Entron EN6001 User Manual
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Entron EN6001 User Manual

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User Manual
700230D: Intended for use with firmware version 5.0 and higher
ENTRON Controls, LLC.
1402 S. Batesville Road
Greer, SC 29650
Phone: 864.416.0190
fax: 864.416.0195
www.entroncontrols.com
ENTRON Controls, LLC. 700230D
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  • Page 1 User Manual 700230D: Intended for use with firmware version 5.0 and higher ENTRON Controls, LLC. 1402 S. Batesville Road Greer, SC 29650 Phone: 864.416.0190 fax: 864.416.0195 www.entroncontrols.com ENTRON Controls, LLC. 700230D...

  • Page 2: Table Of Contents

    5.3 Timing Cycles ...…………………………………………………………. 54 5.3.1 Worksheets ……………………………………………………. 57 5.4 I/O Programming …………………….…………………………………… 59 6.0 Troubleshooting 6.1 Error Codes ………………………………………………………………. 62 6.2 Non-Error Code Issues ..………………………………………..………. 68 6.3 Noise Suppression ………………………………………………………. 71 6.4 Warranty and Service Policy ….……………………………….……….. 72 ENTRON Controls, LLC. 700230D...

  • Page 3: Features

    Current1: 0 to 100.00 kA Impulses: 1 to 99 cycles • • Cool1: 0 to 99 cycles Heat/Current Offset: -15 to +15% • • Slope: 0 to 99 cycles Cycle Mode: Non-repeat / Repeat / Chained / Successive / Wait-here ENTRON Controls, LLC. 700230D...

  • Page 4: Reference Documents

    Additional documentation can be found by visiting http://www.EntronControls.com EN6001 Wiring Diagram 421537 Cabinet Guide 780054 Sell Sheet 780101 Retrofit User Manual 700234 Communication Manual 700231 EN6001 EIP App Note 700237 Water Flow Switch (WFS) App Note 700149 Full Phase Isolation 700098 ENTRON Controls, LLC. 700230D...

  • Page 5: Specifications

    RAM memory Operating voltage: 240, 380, 480, 575 VAC +10% Cooling Water: 1.5GPM at 104°F (40°C) maximum inlet temperature. For water quality requirements, refer to AWS J1.2M/ J1.2:2016 Guide to Installation and Maintenance of Resistance Welding Machines ENTRON Controls, LLC. 700230D...

  • Page 6: Cooling Water

    An open drain is recommended for best operation. If a closed return system is used, be sure return line is properly sized so that back pressure will not reduce water flow be- low recommendations. A sight flow indicator is recommended. ENTRON Controls, LLC. 700230D...

  • Page 7: Warnings And Labels

    #1 and #5 for a complete description. Observe the WARNING, DANGER, and CAUTION labels affixed to control to maintain safe operation. ENTRON Controls, LLC. and its affiliates are not re- sponsible for any harm caused by non-compliance of instructions associated with the aforemen- tioned labels or signal words to follow.
  • Page 8 2.2 Warnings and Labels Adhere to all of the cautions, warnings, and danger alerts on the labels located within the control as well as this document. ENTRON Controls, LLC. 700230D...

  • Page 9: Install And Setup

    3.1 Install and Setup For wall-mount dimensions, refer to the ENTRON Cabinet Guide (doc 780054) on our website. Ensure that all power is removed before connecting the control. Connect the chassis ground to an external earth ground. Connect L1, L2, and H1 as shown in the “CUSTOMER CONNECTIONS” section of the wiring diagram. An H1 connection will be required for each transformer in a multiple-control layout.
  • Page 10 *Note: The display refresh time is 500ms; therefore any sequences less than 30 cycles (60Hz) or 25 cycles (50 Hz) might not be displayed. 10. Once proper sequencing is verified, adjust timing cycles, inputs, and outputs as necessary. ENTRON Controls, LLC. 700230D...

  • Page 11: Wiring Diagram

    4.1 Wiring Diagram ENTRON Controls, LLC. 700230D...
  • Page 12 4.1 Wiring Diagram ENTRON Controls, LLC. 700230D...

  • Page 13: Discrete I/O

    P1—12 Foot Switch Common P2—1 Solenoid Valve Common P2—2 Solenoid Valve #1 P2—3 Solenoid Valve #2 P2—4 Solenoid Valve #3 P2—5 Programmable Output #1 P2—6 Programmable Output #2 P2—7 Programmable Output #3 P2—8 Programmable Output #4 ENTRON Controls, LLC. 700230D...
  • Page 14 Used as a multi-purpose programmable input. Via programming, it may be used as Error Reset, Sch. Select 1, Stepper Reset, or 2nd Stage input. See Section 5.4 for more information. When connected to FSC, it will be active and draw 10 mA. ENTRON Controls, LLC. 700230D...
  • Page 15 Used as a multi-purpose programmable input. Via programming, it may be used as Stepper Reset, Sch. Select 8, Edit Lock, or Escape input. See Section 5.4 for more information. When connected to FSC, it will be active and draw 10 mA. ENTRON Controls, LLC. 700230D...
  • Page 16 24 VDC output rated at 0.5 A maximum. Via programming, it can be used for Step End, Current Er- ror, AVC Error, or Interlock output. See Section 5.4 for more information. Not isolated via Internal Control Relay (CR1). Supplies 24 VDC when active. Connect the other side of the load to SVC. ENTRON Controls, LLC. 700230D...

  • Page 17: Wiring For Ac Option

    [VL2] Valve Power Line #2 (PCB2-TS1-VL2) Typically an internally provided and connected AC power source ranging from 24 to 120 VAC to on- ly provide power for AC valve terminals (SV1, SV3, SV5). Can be connected to ground if required. ENTRON Controls, LLC. 700230D...
  • Page 18 TIMER V3 OUT to TS4-V3IN can be removed. The TS4-V3IN input can then be connected to any of the four programmable output terminals (P2-5 through P2-8) to obtain an AC output that mimics the programming of the output selected. AC wiring information continues on the next page. ENTRON Controls, LLC. 700230D...
  • Page 19 This is to allow for programming features that are in the I/O Map when using PCB2-TS4. Thus, when PCB2-JW1 is in the BYPASS mode, PCB2-TS1-SV5 can turn on independent of the status of the initiations FS1 and FS2. Care MUST be taken to ensure safe operation. ENTRON Controls, LLC. 700230D...

  • Page 20: Keypad Functions

    The FUNCTION key. Used to navigate from the Status screens to the Main Menu. Enables weld current. If not on, then an ER35 (Panel no-weld error) is displayed. ENTRON Controls, LLC. 700230D...

  • Page 21: Menu Navigation

    Status Page List (Default) Main Menu Schedule Select 1. Use Schedule 2. Edit Schedule 3. Copy Schedule TO SCROLL 4. Reset Error HIGHLIGHT ABOUT 5. Edit counter 6. About HOLD THEN PRESS Setup Menu TO SCROLL ENTRON Controls, LLC. 700230D...

  • Page 22: Status Screens

    5.2.1 Status Screens—Status[1] Status screen # Weld 1 current Total weld current Error code. For more infor- Active schedule # mation, see Section 6.1. Main status screen. To get to Status[4]: To get to Status[2]: ENTRON Controls, LLC. 700230D...
  • Page 23 Weld 1 pulse width Weld 2 current Weld 2 pulse width Weld 1 conduction angle Weld 2 conduction angle Active schedule This screen displays the results of the last weld. To get to Status[1]: To get to Status[3]: ENTRON Controls, LLC. 700230D...
  • Page 24 Stepper count This screen displays the counts of the stepper and the counter, if they are enabled. If these features are disabled, this screen displays “Stepper=Off” and/or “Counter=Off” instead. To get to Status[2]: To get to Status[4]: ENTRON Controls, LLC. 700230D...
  • Page 25 This screen displays the status of the control’s inputs and outputs. HIGH signals are represented by a 1, and LOW signals are represented by a 0. Also displayed is the sta- tus of the AC line voltage/frequency. To get to Status[3]: To get to Status[1]: ENTRON Controls, LLC. 700230D...

  • Page 26: Main Menu Screens

    NOTE: Navigation to the ‘Use Schedule’ screen can be done two different ways: 1. Starting from the Status screens, press . (See Menu Navigation for details.) 2. Starting from the Status screens, press and then select ‘Use Schedule’ from the Main Menu. ENTRON Controls, LLC. 700230D...
  • Page 27 Time delay between the signal to the programmed valve(s) and weld initiation. Parameter is replaced by ‘Intensify’ when ‘air-over-oil’ is enabled. >Valve [None/1/2/3/1+2/2+3/1+3/1+2+3] Selection of valve(s) to be activated. Weld 1 [0-99] cycles Default = 0 Also referred to as “pre-heat” ENTRON Controls, LLC. 700230D...
  • Page 28 % current below programmed value that will trigger an error. Only visible when “I1 Monitor’ is on. >>Pre-low [0-99]% Default = 0 % current below programmed value that will trigger ER44. Only visible when ‘I1 Monitor’ is on. ENTRON Controls, LLC. 700230D...
  • Page 29 ‘Current’ setting without triggering an er- ror. Only visible when ‘PW1 Monitor configuration is Cool 1 [0-99] cycles Default = 0 Time delay between ‘Weld 1’ and ‘Weld 2’. Designed to give an impulse effect. ENTRON Controls, LLC. 700230D...
  • Page 30 Phase shift %. Does not apply when Current Mode is set to Const Current. >Current [0.00-100.00] kA Weld current setting. Does not apply when Mode is set to Phase Shift. >I2 Monitor [On/Off] Must be enabled in order to track/report current er- rors. ENTRON Controls, LLC. 700230D...
  • Page 31 Must be enabled in order to track/report phase shift ab- normalities. >>High [0-99]% Default = 0 Maximum phase shift the control can apply in order to achieve the ‘Current’ setting without triggering an error. Only visible when “PW2 Monitor’ is on. ENTRON Controls, LLC. 700230D...
  • Page 32 (s) release; the next schedule/sequence will not begin until the ‘Off’ cycle is complete. Impulses [1-99] cycles Default = 1 Number of times to deliver Weld 2—Cool 2. (Impulses do NOT apply to Weld 1—Cool 1.) ENTRON Controls, LLC. 700230D...
  • Page 33 (Presqueeze, Squeeze, Weld 1, Cool 1, Weld 2, Cool 2, or Hold) are set to 99 cycles. This allows infinite duration until Escape is triggered. ‘Beat Mode’ configuration is authorized to ‘Wait Here’ if this Cycle mode is desired. ENTRON Controls, LLC. 700230D...
  • Page 34 (Mode1 or Mode2) is selected. Otherwise, parameter is replaced by Squeeze. Block Delay [0-99] cycles Default = 0 Timed delay to allow high force of the cylinder to release air pressure after the welding pro- cess. Only visible when ‘air-over-oil’ configuration (Mode2 only) is selected. ENTRON Controls, LLC. 700230D...
  • Page 35 # of the schedule to be copied. Copy To [0-63] # of the schedule to be replaced. Confirm [Yes/No] Must select ‘Yes’ and press the key to complete the above copy/replace. ‘DONE!!!’ will appear in the title bar once complete. ENTRON Controls, LLC. 700230D...
  • Page 36 5.2.2 Main Menu Screens—Reset Error Navigate to the ‘Reset error’ screen. Confirm [Yes/No] Must select ‘Yes’ and press the key to complete the above copy/replace. ‘DONE!!!’ will appear in the title bar once complete. ENTRON Controls, LLC. 700230D...
  • Page 37 Number at which the ‘part count done’ reports ‘ER25’. Weld per part [1-9,999] Default = 1 The number of welds to increment ‘part count done’ by one. RST Counter [None/PCTR/WCTR/Both] Resets counter. PCTR—part counter • WCTR—weld-per-part counter • ENTRON Controls, LLC. 700230D...
  • Page 38 5.2.2 Main Menu Screens—About Navigate to the ‘About’ screen. This screen displays firmware and hardware information. The information on this screen cannot be changed using the keypad. For more information on updating firmware, see Section 5.2.4. ENTRON Controls, LLC. 700230D...

  • Page 39: Setup Menu Screens

    An Escape input is re- quired to release the valve output(s). Addition- al welds are not permitted until Error Reset occurs. Stop—On error, valve signal(s) turn off as nor- • mal. Additional welds are not permitted until Error Reset occurs. ENTRON Controls, LLC. 700230D...
  • Page 40 ‘fully open’ position. Only appears when ‘air-over-oil’ is set to ‘Mode 2’. Retract Close [0-99] cycles Default = 0 Time delay to allow for closure from ‘fully open’ position to ‘pre-weld’ position. Only appears when ‘air-over-oil’ is set to ‘Mode 2’. ENTRON Controls, LLC. 700230D...
  • Page 41 AVC nom. value before ER32 is dis- played. Only operates if enabled. AVC nom. [187-633] volts Default = 480 Supply voltage on which the control is designed to operate. Parameter is only visible when ‘AVC’ is enabled. ENTRON Controls, LLC. 700230D...
  • Page 42 Time duration that the water flow signal will remain on following a weld. Feature available on PO3. 87° delay [On/Off] On—the first half cycle is delated 87 degrees • (51.6% max) phase shift in order to minimize saturation of the weld transformer. ENTRON Controls, LLC. 700230D...
  • Page 43 Length of time before the display returns to ‘Status Page 1’. Clear [None/IO Map/Calibration/Config/ Stepper/Counter/Schedule/ All] Clearing data from this menu does not re- quire a confirmation. ‘DONE!!!’ will appear in the title bar as verification. ENTRON Controls, LLC. 700230D...
  • Page 44 Default = 150 For accurate current monitoring. Max I [6-100] kA Default = 20 AC line scale [0.8-1.2] Default = 1.0 For accurate voltage monitoring. Turns ratio [10-255] Default = 50 Turns ratio of welding transformer. ENTRON Controls, LLC. 700230D...
  • Page 45 This screen allows you to set the function of each input and output. For more information, see Section 5.4. This screens allows for the input source of each programmable input to be changed. The options are local (default) and remote. ENTRON Controls, LLC. 700230D...
  • Page 46 Navigate to the ‘Error Map’ Screen. This screen allows you to set each error message as ‘Major’ or ‘Minor’. All messages are set to Minor by default. For more detailed information on each error message, see Section 6.1. ENTRON Controls, LLC. 700230D...
  • Page 47 Note: RST Stepper input, Step End output, and Tip dressing pre-warn are recommended when uti- lizing the Stepper function. The diagram above is intended to demonstrate a resulting weld- ing timing cycle using the attached parameters; it is not recom- mended as part of a functional weld schedule. ENTRON Controls, LLC. 700230D...
  • Page 48 Heat+ [0-99]% The additional percentage of phase shift to be added to Weld1 and Weld2 of the weld schedule. Current+ [0-99.99]kA The additional current to be added to Weld1 and Weld2 of the weld schedule. ENTRON Controls, LLC. 700230D...
  • Page 49 5.2.3 Setup Menu Screens—Utility Navigate to the ‘Utility’ screen. This screen contains the Utility menu. For more detailed information on back- ing up and restoring data, please see Section 5.2.4. ENTRON Controls, LLC. 700230D...
  • Page 50 5.2.3 Setup Menu Screens—Ethernet Navigate to the ‘Ethernet’ Screen. This screen displays information related to Ethernet communication with the control, including the control’s IP address. The information on this screen can be changed using the keypad. ENTRON Controls, LLC. 700230D...

  • Page 51: Other Screens

    ‘Utility’ Step 3: Select ‘Backup Data’ Step 4: Rename file using Step 5: Set ‘Confirm’ to “YES” using Step 6: Press and verify that ‘DONE!!!’ appears in the top left corner of the title bar ENTRON Controls, LLC. 700230D...
  • Page 52 ‘DONE!!!’ appears in the top left corner of the title bar *Note: The backup file must be on the root directory of the USB drive. And the filename must be EN6001 .EN6 to EN6001 .EN6 ENTRON Controls, LLC. 700230D...
  • Page 53 5.2.4 Other Menus—Update Firmware Step 1: Ensure the control is completely powered down. Step 2: Insert a USB drive with EN6001 firmware into the USB power on the control panel. Step 3: Press and hold Step 4: Power on the control. Once the Bootloader Menu ap- pears, release Step 5: Select ‘Refresh firmware’...

  • Page 54: Timing Cycles

    2 cycles 2 cycles Impulses 1 cycle The diagram above is intended to demonstrate a resulting weld- ing timing cycle using the attached parameters; it is not recom- mended as part of a functional weld schedule. ENTRON Controls, LLC. 700230D...
  • Page 55 2 cycles 2 cycles Impulses 2 cycles The diagram above is intended to demonstrate a resulting weld- ing timing cycle using the attached parameters; it is not recom- mended as part of a functional weld schedule. ENTRON Controls, LLC. 700230D...
  • Page 56 2 cycles 2 cycles Impulses 1 cycle The diagram above is intended to demonstrate a resulting weld- ing timing cycle using the attached parameters; it is not recom- mended as part of a functional weld schedule. ENTRON Controls, LLC. 700230D...

  • Page 57: Worksheets

    P1—11, Programmable Input #6 P2—2, Solenoid Valve #1 P2—3, Solenoid Valve #2 P2—4, Solenoid Valve #3 P2—5, Programmable Output #1 P2—6, Programmable Output #2 P2—7, Programmable Output #3 P2—8, Programmable Output #4 Sensing Coil Not Used Primary Secondary ENTRON Controls, LLC. 700230D...
  • Page 58 SCHEDULE #: Squeeze Delay: cycles Squeeze: cycles Valves: Weld 1: cycles Cool 1: cycles Slope: cycles Weld 2: cycles KVA or Cool 2: cycles Impulses: cycles Hold: cycles Off: cycles Cycle Mode: Comments: Tap Setting: Pressure: Machine: ENTRON Controls, LLC. 700230D...

  • Page 59: I/O Programming

    Current Error Current Error – weld current is outside of current monitoring window AVC Error AVC Error – Automated Voltage Compensation is insufficient (P2 - 8) Interlock Interlock – “Request to weld” signal; used with PI4 ENTRON Controls, LLC. 700230D...
  • Page 60 ER16 (see Section 6.1 for more information). This input must be used in conjunction with the Interlock output. [PCTR] Part Counter Reset A momentary connection to FSC will reset the Part Count to zero. ENTRON Controls, LLC. 700230D...
  • Page 61 1 + 4 = 5. [Stepper Reset] Stepper Reset A momentary connection to FSC will reset the Stepper Count value to zero. [WCTR] Weld Counter Reset A momentary connection to FSC will reset the Weld Count value to zero. ENTRON Controls, LLC. 700230D...
  • Page 62 [Major Error] Major Error A 24 VDC output occurs between the selected Programmable Output and SVC when an error that is programmed to MAJOR in the Error Map is displayed (see Error Map in Section 5.2.3). ENTRON Controls, LLC. 700230D...
  • Page 63 [Water Saver] Water Saver A 24 VDC output occurs between the selected Programmable Output and SVC for as long as is programmed for Water Saver in the Config Menu after input to FS1 or FS2 has been re- moved. ENTRON Controls, LLC. 700230D...

  • Page 64: Error Codes

    The input is not seeing a closed connection from the external “No Weld” circuit to FSC. If this feature is unused, insert a jumper from FSC to NW1. If the feature is being utilized, verify that external circuit is functioning appropriately. ENTRON Controls, LLC. 700230D...
  • Page 65 Reset the counter. If this feature is not being utilized, consider disabling it under the ‘Edit Counter’ menu. Stepper end Reset Stepper. If this feature is not being utilized, consider disabling it under the ‘Stepper’ menu. ENTRON Controls, LLC. 700230D...
  • Page 66 The momentary toggle has remained high for 10 seconds or more. Check the signal to PI5 to ensure proper function. PS1 not ready Control is waiting for a closed connection from external pressure switch to PS1 programmable input. ENTRON Controls, LLC. 700230D...
  • Page 67 2nd Stage not ready Control is waiting for a closed connection from FSC to 2nd Stage programmable input for weld initiation. Interlock not ready Control is waiting for a closed connection from FSC to Interlock programmable input. ENTRON Controls, LLC. 700230D...

  • Page 68: Non-Error Code Issues

    -15%. 2. Defective Timer or AC Valve but solenoid valve PCB2 . 1b. Check if valve coil is proper voltage. chatters. 1c. Insufficient air pressure 1d. Loose connections in valve wiring 2. Replace Timer or PCB2. ENTRON Controls, LLC. 700230D...
  • Page 69 4. Dirty material to be welded. 4. Work should be free from excessive dirt, paint and oxides. 5. Loose connection. 5. Check all terminal and/or lug connec- 6. Material not to specification tions inside the cabinet. 6. Check material. ENTRON Controls, LLC. 700230D...
  • Page 70 6.2 Non-Error Code Issues ENTRON Controls, LLC. 700230D...

  • Page 71: Noise Suppression

    All inductive devices such as valves, solenoids, and other switching elements (or their connecting wires), which are situated in the vicinity of control, require noise suppression or physical isolation with barriers. ENTRON Controls, LLC. 700230D...

  • Page 72: Warranty And Service Policy

    The warranty shall be limited to the warranty of materials and workmanship and compliance with ENTRON’s Designed Use for the Product and ENTRON makes no other warranties. When the Product is sold to be used in combination with other equipment not of ENTRON’s design or manufacture, the warranty is limited to the Product and not the other equipment.
  • Page 73 6.3 Warranty and Service Policy Limitations of the Warranty: The damages for which ENTRON is liable in respect of any one cause of action shall not exceed the sum equal to 100% of the purchase price specified in the equipment purchase agreement.

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