed as specified in the instructions provided It is also the owner s responsibility to ensure that the welder is inspected in accordance with applicable regulatio...

Page 23: ...the welder must be assembled as follows 1 Fit the control panel column a onto the welder unit by tightening hex allen screw b to engage the four hooks c into the column Be careful with the electric c...

Page 24: ...Group AB CTR9 24 49023 EN rev 4 2020 01 3 3 1 C Tong holder assembly Fit the C Tong holder as follows 1 Fit the C Tong holder a onto the panel column by inserting rod b and tightening the two hex all...

Page 25: ...voltage and frequency are the same as shown on the welder The actual voltage and frequency is stated on the name plate see section 1 3 Marking This machine must only be connected to a TN earthing sys...

Page 26: ...es and the amperage of the slow blow fuses to be used It is recommended to feed the welding machine via mains disconnect switch for facilitating maintenance WARNING Before plugging the mains plug into...

Page 27: ...her work with grounded equipment shall not be performed at the same time as welding Always use Ground Fault Circuit Interruptor GFCI to avoid stray current damages on the welder Figure 3 1 Grounding r...

Page 28: ...connector 2 Make sure that the compressed air network pressure to the welder has a minimum pressure of between min 5 bar 73 PSI and max 10 bar 145 PSI IMPORTANT The compressed air must be filtered an...

Page 29: ...utlet 4 Connect welding cable quick connector and lock the locking levers 1 Release the locking levers and disconnect welding cable quick connector 2 Disconnect air hose 3 Before disconnecting water h...

Page 30: ...ar O Liner Group AB CTR9 30 49023 EN rev 4 2020 01 WARNING Water must not come in contact with electrical contacts of the welder when disconnecting the welding cable water hoses Risk of material damag...

Page 31: ...nt IMPORTANT Do not use water that is salt brackish or rich in lime If there is any uncertainity regarding the quality of the water use destilled water IMPORTANT If the heater is used in temperatures...

Page 32: ...ing the C Tong electrodes 3 Place a bucket under the C Tong to collect the cooling liquid 4 Turn on the water flow see section 6 8 Turning off cooling water 5 Turn off the water flow as soon as it sta...

Page 33: ...button 3 Rotating attachment for Support arm 4 Cylinder electrode 5 Yoke electrode 6 Electrode caps 7 Standard electrode yoke 80 mm throat depth water cooled 8 Locking lever for electrode yoke 9 Cool...

Page 34: ...g gun To facilitate welding the C Tong gun can be rotated to desired position This can be performed in two ways 1 Rotating complete C Tong gun 360o continuously when suspended in the Support arm see 3...

Page 35: ...p AB 49023 EN rev 4 2020 01 35 2 Rotating C Tong body without rotating handle 1 Push button left or right side of handle to rotate C Tong body 2 Rotate C Tong body to desired position 3 Release button...

Page 36: ...C Tong handle To further facilitate welding the C Tong handle can also be rotated 355o independently of the C Tong body 1 Push button left or right side of handle to rotate C Tong handle 2 Rotate C T...

Page 37: ...there are three different electrode yokes available for the CTR9 1 40 mm throat depth water cooled 2 350 mm throat depth water cooled 3 500 mm throat depth water cooled Figure 3 3 C Tong accessories e...

Page 38: ...ng electrode arms which increases the range of the welder The A Tong is also fully rotatable to further increase access The A Tong Adapter Kit consists of A Tong 1 electrode holder arms 2 electrodes 3...

Page 39: ...can be fitted with a number of tools to further widen the areas of use for the CTR9 Single spot Dent puller Zig zag wire Screw 6 mm Screw 5 mm Clip rivets Stitch weld Carbon rod Figure 3 4 Multi Funct...

Page 40: ...ion instruction Figure 3 5 The Support arm Note Use extension cord to reach low welding areas WARNING The support arm is only intended for suspension of the C Tong No other objects are alowed Maximum...

Page 41: ...y extended do not pull the hanging C Tong any further The welder might tip causing personal injuries or material damage WARNING To avoid the risk of the welder tipping when using the support arm alway...

Page 42: ...elder Do not pull the cable or the tong to move the welder The welder might tip causing personal injuries or serious damage to the welder When moving the machine the C Tong must be fixed at the intend...

Page 43: ...a fork lift The welder must be securely strapped to the pallet before transport in the same way as when it was delivered from the manufacturer Before transporting a welder that is filled with decalcif...

Page 44: ...chines with empty tank Before storing machines that are filled with clean water accord ing to the water quality information in section 3 6 and Car O Liner High Tech Protection Fluid at temperatures be...

Page 45: ...t place the welder on an unstable or uneven ground The welder might tip causing personal injuries or serious damage to the welder WARNING Never spill liquid of any kind on the welder Risk for injuries...

Page 46: ...stalled as specified in the instructions provided It is also the owner s responsibility to ensure that the welder is inspected in accordance with applicable regulations before use IMPORTANT It is the...

Page 47: ...g cycle can be cut off before the welding current is activated approximately 0 5 sec by releasing the trigger button When the welding current has started you can not cut off the welding cycle Always h...

Page 48: ...weld without anything between the electrodes 2 The Calibration message below is shown on the Control panel display when calibration is necessary To perform a correct calibration the electrode caps mus...

Page 49: ...es that electrode cap service is necessary Can be cleared by using reset button 5 or in Welder control panel Weld quality fail 4 Red LED indicates faulty spot weld Welding could not be performed becau...

Page 50: ...4 5 it is recommend ed to keep the C Tong in the C Tong holder of the welding machine 4 5 1 Changing the C Tong electrode yoke Change the electrode yoke by following the instructions below 1 Press th...

Page 51: ...2020 01 51 4 Release the electrode yoke by pulling the safety knob 5 Remove the yoke 6 To fit a yoke insert the connection shank a into the yoke holder b of the C Tong body WARNING The tools or electr...

Page 52: ...ten the yoke locking lever fully to ensure correct locking of the yoke 8 Reassembly is the reversal of the foregoing instructions WARNING Tighten the yoke locking lever fully to ensure correct locking...

Page 53: ...ong electrodes Change the electrodes by following the instructions below 1 Release the cylinder electrode with a 17 mm wrench placed at the flat area of the electrode 2 When reassembling ensure that t...

Page 54: ...screw b and pull out the electrode When inserting a new electrode fit flat side of the electrode brim to the yoke edge c IMPORTANT All straight electrodes have an inner tube that must be fitted to pro...

Page 55: ...by following the instructions below 1 Electrode cap must be changed BEFORE the rounded tip becomes flat The standard cap radius is R15 2 To remove the old electrode caps use for example locking pliers...

Page 56: ...vice message below is shown on the Control panel display when cleaning or changing electrode caps is necessary IMPORTANT The shape of the caps is essential and the electrode caps must be changed regul...

Page 57: ...to A Tong by following the instructions below Before mounting the A Tong the C Tong electrode yoke must be demounted see section 4 5 1 Changing the electrode yoke 1 Connect the by pass hose to the co...

Page 58: ...e greased with a small amount of copper paste before assembling to prevent sticking and to maintain proper electrical conductivity 3 Grease the A tong adapter connection shank a and the yoke holder b...

Page 59: ...CTR9 Car O Liner Group AB 49023 EN rev 4 2020 01 59 5 Insert and tighten the A Tong adapter electrode 6 Push button to rotate the A Tong adapter 180o 7 Release button to lock the A Tong adapter...

Page 60: ...23 EN rev 4 2020 01 8 Fit the A Tong to the A Tong adapter electrode Push in the A Tong completely a 9 Lock the A tong by tightening the A Tong handle 10 Pull A Tong electrodes apart a and push in the...

Page 61: ...CTR9 Car O Liner Group AB 49023 EN rev 4 2020 01 61 11 Lock the electrode by tightening the locking screw The A Tong is now ready for action...

Page 62: ...nge the A Tong electrodes by following the instructions below 1 Release the two locking screws and detach the electrode IMPORTANT After electrodes are changed they must be aligned to maintain optimal...

Page 63: ...nge the electrode caps by following the instructions below 1 Electrode cap must be changed BEFORE the rounded tip becomes flat The standard cap radius is R15 2 To remove the old electrode caps use for...

Page 64: ...3 EN rev 4 2020 01 4 To clean the electrode caps from impurities use a rasp IMPORTANT The shape of the caps is essential and the electrode caps must be changed regularly to maintain good welding resul...

Page 65: ...cal position The A Tong can be set in either horizontal or vertical position for optimal working angle You can rotate the A Tong stepless to desired position either by using the A Tong handle or the s...

Page 66: ...Car O Liner Group AB CTR9 66 49023 EN rev 4 2020 01 3 Tighten the A Tong handle 4 Alternate rotating method Push button a and rotate b the A Tong to desired position...

Page 67: ...and thickness of material tools for Multi function gun etc WeldLogger Activate the weld logger Water For turning off on cooling water pump when chang ing electrodes Welding mode Auto2 Number of metal...

Page 68: ...ol button 2 Selected tool is displayed in the given example the C Tong 3 Calibrate electrodes will be displayed when entering Full Auto see section 8 2 Display information messages 4 Fitted automatica...

Page 69: ...anual modes 2 Set the material thickness by pressing the up down buttons 3 Material thickness is displayed 4 Select tool by pressing the Change tool button 5 Selected tool is displayed in the given ex...

Page 70: ...function similar to Auto 1 mode 1 Set the Auto 2 mode by pressing the Auto Man button 2 Set the number of metal sheets Change number of metal sheets by using the up down buttons 3 Select Set the type...

Page 71: ...ssing the Auto Man button 2 Set the welding time by pressing the left button twice when you are in Number of metal sheets position Change value by using up or down button 3 Set the welding current by...

Page 72: ...ed off to achieve approved welding result The pre pulse from the welder must be set according to the type of coating 1 Select Pre pulse by pressing the Pre pulse button Toggle between Zn Ed Ed coating...

Page 73: ...CTR9 Car O Liner Group AB 49023 EN rev 4 2020 01 73 3 In Full Auto there are two selections for pre pulse Auto and Auto Dry Glue...

Page 74: ...ng on sheet thickness Attention If the welding spots are placed on the edge of the heat moulded metal sheets see picture above the metal sheets joints will be altered by the increased temperature whic...

Page 75: ...printed using the optional PC software 1 Open the WeldLogger by pressing the WeldLogger button 2 Create new log file or continue to work on existing log file 3 Go to section of the vehicle by pressin...

Page 76: ...t 6 Right Front Fender 22 Left Rear Inner Wing 7 Left Front Upper Chassis Leg 23 Right Rear Inner Wing 8 Right Front Upper Chassis Leg 24 Left Rear Chassis Leg 9 Left Front Chassis Leg 25 Right Rear C...

Page 77: ...pen the Weld logger log files menu by pressing the Menu button 2 Select log file by pressing the up down button 3 Open log file by pressing the right button 4 Selected log file opens up Results of per...

Page 78: ...2020 01 6 7 4 Delete unsatisfactory welding If one or more weldings are unsatisfactory you can remove them 1 When in scroll mode press right button 2 Box with Delete weld is displayed For No press the...

Page 79: ...memory In the WeldLogger log file menu you can save log files to USB memory This allows you to transfer the log files to a PC 1 Select requested log file from menu 2 Press right button to Open mode 3...

Page 80: ...you to document save and print your log files transferred from the USB memory 1 Work orders saved on the computer 2 Basic information form Here you can edit your work order 3 Click on this button to...

Page 81: ...mp in order to prevent water from pouring out from the yoke 1 Press the Water flow button to turn OFF the cooling water pump 2 Red box with Water flow off is shown 3 After changing the electrodes pres...

Page 82: ...ck Save weld logs Saving ALL existing Weld Logs Delete weld logs Deleting ALL existing Weld Logs 1 If you are in welding mode press the Menu button Then the Log files menu appears 2 Then press the Cha...

Page 83: ...N rev 4 2020 01 83 6 10 Multi function gun settings 1 Select Multi function gun by pressing the Change tool button 2 The Multi function gun is displayed 3 Yellow box with Add block is shown 4 Multi fu...

Page 84: ...ty shown on the label 3 Press the trigger button on the C Tong once The gun closes contacts the adapter and stays closed 4 Insert and lock the control plug in the socket at the left sideof the C Tong...

Page 85: ...multi function gun with tools as follows 1 Release the lock nut on the multi function gun by hand or with a wrench to open the tool holder 2 Insert the desired tool into the tool holder 3 Lock the to...

Page 86: ...ector shall be connected NOTE These instructions do not apply to single sided spot welding NOTE The ground connector must be connected to the outer body sheet NOTE For best results apply the ground co...

Page 87: ...6 10 4 Select required tool When Multi function gun is installed you can select the required tool 1 Select tool by pressing the up down button 2 Selected tool is displayed 3 Set welding time and curr...

Page 88: ...ainst the rear plate by using the copper lug that was delivered together with the other equipment Already welded spots produce a parallel resistance and thus an energy loss To reduce this loss to the...

Page 89: ...the multi function gun by hand or with a wrench to open the tool holder 2 Make sure that the tip of the single side electrode is rounded For changing the electrode see section Changing the single spo...

Page 90: ...f pliers Turn the pliers and the electrode back and forth to loosen the electrode from the electrode holder 3 Remove the used electrode from the holder 4 Place a new electrode into the electrode holde...

Page 91: ...inner body sheet is level and not curved NOTE Remove paint primer and rust and apply the ground connector as close to the welding area as possible and at a maximum distance of one me ter from the wel...

Page 92: ...ular pulling eye When using the dent puller standard procedures are welding of washers or triangular pulling eye 1 Select Dent puller tool by pressing the up down button 2 Set welding time and current...

Page 93: ...rev 4 2020 01 93 6 10 7 Screw 6 mm The screw tool is a multi function gun application for fastening trim and clips 1 Select Screw 6mm tool by pressing the up down button 2 Set welding time and curren...

Page 94: ...6 10 8 Screw 5 mm The screw tool is a multi function gun application for fastening for example trim electric cables and brake pipes 1 Select Screw 5mm tool by pressing the up down button 4 Set weldin...

Page 95: ...rev 4 2020 01 95 6 10 9 Clip rivet The clip rivet tool is a multi function gun application for fastening clips 1 Select Clip rivet tool by pressing the up down button 2 Set welding time and current Lo...

Page 96: ...nd welding of Zig zag wire The stitch weld electrode is a multi function gun application for producing a seam weld and for welding Zig zag wire 1 Select Stitch weld tool by pressing the up down button...

Page 97: ...shrinking Carbon rod is a multi function gun application for shrinking metal Use rod for larger area and stamp electrode for smaller area Break off carbon rod to desired length 1 Select Carbon rod too...

Page 98: ...EN rev 4 2020 01 6 10 12 Ending the multi function gun program 1 Select C Tong by pressing the Change tool button 2 The C Tong is displayed 3 Yellow box with Remove block is shown 4 Push the C Tong tr...

Page 99: ...three available modes Auto 1 Auto 2 and Manual Fully Automatic is not available NOTE For mounting of the A Tong see section 4 5 4 Converting C Tong to A Tong 6 11 1 Auto 1 mode 1 Select A Tong by pres...

Page 100: ...ol button 2 The A Tong is displayed For all functions see section 6 3 C Tong Auto 2 mode 6 11 3 Manual mode 1 Select A Tong by pressing the Change tool button 2 The A Tong is displayed 3 The max force...

Page 101: ...test follow the instructions below 1 Set the desired welding program see chapter 6 Welding modes and weld two metal sheets of the same thickness as those to be welded on the vehicle 2 Place the welded...

Page 102: ...nance Risk for electrical shock IMPORTANT Never use water jet detergents solvents thinners or benzene when washing the welder since they can damage the welder 7 1 Service Service must be performed by...

Page 103: ...al regulations Check that all welding caps are in good condition Cleaning with Scotch Brite Hand Pads Use a tip dresser to maintain the proper shape Change caps if necessary Check coolant level Check...

Page 104: ...01 WARNING Do not remove any covers when cleaning the welder Risk for electrical shock IMPORTANT Never use water jet detergents solvents thinners or benzene when washing the welder since they can dama...

Page 105: ...able is useful when tracing welder faults The table presents the most com mon faults and their possible causes There are also information messages yellow display background see 8 2 Display information...

Page 106: ...tween the metal sheets of the welding object for example adhesive Uneven caps on the electrodes The welder does not receive sufficient power Voltage drop from power supply Blown fuse s Clean between t...

Page 107: ...d Wait and try again when Over tempera ture message disappears Check cooling water level Add cooling water if level is low Control voltage error Missing supply voltage or value below specified level C...

Page 108: ...2020 01 Sensor error Sensor malfunction Contact authorized Car O Liner service personnel 3 phase error One or more phases are missing Check fuses in main supply system Pump error Pump malfunction Cont...

Page 109: ...ut anything between the electrodes Add Block is shown when Multi function gun is selected with the Change tool button on the control panel Remove Block is shown when C Tong is selected with the Change...

Page 110: ...eet thickness is over 10 mm Thickness too low is shown when metal sheet thickness is below 0 8 mm Invalid parameter is shown when a material is not supported by the welding process Low Battery is show...

Page 111: ...important that the equipment is dismantled in an environmentally friendly way To limit strain on the environment and its natural resources it is important that the various parts of the welder are recy...

Page 112: ...ing Output Maximum short circuit output current I2cc 16 0 kA Permanent output current 100 duty factor I2p 14 1 kA No load voltage U2d 12 0 V Liquid Cooling Cooling power 1000W Tank capacity 20 l 5 3 g...

Page 113: ...Maximum short circuit output current I2cc 16 0 kA Permanent output current 100 duty factor I2p 15 8 kA No load voltage U2d 13 4 V Liquid Cooling Cooling power 1000W Tank capacity 20 l 5 3 gal Rated c...

Page 114: ...factor Sp 130 kVA Permanent input current ILp 190 A Welding Output Maximum short circuit output current I2cc 16 0 kA Permanent output current 100 duty factor I2p 15 8 kA No load voltage U2d 13 0 V Liq...

Page 115: ...Maximum short circuit output current I2cc 16 0 kA Permanent output current 100 duty factor I2p 15 8 kA No load voltage U2d 14 5 V Liquid Cooling Cooling power 1000W Tank capacity 20 l 5 3 gal Rated c...

Page 116: ...Car O Liner Group AB CTR9 116 49023 EN rev 4 2020 01 11 Electrical diagram...

Page 117: ...LED D10 D11 Bi Color LED K1 Contactor M1 Water pump M2 Fan for water cooler P2 USB connector R1 R2 Resistors SW1 Trigger button SW2 Main switch SW3 Thermal switch for over temperature protection SW4...

Page 118: ...Car O Liner Group AB CTR9 118 49023 EN rev 4 2020 01 12 Spare Parts and Accessories 12 1 Multi Function Gun and Accessories Box...

Page 119: ...6x1 5 mm coppered 13 100 A 41905 Trim strip nipple 3x3 2 mm 14 100 A 41906 Trim strip nipple 3x4 5 mm 15 100 A 41907 Holding nipple 5x8 2 mm 16 100 A 41908 Set screw M4x12 mm 17 100 A 41909 Set screw...

Page 120: ...Car O Liner Group AB CTR9 120 49023 EN rev 4 2020 01 13 CTR9 Electrodes Chart Electrode combinations for 500 mm yoke 48251 with 48250 48252 with 48249...

Page 121: ...ion repair equipment to the automotive aftermarket For more than forty years we have supplied the industry with innovative solutions technical development training and customer support Car O Liner is...

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