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Entron EN1000 series, Installation And Operation Manual

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6. GENERAL OPERATING INSTRUCTIONS

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6.1  WELD  SEQUENCE  EXAMPLE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.2  CYCLE  MODES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

6.2.1  NON  REPEAT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65

6.2.2  REPEAT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66

6.2.3  CHAIN  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66

6.2.4  SUCCESSIVE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68

6.2.5  CONDITIONAL  SUCCESSIVE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69

6.2.6  WAIT-HERE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

6.3  SLOPE  MODES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6.3.1  NO  SLOPE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71

6.3.2  UP  SLOPE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72

6.3.3  DOWN  SLOPE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72

6.4  VALVE  MODES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

7. STEPPER ON EN1000 SERIES CONTROLS

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7.1  SCHEDULE  MAP  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

7.2  STEPPER  PROGRAMMING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

7.3  SCHEDULE  INITIATION  IN  STEPPER  MODE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

7.4  STEPPER  ALGORITHM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

7.5  STEPPER  RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

7.6  USING  STEPPER  AS  A  COUNTER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

7.7  DISPLAYING  STEPPER  COUNT  DURING  OPERATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

7.8  END  OF  STEPPER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

8. CONSTANT CURRENT OPERATION

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8.1 INTRODUCTION TO CONSTANT CURRENT OPERATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

8.2  CONSTANT  CURRENT  OPERATION  WITH  PRIMARY  SENSOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

8.3  CONSTANT  CURRENT  OPERATION  WITH  SECONDARY  HALL-EFFECT  SENSOR  . . . . . . . . . . . . . . . . . . . . . . . 90

8.4  CONSTANT  CURRENT  OPERATION  WITH  SECONDARY  SENSOR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

8.5  SENSOR  SELECTION  JUMPER  SETTINGS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

9. APPLICATIONS AND PROGRAMMING EXAMPLES

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9.1  SPOT  MODE  EXAMPLES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

9.2  SEAM  MODE  EXAMPLES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

9.3  BRAZING  APPLICATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

9.4  SQUEEZE  DELAY  APPLICATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

9.5  RETRACTION  APPLICATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

9.5.1 MOMENTARY CLOSURE - [

;!:!

]=[08]  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104

9.5.2 MAINTAINED CLOSURE - [

H!=!

]=[09]  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105

9.5.3 AIR OVER OIL RETRACTION - [

;!:!

]=[07]  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106

9.6  MULTIPLE  SCHEDULE  OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

10. OPTIONS FOR EN1000 AND EN1001 SERIES CONTROLS

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11. ERROR CODES AND TROUBLESHOOTING

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11.1  ERROR  CODES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

11.2 TROUBLE SHOOTING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

11.3 TROUBLE SHOOTING GUIDE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

11.4  BLOCK  DIAGRAM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

12. WARRANTY AND SERVICE 

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APPENDIX  A  -  ERROR  CODES  LIST    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

APPENDIX B - INTRODUCTION TO PROGRAMMING EN1000 SERIES CONTROLS  . . . . . . . . . . . . . . . . . . . . . . . . 123

StockCheck.com

Summary of Contents for EN1000 series

Page 1: ...id State Thyristor Contactors Wiring Diagrams Cabinet Style EN1000 EN1001 S 421180 421270 T D LS LF FP 421210 421269 E 421212 421268 D T 421377 421288 RDE 421274 421274 ENTRON Controls Inc 465 Randy Road Carol Stream IL 60188 630 682 9600 Fax 630 682 3374 www entroncontrols com S t o c k C h e c k c o m ...

Page 2: ...S t o c k C h e c k c o m ...

Page 3: ... FOR Model Series EN1000 EN1001 NEMA Type ALL READ THIS MANUAL COMPLETELY BEFORE ATTEMPTING TO INSTALL OR OPERATE THIS CONTROL ENTRON Controls Inc reserves the right to alter the contents of this manual without previous notice ENTRON Controls Inc Carol Stream Illinois 60188 S t o c k C h e c k c o m ...

Page 4: ... 4 4 1 INITIATION SINGLE STAGE 27 4 4 2 INITIATION TWO STAGE 27 4 5 OTHER TERMINAL STRIP INPUTS 27 4 6 NON VOLATILE MEMORY ERROR 29 4 7 ISOLATION CIRCUITRY DESCRIPTION 31 5 INTRODUCTION TO DATA PROGRAMMING 33 5 1 GENERAL PROGRAMMING 33 5 2 PROGRAM LOCKOUT OPTIONS 34 5 2 1 PROGRAM LOCKOUT KEY OPTION 34 5 2 2 USING PROGRAM LOCKOUT KEY FOR ERROR CLEARING 34 5 3 SEQUENCE PARAMETERS PROGRAMMING 35 5 3 ...

Page 5: ...ANT CURRENT OPERATION WITH PRIMARY SENSOR 88 8 3 CONSTANT CURRENT OPERATION WITH SECONDARY HALL EFFECT SENSOR 90 8 4 CONSTANT CURRENT OPERATION WITH SECONDARY SENSOR 92 8 5 SENSOR SELECTION JUMPER SETTINGS 94 9 APPLICATIONS AND PROGRAMMING EXAMPLES 95 9 1 SPOT MODE EXAMPLES 95 9 2 SEAM MODE EXAMPLES 99 9 3 BRAZING APPLICATION 102 9 4 SQUEEZE DELAY APPLICATION 103 9 5 RETRACTION APPLICATION 104 9 5...

Page 6: ... rated for the 60 Hz or 50 Hz output frequency These controls can be used either on 60 Hz or 50 Hz without any additional settings or changing parameters These controls are not designed to operate with mid frequency transformers 500 Hz to 2000 Hz operating frequency rating The EN1001 differs from EN1000 as it has a Constant Current mode of operation see Section 5 4 14 and Section 8 1 1 STANDARD FE...

Page 7: ...nished with control VALVE CONTROL TRANSFORMER This transformer provides the necessary voltage for powering the welding machine solenoid valve s Input voltage may be either 240 VAC or 480 VAC see Customer Wiring Diagram Valve transformer output is 115 VAC Optional low voltage transformer for certain operations provides a 24 48 VAC output A 50VA transformer is provided in S Cabinets and 150VA transf...

Page 8: ...LOCKOUT SWITCH 9 INDICATOR LED PERCENT 25 INDICATOR LED CONTROL IN OPERATE MODE 10 INDICATOR LED HOLD FUNCTION 26 PROGRAM OPERATE PUSH BUTTON 11 FUNCTION SELECTION PUSH BUTTON SWITCH 27 INDICATOR LED PROGRAM MODE 12 INDICATOR LED OFF FUNCTION 28 ENTER PUSH BUTTON SWITCH 13 INDICATOR LED IMPULSES FUNCTION 29 INDICATOR LED VALVE 3 14 INDICATOR LED COOL FUNCTION 30 INDICATOR LED VALVE 2 15 INDICATOR ...

Page 9: ...TROL PANEL LAYOUT WELD NO WELD BUTTON 1 This push button is active at all times It puts the control in the WELD MODE enables the weld firing pulse or NO WELD MODE disables firing This function is accessible while in operate mode or while welding with few exceptions generally during error conditions INDICATOR LEDs WELD 3 NO WELD 2 These lights indicate the firing status of the control The LEDs togg...

Page 10: ...which mode the control is in PROGRAM mode is the mode in which the individual schedules can be entered or modified DATA such as weld time percent of current valve select etc can only be changed in the PROGRAM MODE OPERATE mode is the normal operating mode for the control This is the only mode in which the control can be initiated for a weld When the control is in OPERATE mode the control is in a R...

Page 11: ...rom 0 to 99 cycles 50 60 Hz OFF Programmable from 0 to 99 cycles 50 60 Hz IMPULSES Programmable from 1 to 99 COOL Programmable from 0 to 99 cycles 50 60 Hz SLOPE COUNT Programmable from 0 to 99 cycles 50 60 Hz NOTE NO ADJUSTMENT is required for timing to change from 60 to 50 Hz operation SQUEEZE COUNT 7 The time duration for the electrodes to close on the work and build up pressure before WELD tim...

Page 12: ...itiates as long as the initiation switch is maintained closed 02 CHAINED Several schedules can be chained together so that several consecutive schedules can be sequenced from one initiation 03 SUCCESSIVE In the SUCCESSIVE mode several schedules can be sequenced successively upon separate initiations 04 CONDITIONAL SUCCESSIVE Valves remains active at the end of HOLD this is indicated by blinking th...

Page 13: ...ff 01 0 0 1 Valve 1 SV1 SV2 02 0 1 0 Valve 2 SV3 SV4 03 0 1 1 Valves 1 2 04 1 0 0 Valve 3 SV5 SV6 05 1 0 1 Valves 1 3 06 1 1 0 Valves 2 3 07 1 1 1 Valves 1 2 3 When in the PROGRAM mode and selection of a valve code is being made the valve LED indicators 29 30 31 will indicate the selected valve s The valve output will not be energized while in program mode NOTE The valve code indicated above can b...

Page 14: ...Series of controls can be provided in different cabinet style 3 1 INSTALLATION DIAGRAMS S CABINET The Installations diagrams for S cabinet are shown on the Figure 3 1 Figure 3 1 Style S Cabinet for EN1000 EN1001 Controls S t o c k C h e c k c o m ...

Page 15: ... 3 2 1 Style E Cabinet 300 600 1200A Contactor Figure 3 2 2 Style E Cabinet 1800 2200 A Contactor 3 2 INSTALLATION DIAGRAMS E CABINET NOTE See Section 3 4 for more information about mounting S t o c k C h e c k c o m ...

Page 16: ...0 1200 A Figure 3 3 2 Style T D and L Cabinet 1800 2200 A 3 3 INSTALLATION DIAGRAMS T D AND L CABINET Style T D and L Cabinets are shown on the Figure 3 3 1 and 3 3 2 NOTE See Section 3 4 for more information about mounting S t o c k C h e c k c o m ...

Page 17: ...Page 15 Figure 3 4 2 Mechanical mounting diagram for T Cabinet Figure 3 4 1 Mechanical mounting diagram for E Cabinet 3 4 MECHANICAL MOUNTING DIAGRAMS E AND T CABINETS S t o c k C h e c k c o m ...

Page 18: ...AGRAM for other connections 3 When control is supplied with a circuit isolation device L1 is factory installed and the L2 control wire is connected to TS1 CTH4 L2 NOTE Connect a CHASSIS GROUND to the lug provided on the right wall of the control cabinet and to an external earth ground A good earth ground is necessary for proper control operation 3 6 EXTERNAL SCR CONTACTOR WIRING External SCR Conta...

Page 19: ...Page 17 Figure 3 6 External SCR Contactor connection S t o c k C h e c k c o m ...

Page 20: ...r Heater hose has a very high carbon content and should not be used for contactor plumbing A low carbon reinforced hose such as the hose originally supplied with the unit no less than 18 long must be used to connect the heat sinks to each other and to the bulkhead fitting on the inside wall of the cabinet see plumbing instructions on wiring diagram The EN1000 water cooled SCR contactors are electr...

Page 21: ...NING THIS WELDING CONTROL IS A MULTI VOLTAGE UNIT WHICH CAN BE CHANGED FROM ONE VOLTAGE TO ANOTHER BY RE ARRANGING JUMPERS ON THE TERMINAL STRIP FOUND INSIDE THE UNIT IF THE CONTROL IS USED ON A VOLTAGE OTHER THAN THE ONE FOR WHICH IT IS WIRED SERIOUS DAMAGE CAN RESULT It is possible to operate the EN1000 Series control at 208 240 380 480 and 575 VAC When a 380 or 575 VAC main is desired please co...

Page 22: ...g them from TS1 NOTE Whether valve power is supplied by the Valve transformer or by an external valve power supply the maximum current that can be switched by the solid state relays on the Firing Board is max 1 A per valve If more current is desired the valve circuit should be wired to an external relay having a suitable contact rating to switch the desired valve For more information refer to CUST...

Page 23: ...are used to protect the ignitor circuits of the ignitron tubes The fuse holders are located on the IGNITRON FIRING BOARD MODULE A N 410318 CAUTION INSTALL PROPERLY SIZED FUSES IN SERVICE DISCONNECT SWITCH CHECK WELDING MACHINE MANUFACTURER S RECOMMENDATIONS WARNING VOLTAGES PRESENT IN THIS CONTROL CAN CAUSE SEVERE OR FATAL INJURY DO NOT SERVICE ANY COMPONENT WITH POWER ON USE ONLY THE FUSE TYPE SP...

Page 24: ...RIP DIAGRAMS AND CONNECTIONS 4 3 1 TERMINAL STRIP TS1 PCB2 SEE CUSTOMER WIRING DIAGRAM 421269 T D or L LS STYLE CABINET 421270 S CABINET OR 421268 E CABINET For most current revision of the component placement on this board see Figure 4 3 1b S t o c k C h e c k c o m ...

Page 25: ... the board board now includes optional manufacture of assembly with 24VDC Valves For more information about 24VDC Valve option see Application Note 700189 Valve load resistors have also been omitted Internal leakage on solid state relays can cause voltages to be seen across unloaded valve outputs When Valve Terminals are loaded these voltages will disappear For hookup and all terminal connections ...

Page 26: ... of a Single Stage Pilot for Dual Schedule operation Connect a Single Stage Pilot between TS1 FS7 and TS1 GND terminals Use a single pole normally open momentary type switch TS1 FS7 When initiated via TS1 FS7 SS1 the weld control will begin execution at SCHEDULE 10 or Used to connect one side of a Two Stage Pilot Connect the Second Stage of a two Stage pilot between TS1 FS7 and TS1 GND terminals U...

Page 27: ...tion or Terminal TS1 FS11 SS3 along with TS1 FS7 SS1 can also function as inputs for ANTI TIE DOWN Initiations when Extended Function To configure TS1 FS11 SS3 and TS1 FS7 SS1 as inputs for ANTI TIE DOWN use two single pole normally open switches one connected between TS1 FS11 SS3 and TS GND the other between TS1 FS7 SS1 and TS1 GND See section 5 4 3 TS1 PS1 Used to connect one side of a PRESSURE ...

Page 28: ...3 coil TS1 SV6 VL2 Used to connect other side of Solenoid Valve 3 coil CAUTION When external valve power is used 24 240 VAC Internal valve transformer must be disconnected at TS1 VL1 and TS1 SV2 SV4 VL2 Properly insulate the wires from X1 and X2 of the valve transformer TS3 Terminal Strip TS3 Customer Connections Description TS3 1 Used as other point for Jumper JA TS3 2 Used as common point for Ju...

Page 29: ...1 and TS1 GND then connect the second stage between TS1 FS3 and TS1 GND The FIRST STAGE FS1 activates the solenoid valves programmed in the selected schedule and will not initiate a sequence The SECOND STAGE FS3 FS7 or FS11 INITIATES the sequence in the schedule associated with the chosen foot switch FS connection See also section 5 4 3 It is possible to initiate three separate schedules in two st...

Page 30: ...ision the Pressure Switch was checked after squeeze in all schedules including chained schedules TEMPERATURE LIMIT SWITCH This feature is used to inhibit welding if the TEMPERATURE of the switching circuitry is above the rated operating temperature If the Temperature Limit Switch is active open the control cannot be initiated until the temperature limit switch cools resets If the Temperature Limit...

Page 31: ...1 Press the SELECT push button to stop the flashing 2 Place the control in the PROGRAM MODE At this point the operator can use SELECT to find the Function containing the invalid data 3 Use the DATA push buttons to correct the DATA 4 Press ENTER 5 Return the control to the OPERATE MODE If more than one location has been affected it may be necessary to use the CLEAR ALL command in the EXTENDED FUNCT...

Page 32: ...tage circuits Use BEST wiring method shown on Figure 4 6 3 to minimize the introduction of induced electrical transient spikes that cause corrupt data to be stored in the controls microprocessor Note that all low voltage initiation wires have been physically isolated fromany high voltage wiring The routing method used in our example is not possible in all applications but should be considered the ...

Page 33: ... are microprocessor based resistance welding controls that incorporate circuitry designed to prevent any output from the control due to spurious or unexpected or false conditions or failure of circuit components The intent of this application note is to explain how the circuitry accomplishes this isolation S t o c k C h e c k c o m ...

Page 34: ...personal safety precautions when operating any machinery Through a process output system the EN1000 Series of controls can be programmed so that if the 20 volt energizing voltage for the isolation relays appears in the absence of an initiation or if the SCR contactor conducts current at any time other than when programmed an output voltage will appear at the valve 3 terminals This voltage can be u...

Page 35: ...red schedule number appears on the schedule display The left push button increments the display by ten and the right push button increments the display by one When the maximum number is reached for either digit that digit resets to zero 3 Press the SELECT push button to reach the required function Pressing and holding the select button momentarily will move to the previous parameter The FUNCTION I...

Page 36: ...the nut provided Plug the wires from the switch onto the mating two prong connector on the back of the control circuit board Mounting the key switch will be easier if the front panel control circuit board assembly is removed from the enclosure Remove the four mounting screws from the front panel and lift it off of the enclosure To put the control in the PROGRAM mode using the PROGRAM LOCKOUT Switc...

Page 37: ...tepper 4 Schedule to Stepper 5 Schedule to 0000 9999 7 Last Step for Stepper Z 01 00 49 7 Last Count for Stepper Z 01 0000 9999 CURRENT Percent Current phase shift mode 00 99 mode EN1001 only Current in or kA X 00 00 00 99 99 or 7 U Low current limit window 00 00 99 99 kA mode 3 O High current limit window 00 00 99 99 HOLD 00 99 OFF 00 99 IMPULSES 01 99 COOL 00 99 VALVE MODE 00 07 CYCLE MODE 00 05...

Page 38: ... Press and hold ENTER 3 Click the SCHEDULE ONES button The displayed schedule is copied to the next higher schedule The new schedule is displayed TO QUICK COPY A SCHEDULE UP TEN SCHEDULES 1 Put the control in the PROGRAM mode 2 Press and hold ENTER 3 Click the SCHEDULE TENS button The displayed schedule is copied to that schedule number plus ten The new schedule is displayed S t o c k C h e c k c ...

Page 39: ...hers it is necessary to just enable a front panel accessible Extended Function such as the Stepper Z For others it is necessary to add optional hardware to the base control such as the Integrated Pressure Sense Control System or Constant Current operation To change settings of the EXTENDED FUNCTIONS use SELECT to step ONCE past SLOPE COUNT At this point all function indicator LEDs are off and the ...

Page 40: ...ower Factor Measuring 5 4 11 J Squeeze Delay 5 4 12 H 7 Block Delay if only 5 4 13 X Constant Current mode EN1001 only 5 4 14 X Range or Ratio EN1001 only 5 4 15 Current Offset 5 4 16 Z Stepper 7 0 Pressure Control mode IPSC Manual H J Background pressure IPSC Manual 4 Input from the Pressure Sensor IPSC Manual T PIN for Software Lockout mode 5 4 17 5 4 1 IDENTIFICATION NUMBER 4 J The EN1000 EN100...

Page 41: ...pened during a COOL time the sequence ends at the end of the programmed COOL Time and advances to HOLD Time CONTINUOUS SEAM MODE CONTINUOUS SEAM welding is the mode in which current flows continuously as long as the pilot switch remains closed COOL Time is programmed to 00 and WELD must be programmed for at least 1 cycle for CONTINUOUS SEAM mode Notice that in either seam mode initiations can be c...

Page 42: ...INTERNAL EXTERNAL SCHEDULE selection or ANTI TIE DOWN initiations 1 Put the control in PROGRAM MODE 2 Use SELECT to find 01 3 Use the SCHEDULE push buttons to page through the extended functions and find 4 Enter a value for of or using the DATA push buttons Where for INTERNAL SCHEDULE SELECT default for EXTERNAL SCHEDULE SELECT for ANTI TIEDOWN INITIATIONS for S49 EXTERNAL SCHEDULE SELECT See S49 ...

Page 43: ...evice or operator acting on TS FS7 and TS FS11 as shown on the Table 5 4 3 Table 5 4 3 External Schedule select with FS7 and FS11 SCHEDULE TS1 FS7 SS1 TS1 FS11 SS3 INITIATION 00 OPEN OPEN FS3 10 CLOSED OPEN FS3 20 OPEN CLOSED FS3 30 CLOSED CLOSED FS3 NOTE In this mode the operator cannot select schedules using the front panel in OPERATE mode and can only initiate using FS3 Binary selects FS7 FS11 ...

Page 44: ...how error 0 X This error will be cleared after releasing remained closed initiations With ANTI TIEDOWN operation the machine electrodes will retract if either or both initiation push buttons are released before the end of squeeze time To provide both ANTI TIEDOWN dual push button and SINGLE CONTACT initiations with lockout The terminals FS3 FS7 SS1 and FS11 SS3 may be connected as shown on Figure ...

Page 45: ...make all 49 schedules remotely available to the operator or machine process control system In this mode the initiation input on TS1 FS3 and binary schedule select inputs on S49 Option Board TS12 SS1 SS32 are dedicated as follows 1 SELECT one of 49 schedules by an external device or operator acting on TS12 SS1 through TS12 SS32 See S49 Option Application Note 700182 for connection diagram and corre...

Page 46: ... Press ENTER AVC parameter Line Voltage in VAC 00 AVC disabled 01 110 02 230 03 380 04 460 05 575 Additional AVC and VM settings are shown in the following table These setting are available only on Controls with PROM P N 619016 002 revision A or later MONITORING AND COMPENSATION MONITORING ONLY THRESHOLD AVC parameter AVC Parameter 10 11 3 12 13 5 14 15 10 16 17 15 18 19 20 20 21 25 22 23 30 24 25...

Page 47: ...values determine a window within which error messages are not triggered These values are valid for any voltage level from 110VAC to 575VAC since the Control uses nominal set point Any time when is reprogrammed nominal voltage set point will be reset If the line voltage surpasses the threshold the Control will display an error announcing that the line voltage threshold has been exceeded If measured...

Page 48: ... push button to return the control to the OPERATE mode NOTE ONCE THE CLEAR ALL FUNCTION IS EXECUTED ERASED DATA CANNOT BE RESTORED SHORTCUT TO CLEAR DATA FOR THE CURRENTLY DISPLAYED SCHEDULE 1 Put the Control in the PROGRAM Mode 2 Press and hold ENTER 3 Click the PROGRAM OPERATE button All schedule data for the displayed schedule are erased SHORTCUT TO CLEAR ALL EXTENDED FUNCTIONS FROM THE CONTROL...

Page 49: ... ENTER push button When in the BACK STEP Mode of operation the switch connected between TLS AUX1 and GND must be open for normal operation and momentarily closed to BACK STEP one schedule If left closed the data display will show ERROR CODE and the schedule display will show 0 X The control has configured the TLS1 AUX1 to GND as an input which looks for a momentary closure NOTE If BACK STEP remain...

Page 50: ...esigners with complete flexibility See the data codes table below To use any PROCESS OUTPUT Modes 1 Put the control in PROGRAM MODE 2 Use SELECT to find 01 3 Use the SCHEDULE push buttons to find 4 Use the table below as a guide for the necessary process 5 Press the ENTER push button Valve three may be connected to the shunt trip of a circuit breaker Under certain conditions as listed below when a...

Page 51: ...E error or ON for CONTROL RELAY error 16 ON for shorted SCR or L2 missing Error 0 X 26 17 ON for following errors TLS error error 14 AVC errors End of Stepper etc 18 ON when SCR full conduction is detected 0 X 13 19 ON during WELD only in WELD mode and closed NW1 GND input on TS1 reserved reserved 22 Send HI LO with RS232 or RS485 Option 23 Send HI LO and Current with RS232 or RS485 Option 24 Flas...

Page 52: ...t will toggle if TS TLS1 AUX1 is momentarily closed to TS1 GND The control will not initiate if this output is off HALF WELD CYCLE Mode PROCESS OUTPUT When and WELD time is 01 cycle the Control will operate in half cycle mode ANY ERROR PROCESS OUTPUT When the valve 3 output will turn on if any error is detected also if the front panel is in a NO WELD condition or in PROGRAM Mode and or in the even...

Page 53: ...o put Control back in WELD mode This Process Output does not use Valve 3 for error indication See 27 if Valve 3 is required HARDWARE ERROR CONTROL RELAY PROCESS OUTPUT When the valve 3 output will turn ON if a Control Board error is detected ERROR 0 X 26 INDICATION PROCESS OUTPUT When the valve 3 output will turn ON if shorted SCR or L2 missing error 0 X 26 is detected SEVERAL ERROR INDICATION PRO...

Page 54: ...grammed may be used to hold the part after the weld Refer to Application Note 700187 EN1001 ONLY CURRENT OUTSIDE OF LIMIT FLASH HI or LO and Stop the Sequence PROCESS OUTPUT This Process Output is the same as 14 except that in this case the Valve 3 output will be ON for 0 5 second to indicate High or Low current EN1001 ONLY EOS INDICATION IF CURRENT WITHIN THE LIMITS AND CONTROL IN WELD MODE PROCE...

Page 55: ...before entering the WELD period This allows the operator to check tip placement before welding If the placement is not correct the initiation can be interrupted and the sequence can be terminated The operator can then reposition the tip NOTE If the initiation is opened during the WELD or HOLD period the sequence will not be interrupted To program the control for BEAT INITIATION during SQUEEZE 1 Pu...

Page 56: ...ithout redundant checking schedules data validity It will eliminate all unnecessary delays as well This mode was added in revision 619016 002J and it does not affect initiation and Control will operate after closing initiation exactly the same as in default non beat mode H 0 00 except that Control will be ready for initiation much faster Faster initialization after closing Emergency Stop input may...

Page 57: ...ll allow programming the Cycle mode 05 This mode was added in revision 619016 002P and it does not affect initiation and Control will operate after closing initiation exactly the same as in default non beat mode H 0 00 NON BEAT INITIATION MODE H 0 This mode is used for External Stepper Reset with momentary push button type switch connected on TS1 ES1 GND input This mode was added in revision 61901...

Page 58: ...not required This has two benefits 1 It is not necessary to make manual adjustments when installing the control to match its circuitry to the POWER FACTOR of the welding machine 2 It assures that maximum welding current for any welding transformer tap switch setting will occur when the selected percent current is 99 If desired for some applications the AUTOMATIC MODE can be disabled and the machin...

Page 59: ...oil gun to have a programmed partial retraction in the middle of a sequence The output may be turned off by momentarily opening EMERGENCY STOP terminals TS ES1 TS1 GND BLOCKING DELAY H 7 is an interval of time that occurs immediately before overlapping the programmed OFF time interval When and delays have been programmed properly the valve 3 output will turn on during the programmed OFF time start...

Page 60: ... buttons to enter one of the desired constant current modes from Table 5 4 14 5 Press the ENTER push button Table 5 4 14 Constant Current modes X CONSTANT CURRENT MODE RANGE 00 disabled CONSTANT CURRENT primary Current Transformer PT2 PT5 PT10 or PT20 10 Primary Compensation any max range 11 Primary Monitoring any max range 12 Primary Compensation PT2 ratio 200 A 13 Primary Monitoring PT2 ratio 20...

Page 61: ...urrent on the secondary of the welding transformer Table 5 4 15 Ratio or Range for Constant Current modes X CONSTANT CURRENT X MODE kA rAWT 00 disabled primary Current Transformer PT2 PT5 PT10 or PT20 10 Primary Compensation max range 00 99 xx xx 11 Primary Monitoring max range 00 99 xx xx 12 14 16 Primary Compensation ratio up to 0125 13 15 17 Primary Monitoring ratio up to 0125 Hall Effect secon...

Page 62: ...creases in resistance affecting all weld schedules Current Offset Programming To program the Current Offset Limits 1 Put the control in PROGRAM Mode 2 Click SELECT until the DATA display shows 01 3 Click the left SCHEDULE push button until the SCHEDULE display shows 4 Use the DATA push buttons to program the desired values where 00 Current Offset is disabled 01 to 19 Current Offset is enabled ONLY...

Page 63: ...wed Current Offset for Single Schedules to New weld Percent Current will be only for that schedule Current Offset for All Schedules to Percent Current will be increased or decreased with the same offset in percent in all schedules Changing Base Current To change base percent currents simply programthe schedule as done normally by switching to the PROGRAM mode and following normal programming proce...

Page 64: ...l Schedules the Current can be changed in OPERATE mode within 10 window i e up to 5 from original base value programmed in PROGRAM mode For example For an original base Weld Current value of 70 a new values may be from 65 to 75 4 05 or 05 kA mode Current Offset is 5 For Single Schedule the Current can be changed in OPERATE mode within 10 of maximum RMS current window i e up to 5 from original valu...

Page 65: ...t PIN must be entered 1 Click SELECT until the DATA display shows 01 2 Scroll trough Extended Functions using the right SCHEDULE push button until the SCHEDULEdisplayshows T OnDATA displays Control will show andPIN will be hidden NOTE WheneverPROGRAM OPERATEpush buttonispressed whileControlislockedwithPIN the Control will flash for half a second on DATA displays O T and PROGRAM LED will flash as w...

Page 66: ...ed to the Terminal Strip between NW1 and GND 6 1 WELD SEQUENCE EXAMPLE Program a simple SINGLE SPOT schedule into the control as follows SQUEEZE count 30 to 60 cycles WELD HEAT count 12 to 25 cycles PERCENT CURRENT 50 to 60 HOLD count 10 to 15 cycles OFF count 00 cycles IMPULSES 01 no impulses COOL count 00 cycles VALVE MODE 01 valve 1 CYCLE MODE 00 non repeat SLOPE MODE 00 no slope SLOPE COUNT 00...

Page 67: ...perate in several operating modes They are Non Repeat Repeat and Successive Each of the 50 possible schedules has a cycle mode parameter that dictates the sequence of events that will follow an initiation The cycle modes are as follows Non Repeat Repeat Chained Successive Conditional Successive Wait Here The CYCLE MODE parameter is entered into a schedule when the control in the Program 23 mode wi...

Page 68: ...h the sequence is as shown in the following diagram Figure 6 2 In this example the sequence is much the same as the previous example with the exception of no Impulse welding If the initiation Foot Switch is held closed until after the Off time the control will move to the beginning of Squeeze time and REPEAT the scheduled sequence Each individual sequence intended to REPEAT must be programmed sepa...

Page 69: ...HEDULE N is sequencing the times and parameters will be in accordance with those stored in SCHEDULE N When N has finished the sequence jumps to SCHEDULE N 1 SCHEDULE N 1 is then performed and so on until the sequence encounters a or in the CYCLE MODE FUNCTION The various Cycle modes will cause the sequence to continue in the following manner Within the CHAINED sequence the control will encounter S...

Page 70: ... was programmed to the INTERNAL mode the SCHEDULE number will be the last number entered using keys 21 and 20 The number displayed need not be the first number in a sequence of CHAINED SCHEDULES For example if SCHEDULES 01 02 03 and 04 are chained together and we select SCHEDULE 02 after initiation the sequence would be as follows SCHEDULE 02 03 04 and at the completion of SCHEDULE 04 the SCHEDULE...

Page 71: ...ait in this state and indicate the state by blinking the front panel HOLD LED If the control is initiated a second time when the initiation input closes the control will continue by selecting the next schedule and executing it as programmed EXAMPLE Part Locator Clamp In some cases fixturing may require a locating pin be extended to accurately locate a part beforewelding Thefollowingshows howthree ...

Page 72: ...ule is programmed with Cycle mode 05 and if initiated by FS3 initiation the Control will execute the schedule sequence and it will wait either in SQUEEZE or WELD COOL or HOLD part of the sequence depending on programmed data in the given schedule and it will maintain the schedule valves active indefinitely At this point WAIT HERE part of the sequence can be stopped by activating ES or TLS input or...

Page 73: ...trol will reach the programmed Weld current Slope Count is programmable from 01 to 99 in ms at 1000 Hz When Slope Mode is used its function is to change the current gradually The Up Slope mode causes the current to start from a low level and increase for a predetermined number of cycles When Down Slope is in use the reverse is true Current will start to decrease to low level for a predetermined nu...

Page 74: ...n is selected and the control initiated DOWN SLOPE will occur after WELD If the control is in REPEAT Mode or PULSATION Mode the DOWN SLOPE will only occur after the last WELD IMPULSE For example if the SCHEDULE has programmed 10 cycles of DOWN SLOPE and 25 cycles of weld the DOWN SLOPE will start after WELD The complete weld and down slope time would add to 35 cycles If in INTERMITTENT or CONTINUO...

Page 75: ...V1 00 0 0 0 01 0 0 1 X 02 0 1 0 X 03 0 1 1 X X 04 1 0 0 X 05 1 0 1 X X 06 1 1 0 X X 07 1 1 1 X X X When in the PROGRAM Mode and selection of a valve code is being made the VALVE LED indicators will indicate the selected valve s The valve s output will not be energized while in PROGRAM Mode NOTE The valve codes indicated within the valve selection chart may differ with the use of PROCESS OUTPUTS Re...

Page 76: ...g current but also the weld time and even the complete welding schedule if desired Each of the steppers may have up to maximum ten steps and each step may be programmed from 0000 to 9999 welds The Stepper can also be programed to provide an electrical output after the last step to sound an alarm to alert the operator that the electrodes need to be re dressed or replaced After end of last step step...

Page 77: ... to 9999 FS3 B 10 11 12 13 14 15 16 17 18 19 H H H H H H H H H H 0000 to 9999 7 10 to 19 7 0000 to 9999 FS3 or FS7 C 20 21 22 23 24 25 26 27 28 29 0000 to 9999 7 20 to 29 7 0000 to 9999 FS3 or FS11 D 30 31 32 33 34 35 36 37 38 39 J J J J J J J J J J 0000 to 9999 7 30 to 39 7 0000 to 9999 FS3 E 40 41 42 43 44 45 46 47 48 49 0 0 0 0 0 0 0 0 0 0 0000 to 9999 7 40 to 49 7 0000 to 9999 FS3 For Stepper ...

Page 78: ...ogram all weld sequence parameters for first schedule for desired stepper 3 Usingcopyschedule frontpanelshortcuts i e pressENTERandrightSCHEDULE push button in program mode copy current schedule to the next one and repeat this as many times as number of steps is necessary for that stepper 4 Percent Current or Weld Heat must be adjusted in each next step after the first one 5 Put the control in OPE...

Page 79: ...c For stepper mode 02 dial any schedule 2 Put the control in PROGRAM mode 3 PresstheSCHEDULEpushbuttonsto find 7 in the SCHEDULE display as shown on Figure 7 4 4 Program the desired last step for this stepper e g for stepper A last step in stepper mode 01 may be any number from 00 to 09 as shown on Figure 7 4 but in stepper mode 02 it may be any schedule number from 00 to 49 In fact this value wil...

Page 80: ...e only if FS7 and FS11 are used for stepper selection as shown in the next table STEPPER SCHEDULE FS7 SS1 FS11 SS3 INITIATION A 00 OPEN OPEN FS3 B 10 CLOSED OPEN FS3 C 20 OPEN CLOSED FS3 D 30 CLOSED CLOSED FS3 Anti Tiedown Option 02 In this mode any stepper can be initiated with the both FS7 FS11 initiation switches The stepper operation is the same as with standard FS3 initiation External Schedul...

Page 81: ...sabled if Z 01 stepper enabled YES NO Update STEPPER store 7 an 7 WELD Prepare STEPPER reload 7 and 7 HOLD Decrement 7 7 0000 OFF continue YES NO 0 T J Z Increment 7 7 max where max 09 19 29 39 49 7 0000 YES NO Z 01 AND CYCLE MODE 02 AND weld was made Figure 7 6 Algorithm 7 4 STEPPER OPERATION 7 4 1 OPERATION ALGORITHM FOR STEPPER MODE Z S t o c k C h e c k c o m ...

Page 82: ...irst step last step is 7 00 and last count 7 will be from 0325 to 0000 00 40 00 0 0 0325 00 20 00 1 00 1 02 00 00 01 10 25 0 1 xxxx 60 10 00 1 00 1 2 04 00 00 02 10 00 0 2 xxxx 00 00 00 1 00 1 02 00 00 03 30 20 0 3 xxxx 50 10 00 1 00 1 2 03 00 00 04 10 00 0 4 xxxx 00 00 00 1 00 1 2 3 00 00 00 second step last step is 7 05 and last count 7 will be from 0250 to 0000 05 40 00 0 5 0250 00 20 00 1 00 1...

Page 83: ...ssary the stepper can be automatically reset by adding the RESET command using an additional schedule after the last step The RESET command is simply an empty schedule no valves no any other parameters except for the OFF time If the stepper counter reaches zero on the last step the Control will read the next schedule If it finds the RESET command it will reload the stepper automatically Any new se...

Page 84: ...desired count in the Data display to Press ENTER 8 ResettheStepperbypushingENTER andthetwoDATAPush buttonsSimultaneously 9 Put the control back in OPERATE mode NOTE If necessary the message Z 0 T J may be shown at the end of the countdown Select the next Schedule and clear it by using the Erase Schedule Shortcut shown on page 3 Program a Weld time of 01 cycles and return to the operating schedule ...

Page 85: ...ary sensing with Rogowski Coil 8 1 INTRODUCTION TO CONSTANT CURRENT OPERATION In Constant Current EN1001 there are two basic modes mode if X 00 99 current is programmable in percent steps from 0000 0 to 0099 99 kA mode current programmable in kA from 00 00 0 A to 99 99 99 990 A using the four digit data display Based on current sensor and desired constant current modes program one of the modes fro...

Page 86: ...ing will allow the control to maintain the current constant If the machine is already at the highest tap setting the maximum current range of the machine is much lower than the programmed range in X In this case choose a lower current range from the table and program the corresponding value in X Phase Shift in and RMS current in kA are also available during this condition To show the Percent Phase...

Page 87: ...value the control will flash LO or HI depending on the case In addition the Control will turn Valve 3 ON for 1 2 of a second 30 cycles To INTERRUPT A repeat Sequence or STOP at the end of a weld find in the Extended Functions and program a value of 14 While in the constant current mode the Control will measure the value of current maintained during the weld and show this value on DATA displays at ...

Page 88: ...is presets schedule 49 with specific set up parameters including 30 cycles of squeeze time 99 cycles of Squeeze Delay time and solenoid Valve 1 output The control will automatically switch to Operate Mode and flashing on the DATA display K Z If necessary Squeeze Time or valve output may be changed to match machine requirements Switch to Program mode change the Squeeze time or Valve and press Enter...

Page 89: ...ed Function X program 00 99 and press Enter c Select Extended Function program 04 and press Enter This presets schedule 00 with specific set up parameters including 30 cycles of squeeze time and 1 solenoid valve output d You may change Squeeze Time to match your machine requirements and press Enter e You may change Valve Output to match your machine requirements and press Enter NOTE DO NOT MAKE AN...

Page 90: ...n or X xx xx for program and display current in kA Where xx xx is maximum RMS current might be any number except 00 99 7 Follow instructions from Section 8 1 3 for setting up current regulator After programming X and X Extended Functions parameters Control is ready for Setup Procedure After setup is done parameter X in kA mode should hold approximately the maximum RMS current in kA for the used Tr...

Page 91: ... end of the sequence which may be useful for setting Hi Low limit window NOTE For X 0010 schedule parameter current will be programmed in primary Amps and Control will show on display primary current in A This may be useful if welding transformer ratio is unknown 8 2 3 SET POINT SETUP FOR PRIMARY COMPENSATION MODE Since the setup is not required in Ratio Mode the Control will use calibrated gain t...

Page 92: ...ration In both cases setup procedure for auto gain selection is required as described in Section 8 1 3 Manual gain or range selection along with sensor positioning should be performed as described in Section 8 3 2 if setup is not possible Choose and program one of the modes from the Table 5 4 14 or Table 5 4 15 as described in sections 5 4 14 and 5 4 15 8 3 1 AUTO RANGE OR PROPORTIONAL MODE WITH S...

Page 93: ...y 5 Press ENTER 6 Click the left SCHEDULE push button until the SCHEDULE display shows X 7 Use the DATA push buttons to program X 99 99 for operate with maximum possible range 8 Press ENTER 9 Click the SELECT push button and select CURRENT or kA 10 Program the desired Weld Time and Weld Current in for the dialed Schedule for example 4 weld cycles and 50 current phase shift 11 Press ENTER 12 Put th...

Page 94: ... This is similar mode to constant current with primary sensing or secondary sensing with Hall Effect sensor 1 Put the control in PROGRAM Mode 2 Click SELECT until the DATA display shows 01 3 Click the left SCHEDULE push button until the SCHEDULE display shows X 4 Use the DATA and ENTER push buttons to program X 30 for Regulation and Monitoring or X 31 for Monitoring only 5 Click the left SCHEDULE ...

Page 95: ...or Regulation and Monitoring or X 33 for Monitoring only 5 Press ENTER 6 Click the left SCHEDULE push button until the SCHEDULE display shows X 7 Use the DATA push buttons to program X xx xx for operate in desired range Where xx xx must correspond to desired range as shown in the Table 8 4 1 Table 8 4 1 Operating Ranges for Manual Range Selection with Rogowski Coil Current Range in kA Range Parame...

Page 96: ...r HI or LO In such cases the range has to be changed by programming lower or higher X otherwise the Transformer TAP has to be moved up or down if that is possible If the operating range of the welding machine is unknown running the setup procedure is recommended After running the setup for X 30 and X is any value except 00 99 approximately the maximum RMS value will be stored in X Once that value ...

Page 97: ...closed the sequence will continue repeating Valve output 2 is used SCHEDULE SQUEEZE WELD HEAT PERCENT CURRENT HOLD OFF IMPULSES COOL VALVE MODE CYCLE MODE SLOPE MODE SLOPE COUNT 00 40 30 60 10 15 01 00 02 01 00 00 9 1 2 PULSATION AND SUCCESSIVE MODE Schedule 00 and 01 are pulsation and spot schedules combined in the successive mode Schedule 01 is initiated first When it is completed schedule 02 wi...

Page 98: ...d 08 are chained together to illustrate up down slope operation Schedule 05 performs the squeeze function and establishes the percent current at which the up slope will begin bottom current Schedule 06 performs the weld function and sets the up slope time Schedule 07 sets the downslope time and the current it starts from Schedule 08 establishes the percent current at which the downslope will end a...

Page 99: ...he weld will have solidified and the forging force will do no good Forge delay is defined as the delay from the beginning of the weld to the activation of the forging solenoid valve To accomplish a FORGE DELAY operation on EN1000 EN1001 series controls it is necessary to chain together 2 or more SCHEDULES as outlined below 1 Program the first SCHEDULE with the amount of WELD time desired before th...

Page 100: ... COOL VALVE MODE CYCLE MODE SLOPE MODE SLOPE COUNT 00 20 10 95 00 00 01 00 01 02 00 00 01 00 05 95 20 00 01 00 03 00 00 00 SCHEDULE 00 SCHEDULE 01 SQUEEZE count 20 cycles SQUEEZE count 00 cycles WELD HEAT count 10 cycles WELD HEAT count 05 cycles PERCENT CURRENT 95 PERCENT CURRENT 95 HOLD count 00 cycles HOLD count 20 cycles OFF count 00 cycles OFF count 00 cycles IMPULSES 01 no impulses IMPULSES ...

Page 101: ...o 00 SCHEDULE SQUEEZE WELD HEAT PERCENT CURRENT HOLD OFF IMPULSES COOL VALVE MODE CYCLE MODE SLOPE MODE SLOPE COUNT 14 10 20 40 10 10 01 05 01 00 00 00 9 2 3 WELD CURRENT DELAY WELD CURRENT DELAY provides a time delay and output to a seam welding machine solenoid valve circuit When the weld wheels are lowered a delay before applying weld current is required to insure the wheels are together and su...

Page 102: ...IME PERCENT CURRENT PERCENT 1 NORMAL PERCENT HOLD count NORMAL HOLD TIME OFF count PERCENT 2 NEW SECOND PERCENT HEAT IMPULSES Weld 1 2 Factor REPETITION FACTOR for overall WELD time COOL count WELD 2 NEW COOL WILL EXECUTE A SECOND WELD HEAT VALVE MODE NORMAL VALVE MODE CYCLE MODE NORMAL CYCLE MODE SLOPE MODE NORMAL SLOPE MODE SLOPE COUNT NORMAL SLOPE COUNT In order to obtain a long series of heat ...

Page 103: ... closed Control will jump from Seam to Spot sequence on Schedule 10 Also in this mode from firmware revision 619016 002P it is possible to add chained spot sequence of none welding schedules before continuous or intermittent SEAM part of the sequence with FS3 initiation SEAM MODE x4 DELAY COMPENSATION In Constant Current mode on EN1001 Controls this mode is used to add delay before control starts ...

Page 104: ...sh Buttons 5 6 As typical of other data entry the ENTER Push Button 29 must be depressed to load the desired data In this mode the initiation must be held closed for the time required to bring the parts to the required brazing temperature If this time is longer than 99 cycles two or more schedules must be chained together If the operator then opens the initiation the brazing current turns off imme...

Page 105: ...me occurs only during the first Squeeze of a series of repeated welding sequences Repeat Mode Squeeze Delay will be present in all schedules even if no other data has been entered Squeeze Delay is not intended for use with Seam or Anti Tie Down modes of operation If not required set J to 9 4 2 SQUEEZE DELAY PROGRAMING 1 Press the SELECT push button repeatedly until the Function indicator has advan...

Page 106: ... weld sequence and an error 0 X message will appear on the display if initiation is attempted Only when the valve is on and the electrodes are in the pre weld or extended position will the initiations be enabled The valve output between TS1 SV5 and TS1 SV6 is enabled by toggling the TLS1 AUX1 to GND switch TS1 SV5 and TS1 SV6 remains on during and after a weld as long as the switch is not activate...

Page 107: ... that the control uses to turn on the Retraction Output V3 The software has a power on interlock of the V3 output to block the V3 from turning on with power on This new feature simple as its operation may be will help users implement this type of retraction without putting high voltage on one pole and or in the same conduit as the low voltage foot switch wiring The valve output between TS1 SV5 and...

Page 108: ...shut off and a BLOCKING delay timer is then started At the end of BLOCKING delay the BLOCKING valve Valve 3 is turned on This valve is connected to the EXTEND port of the cylinder and when energized or closed the return stroke can be halted before the gun completely opens Initiating the EXTEND valve will de energize the blocking valve solenoid Air Over Oil Retraction is available through the Exten...

Page 109: ...emain off after the emergency stop is activated WARNING The jumper on TS3 on Terminal Strip Firing Board A N 410319 must be installed as JB to connect terminal 1 to VL1 as indicated by JB printed on the board Moving this jumper will bypass the Valve Control Relay which normally prevents valve activation until a weld sequence is initiated Since this valve may nowbe activated without energizing the ...

Page 110: ...scheduledisplayto H 7 BLOCKING DELAY 9 Press the DATA push buttons until the desired BLOCKING DELAY TIME appears in the DATA display NOTE Extended Function H 7 can only be accessed when is programmed 10 Press the ENTER push button to store the data 11 Using the examples below enter chained schedules that will control the EXTEND AND INTENSIFY valve sequencing Note Schedule 00 uses Valve 1 to activa...

Page 111: ...then proceeds into Squeeze time EXTEND A valve mode of 01 is selected to turn on valve 1 only Schedule 00 is Chained to Schedule 01 Schedule 01 begins and enters into Squeeze time INTENSIFY Weld time and Hold time A valve mode of 03 is selected to enable both valve 1 EXTEND and valve 2 INTENSIFY After Hold time is complete the delay if programmed before blocking begins When this delay is complete ...

Page 112: ...equence Since Off time is less than BLOCKING time the sequence will repeat when the blocking time has ended SECTION E Section F illustrates that different schedules may be selected having common SQUEEZE DELAY and BLOCKING times SECTION F Section F shows how a momentary switch attached to FS1 can toggle the gun from Retracted to Non Retracted mode or vice versa After a momentary closure of FS1 Sque...

Page 113: ...umbers can be externally selected in the EXTERNAL SCHEDULE SELECT Mode with use of the Extended Function 01 In this mode 1 TS1 FS7 SS1 and TS1 FS11 SS3 become binary schedule selects and can point to one of 4 schedules 0 10 20 30 2 The control is then initiated via TS1 FS3 for any one of the 4 schedules Table 9 1 External Schedule select with FS7 and FS11 SCHEDULE TS1 FS7 SS1 TS1 FS11 SS3 INITIATI...

Page 114: ...reading depends on the location of the Sensor PRESSURE CONTROL The Integrated Pressure Control System is designed for any application that requires automaticselectionofa pre programmedpressure or automatic switchingbetweendifferent pressure settings Weld control schedules may be chained to obtain sequential pressure changes The benefits of the system depend on the application The ENTRON IPSC syste...

Page 115: ... other devices It describes the process which a host uses to request access to different Controls how the host will respond to request from the Controls and how errors will be detected and reported This protocol provides an internal standard which Hosts and Controls use for parsing messages During communication on a ENBUS network the protocol determines how each Host and Control will know its addr...

Page 116: ...pened Initiations must be open at power on or after an ES Emergency Stop See section 1 1 4 3 and 4 4 Data Schedule Display E r 06 Error Code 06 Backstep or Retraction is closed too long or at start of sequence Open TS1 TLS1 AUX1 See section 4 3 4 5 and 5 4 6 Data Schedule Display E r 07 Error Code 07 FS1 initiated while another seq active Open TS1 FS1 See section 4 3 4 5 5 4 3 9 3 Data Schedule Di...

Page 117: ... Error Code 22 18 Vdc out of range High line voltage 1 Line voltage too high 2 Wrong voltage jumper settings See section 4 1 Data Schedule Display E r 23 24 Error Code 23 or 24 Manual power factor error 1 Full Conduction reached 2 Set automatic power factor See section 5 4 10 Data Schedule Display E r 26 Error Code 26 SCR Contactor short detected 1 Check contactor for short 2 Check Firing Board Da...

Page 118: ...on switch 3 Fuses F6 F8 valve fuses blown 4 Defective Control Display or Terminal Strip Firing PCB 1 Replace switch s 2 Check for loose or broken wire s at initiation switch s and at customer terminal strip FS1 FS2 etc 3 Check valve solenoid coil 4 Replace board with another board stamped with the same A N Control initiates valve light comes on but electrodes do not close 1 Solenoid valve circuit ...

Page 119: ...lace board See wiring diagram for correct Assembly Number 5 Replace board with another board stamped with the same A N 6 Check for missing phase Weld too cool 1 Line voltage drop 2 Excessive pressure at electrodes 3 Weld Count too short 4 Excessive tip mushrooming 1 KVA demand for welding transformer too high for input power line Check line voltage 2 Check air system regulator 3 Increase Weld Coun...

Page 120: ...Page 118 11 3 TROUBLESHOOTING GUIDE S t o c k C h e c k c o m ...

Page 121: ...Page 119 S t o c k C h e c k c o m ...

Page 122: ...Page 120 11 4 BLOCK DIAGRAM S t o c k C h e c k c o m ...

Page 123: ...rer in accordance with said manufacturer s warranty To obtain repairs or replacement parts under this warranty the defective parts must be returned to ENTRON Controls Inc 465 Randy Road Carol Stream IL 60188 Exclusions This warranty does not cover damage by accident misuse unauthorized repair or modification Use of Out of Warranty Repair service To obtain service for any printed circuit board asse...

Page 124: ...witch is active for P O 10 29 Schedule out of range for S S 03 when using S49 or S99 option 30 Over Current EN1000 only 31 IIC Error 32 Invalid data in EEPROM 33 MM2 is not found Memory Module required 34 Downloading data from MM2 Checksum Error 35 Copy data to MM2 Checksum Error 36 Pressure Sense input is too low or too high 37 Calibration data out of range EN1001 only 38 DC bus voltage is too lo...

Page 125: ...r arms Fig B3 Set welder switch LOW Fig B5 Turn ON Power to Control Fig B6 POWER ON light indicator APPENDIX B INTRODUCTION TO PROGRAMMING EN1000 SERIES CONTROLS Be sure welder head or arms are fully retracted Fig B1 Turn ON Air supply to machine S t o c k C h e c k c o m ...

Page 126: ...rcent Current and program 70 to 80 e g 75 Fig B7 Put Control in NO WELD Fig B8 Put Control in PROGRAM Mode Fig B10 SELECT Squeeze and program 30 to 60 cycles e g 45 cycles Fig B11 SELECT Weld Heat and program 2 to 3 cycles e g 3 cycles S t o c k C h e c k c o m ...

Page 127: ...rameter are programmed Make sure that all unnecessary parameters are set to 00 before going to OPERATE Mode Fig B14 SELECT Impulses and program 01 one pulse Fig B13 SELECT Hold and program 10 to 15 cycles e g 12 cycles Fig B15 SELECT Valve Mode and program 01 Valve 1 S t o c k C h e c k c o m ...

Page 128: ...t will not weld then the head or arms will retract Put the Control in WELD mode Place sample parts to be welded between electrodes and initiate weld sequence again Machine head or arms will close on parts to be welded On machines withsingle stage initiation depressing the foot switch will sequence the machine and weld Machine will go trough sequence and weld then the head or arms will retract Fig ...

Page 129: ...trol in PROGRAM Mode as shown in Figure B9 Find the Extended Functions by pressing the SELECT button until 01 appears in the DATA Display Use SCHEDULE push buttons o scroll through the Extended Functions Based on current sensor and desired constant current mode program X and X accordingly to enable Constant Current For X 32 or 33 only kA mode is possible and X must be programmed according to desir...

Page 130: ...4 For Secondary Hall Effect Fig B25 For Secondary Rogowski Coil For Primary Coil Sensing program 10 11 12 18 or 19 For Hall Effect Secondary Sensing program 20 or 21 For Secondary Rogowski Coil Sensing program 30 31 32 or 33 S t o c k C h e c k c o m ...

Page 131: ...minal input ONLY Bring the heads together on a previously WELDED part Hold the initiation contacts closed while the machine sets up the Constant Current parameters When a Primary Sensing Coil is used this initiation will cause the Control to fire several times then count down on the dial plate from 99 99 98 97 to 20 The display will switch to Schedule 00 when the Constant Current routine has compl...

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