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Entron EN7000-TS Technical Manual

Welding control for 50/60 hz spot, projection, roll-spot, seam and multi-welding applications
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EN7000 Technical Manual
Welding control for 50/60 Hz spot, projection, roll-spot, seam and multi-welding applications

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  • Page 1 EN7000 Technical Manual Welding control for 50/60 Hz spot, projection, roll-spot, seam and multi-welding applications...
  • Page 2 BF ENTRON's trademarks and trade dress may not be used in connection with any product or service that is not BF ENTRON's, in any manner that is likely to cause confusion among customers or in any manner that disparages or discredits BF ENTRON. All other trademarks not owned by BF ENTRON are the property of their respective owners, who may or may not be affiliated with, connected to, or sponsored by BF ENTRON.
  • Page 3 WARNING DO NOT DISASSEMBLE, REPAIR, OR MODIFY THE EN7000. These actions can cause electric shock and fire.  Use only as described in this manual. Use only BF ENTRON recommended accessories and replacement parts.  Stop operation if any problems occur. If the equipment is not working as it should, has been dropped, damaged, left outdoors, or been in contact with water, contact BF ENTRON.

  • Page 4: Table Of Contents

    EN7000 Technical Manual Contents Section 1 Introduction …………………………………………………………………………………………...…5 Section 2 Mounting …………………………………………………………………………………..………………15 Section 3 Inputs and outputs …………………….…..……………………………………………………17 Section 4 Discrete i/o ……………………………..…….…………………………………………………….……19 Section 5 MODBUS i/o …………………..…….………………………………………………………….….…...24 Section 6 Weld control …………………..…….………………………………………………………………..30 Section 7 Electrode management …………………..…….…………………………………….………38 Section 8 Status information …………………………………………………………………….………….44 Section 9...

  • Page 5: Introduction

    Gear-plate mounted.  EN7000-TS: as EN7000, plus built-in touch screen display. Front panel mounted. EN7000 EN7000-TS Multiple communication and control options are supported by a number of programming methods. The Ethernet port supports simultaneous programming and control connection via a single physical cable.
  • Page 6 Section 1 Introduction Features Model EN7000 EN7000-TS   Netflash programming   WSP3 programming  Built-in programmer  Panel mounting  Gear-plate mounting   Ethernet   RS232   RS485   MODBUS TCP/IP   MODBUS RTU...
  • Page 7 Section 1 Introduction Weld parameters EN7000/EN7000-TS  Presqueeze  Squeeze  Pre-heat  Cool1  Upslope  Main heat  Cool2  Downslope  Pulses  Post-heat  Hold   WAV selection  Aux valve control  Retract/Hi-lift ...
  • Page 8 EN7000s. All parameters are directly mapped to MODBUS registers for easy access. Both MODBUS-TCP/IP (Ethernet) and MODBUS-RTU (RS485) protocols are supported. Built-in touch screen EN7000-TS has a touch screen panel which provides easy access to all parameters and indications.
  • Page 9 Section 1 Introduction Communications...
  • Page 10 Section 1 Introduction Applications Standard machines, portable/manual guns, robot guns, multi-welders and seam welders. 12.5 kA Prog 01 Low current W 2 Edit Program BF701 V1.01 Program 1 I1 = 17.0 kA H1 = 23.5% PHA PSQ = 0 ~ SQZ = 10 ~ W1 = 12 ~ C1 = 0 ~ W2 = 12 ~ C2...
  • Page 11 Section 1 Introduction 12.5 kA Prog 01 Low current W 2 Edit Program BF701 V1.01 Program 1 I1 = 17.0 kA H1 = 23.5% PHA PSQ = 0 ~ SQZ = 10 ~ W1 = 12 ~ C1 = 0 ~ W2 = 12 ~ C2 = 0 ~ HLD = 10 ~...
  • Page 12 Section 1 Introduction 12.5 kA Prog 01 Low current W 2 Edit Program BF701 V1.01 Program 1 I1 = 17.0 kA H1 = 23.5% PHA PSQ = 0 ~ SQZ = 10 ~ W1 = 12 ~ C1 = 0 ~ W2 = 12 ~ C2 = 0 ~ HLD = 10 ~...

  • Page 13: Section 2

    Section 1 Introduction Getting started  Section 2 Mounting: Ensure the EN7000 is securely mounted.  Section 3 Inputs and outputs: connect the essential services and inputs/outputs depending on the application.  Make sure that you have sufficient air pressure and cooling water where necessary. ...
  • Page 14 Section 1 Introduction This page intentionally left blank...

  • Page 15: Mounting

    Section 2 Mounting Mounting EN7000 is gear-plate mounted and EN7000-TS is front panel mounted. If you have purchased a complete system the EN7000 will already be mounted in the case. If you have purchased a timer only kit you will need to mount the EN7000 to the rest of your equipment.
  • Page 16 Section 2 Mounting Front panel mounting The mounting arrangements for EN7000-TS are shown below. All dimensions are in mm. Allow space for the connectors when mounting EN7000 or EN7000-TS...

  • Page 17: Inputs And Outputs

    Section 3 Inputs and outputs Inputs and outputs EN7000 uses a number of inputs and outputs to control and monitor the weld sequence. Inputs Input AWS designation Description Start When this input is activated a weld sequence begins. If the input is removed during the Squeeze interval the sequence is aborted.
  • Page 18 Section 3 Inputs and outputs Outputs Output AWS designation Description This output switches on to indicate the end of the weld sequence. Used in conjunction with the Retract input to control the welding head. Fault This output indicates a fault condition. Ready This output is active if EN7000 is ready to weld.

  • Page 19: Discrete I/O

    The inputs and outputs are accessible via connectors X2, X3, X4 and X5. The connectors are two-part terminals for use with wires up to 1 mm If the EN7000 is supplied fitted into a case some connections will have been pre-wired by BF ENTRON. See the case wiring diagram for details.
  • Page 20 Section 4 Discrete i/o EN7000 NetFlash MODBUS-RTU Outputs are rated 500 mA @24 V dc MODBUS-TCP/IP AWS designations in parenthesis inputs must be linked if not required Heartbeat Synchronised to ac mains Sequence initiated Weld current Data receive COM0 Data send COM0 Data receive COM1 Data send COM1 Data receive COM2...
  • Page 21 Section 4 Discrete i/o WSP3 i/o bit 24 V (24 VDC) 16. 15 P64 (BP64) 15. 14 P32 (BP32) 14. 13 P16 (BP16) 13. 12 P8 (BP8) 12. 11 P4 (BP4) 11. 10 P2 (BP2) 9 P1 (BP1) 8 Reset stepper (SR1) 7 Reset counter/tip dress ack 6 Reset fault (FR1) 5 Retract (RT1)
  • Page 22 Section 4 Discrete i/o EN7000-TS NetFlash MODBUS-RTU Outputs are rated 500 mA @24 V dc MODBUS-TCP/IP AWS designations in parenthesis inputs must be linked if not required Heartbeat Synchronised to ac mains Sequence initiated Weld current Data receive COM0 Data send COM0...
  • Page 23 Section 4 Discrete i/o WSP3 i/o bit 24 V DC out 15 P64 (BP64) 14 P32 (BP32) 13 P16 (BP16) 12 P8 (BP8) 11 P4 (BP4) 10 P2 (BP2) 9 P1 (BP1) 8 Reset stepper (SR1) 7 Reset counter/tip-dress ack 6 Reset fault (FR1) 5 Retract (RT1) stage (PS1)

  • Page 24: Modbus I/O

    Section 5 MODBUS i/o MODBUS i/o EN7000 can be operated via MODBUS instead of using the discrete inputs and outputs. Both MODBUS TCP/IP (Ethernet) and MODBUS RTU (RS485) protocols are supported. Write the inputs using MODBUS function 16 Read the outputs using MODBUS function 3 MODBUS access types Write inputs Type...
  • Page 25 Section 5 MODBUS i/o MODBUS mapping (inputs to EN7000) Variable Channel Address Type Description Write inputs %QW0 WORD ARRAY [0..1] Write multiple registers Write inputs [0] %QW0 WORD WRITE 16#8000 (= 32768) Start Bit 0 %QX0.0 BOOL Weld on Bit 1 %QX0.1 BOOL Stop...
  • Page 26 Section 5 MODBUS i/o MODBUS mapping (outputs from EN7000) Variable Channel Address Type Description Read outputs %IW0 WORD ARRAY [0..23] Read holding registers Read outputs [0] %IW0 WORD READ 16#9000 (= 36864) Bit 0 %IX0.0 BOOL Bit 1 %IX0.1 BOOL Fault Bit 2 %IX0.2...
  • Page 27 Section 5 MODBUS i/o Variable Channel Address Type Description Analog input (mV) Read outputs [3] %IW6 WORD READ 16#9003 (= 36867) Analog output (mV) Read outputs [4] %IW8 WORD READ 16#9004 (= 36868) % conduction Read outputs [5] %IW10 WORD READ 16#9005 (= 36869) Reserved Read outputs [6]...
  • Page 28 Section 5 MODBUS i/o Variable Channel Address Type Description Status register 3 Read outputs [11] %IW22 WORD READ 16#900B (= 36875) End of count 0 Bit 0 %IX22.0 BOOL Bit 48 End of count 1 Bit 1 %IX22.1 BOOL Bit 49 End of count 2 Bit 2 %IX22.2...
  • Page 29 Section 5 MODBUS i/o Variable Channel Address Type Description Status register 6 Read outputs [14] %IW28 WORD READ 16#900E (= 36878) Prewarn 0 Bit 0 %IX28.0 BOOL Bit 96 Prewarn 1 Bit 1 %IX28.1 BOOL Bit 97 Prewarn 2 Bit 2 %IX28.2 BOOL Bit 98...

  • Page 30: Weld Control

    Section 6 Weld control Weld control EN7000 controls the weld sequence by using the i/o in conjunction with the welding parameters. The parameters are stored in programs so that different materials and machine sequences can be used. There are 256 weld programs.
  • Page 31 Section 6 Weld control Spot sequence timing The weld programs contain the following timing parameters. Parameter Units Range Description Squeeze cycles 0 - 99 The time between the initial application of the electrode force and the first application of welding current Pre-heat cycles 0 - 99...
  • Page 32 Section 6 Weld control Seam sequence timing (extended feature) The weld programs contain the following timing parameters. All parameters can be adjusted during the sequence. Parameter Units Range Description Squeeze cycles 0 - 99 The time between the initial application of the electrode force and the first application of welding current Pre-heat cycles...
  • Page 33 Section 6 Weld control Spot current control The weld programs contain the following current control parameters. Parameter Units Range Description Pre-mode PHA/CCR Operating mode of the Pre-heat interval 0.0 – 99.9 Pre-heat The % heat used during the Pre-heat interval in PHA mode 0 –...
  • Page 34 Section 6 Weld control Seam current control (extended feature) The weld programs contain the following current control parameters. Parameter Units Range Description Pre-mode PHA/CCR Operating mode of the Pre-heat interval 0.0 – 99.9 Pre-heat The % heat used during the Pre-heat interval in PHA mode 0 –...
  • Page 35 Section 6 Weld control Force control The weld programs contain the following force control parameters. Parameter Units Range Description Squeeze kN/lbf variable Force used from the start of the Squeeze interval Pre-heat kN/lbf variable Force used from the start the Pre-heat interval Cool1 kN/lbf variable...
  • Page 36 Section 6 Weld control Valves EN7000 has eight digital outputs or valves (AV1 – AV8) that can be operated independently during a weld sequence. The valves are categorised as WAV, motor or AUX valves.  A WAV valve turns on at start of sequence and turns off at the end of the Hold interval. ...
  • Page 37 Section 6 Weld control Options Each weld program has a number of optional features. Parameter Range Description Pre-heat on/off Enables or disables the Pre-heat parameters Post-heat on/off Enables or disables the Post-heat parameters The number of times the Main heat – Cool2 interval is repeated Pulsations 1 - 99 Link...

  • Page 38: Electrode Management

    Section 7 Electrode management Electrode management Electrode management is provided via a combination of stepper and counter functions. The stepper provides a means of gradually increasing the current to compensate for electrode wear. The counter counts the number of welds that the electrode has done and allows the electrode to be dressed a number of times before it is replaced.
  • Page 39 Section 7 Electrode management Steppers A stepper is programmed by means of a curve which will provide values of heat and current increments related to the number of spots done. The curve is defined by a set of 10 points. Current or Heat Spots Step 0...
  • Page 40 Section 7 Electrode management Counters A counter is programmed by entering values related to the electrode maintenance and lifetime. Parameter Units Range Description Enable counter on/off Enables or disables the counter Count welds 0 - 9999 The number of welds that have been done since the last reset End count welds 0 - 99999...
  • Page 41 Section 7 Electrode management Current calibration The welding current can be measured by a Current Transformer (CT) or by a coil (toroid) on the primary or secondary circuit. If the sensor is measuring the primary current EN7000 can display secondary current when the relationship between primary and secondary current has been calibrated.
  • Page 42 Section 7 Electrode management Force calibration The analog input and analog output can be used for force control in terms of kN or lbf when they have been calibrated. Parameter Units Range Description OUT Point 1 0 - 10000 Analog output (point 1) OUT Point 1 kN/lbf Measured output force (point 1)
  • Page 43 Section 7 Electrode management Multi-electrode operation (extended feature) This extended mode feature allows the assignment of an electrode to a transformer or SCR. Parameter Units Range Description Electrode 0 - 7 The electrode number Transformer/SCR 0 - 7 The transformer or SCR that the electrode is connected to The diagram shows how the electrodes can be assigned to transformers/SCRs Electrodes 0 and 1 are assigned to transformer/SCR 0 Electrodes 2 and 3 are assigned to transformer/SCR 1...

  • Page 44: Status Information

    Section 8 Status Status information EN7000 reports a number of conditions to assist with diagnostics, quality control and maintenance. Each condition corresponds to a code which is accessible via MODBUS. Code Condition Action Normal Stop Check the Stop input Sync. error Check 27 V ac sync signal and/or the Frequency parameter in Configuration Retract not ready Operate the Retract input...
  • Page 45 Section 8 Status Reserved Reserved Reserved Reserved Reserved Reserved End of count 0 Reset counter 0 End of count 1 Reset counter 1 End of count 2 Reset counter 2 End of count 3 Reset counter 3 End of count 4 Reset counter 4 End of count 5 Reset counter 5...
  • Page 46 Section 8 Status Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved...

  • Page 47: History Log

    Section 9 History log History log EN7000 stores the results of the last 6000 spot welds in a history log. Each record contains the following information: Parameter Units Range Description Time and date The time and date when the entry was recorded Program 0 - 255 The weld program used...

  • Page 48: Multiwelding

    Section 10 Multiwelding Multiwelding (extended feature) The extended features allow up to four transformers/SCRs to be directly connected or up to eight when used with a decoder. Up to 8 electrodes can be assigned to the welding transformers The electrode number is determined by the weld program: Parameter Units Range...
  • Page 49 Section 10 Multiwelding The diagram shows how the electrodes can be assigned to transformers/SCRs Electrodes 0 and 1 are assigned to transformer/SCR 0 Electrodes 2 and 3 are assigned to transformer/SCR 1 Electrodes 4 and 5 are assigned to transformer/SCR 2 Electrodes 6 and 7 are assigned to transformer/SCR 3 There are two methods available for multiwelding.
  • Page 50 Section 10 Multiwelding Multi-gun operation Each welding program is started independently but different electrodes and transformers can be selected. Start input EOS output WAV output Program select Current (transformer 0) Current (transformer 1) Current (transformer 2) Current (transformer 3) The WAV output can be a separate output for each program...
  • Page 51 Section 10 Multiwelding Multi-gun cascade operation Different electrodes and transformers can still be selected but the welding programs are linked together and started by a single Start command Start input EOS output WAV output Program First program # select Current (transformer 0) Current (transformer 1)

  • Page 52: Seam Welding

    Section 11 Seam welding Seam welding (extended feature) EN7000 can be used for seam welding applications. The seam program parameters provide a flexible sequence that works in conjunction with the inputs and outputs to produce many different types of seam weld e.g. ...
  • Page 53 Section 11 Seam welding Continuous seam A continuous seam weld maintains a set current for the duration of the weld. The following example shows how this type of sequence may be implemented. Parameter Setting Description Sequence timing Squeeze cycles The time between the initial application of the electrode force and the first application of welding current Main heat cycles...
  • Page 54 Section 11 Seam welding Seam pulsation Seam pulsation can be used in applications where a continuous weld is not required. The Main heat and the Cool2 intervals are repeated for the duration of the weld. The following example shows how this type of sequence may be implemented.
  • Page 55 Section 11 Seam welding Seam modulation Seam modulation can be used in applications where a change in current is required. Two Heat intervals are repeated for the duration of the weld. The following example shows how this type of sequence may be implemented.
  • Page 56 Section 11 Seam welding Seam pre-heat Pre-heat can be used in applications where the initial current needs to be different to the main current. The following example shows a continuous seam weld with a pre-heat. Parameter Setting Description Sequence timing Squeeze cycles The time between the initial application of the electrode force and...
  • Page 57 Section 11 Seam welding Seam pre-heat only Pre-heat can be used in situations when a spot weld is required. The following example shows how to use the pre-heat to produce a spot weld. Parameter Setting Description Sequence timing Squeeze cycles The time between the initial application of the electrode force and the first application of welding current Pre-heat...
  • Page 58 Section 11 Seam welding Roll-spot Roll-spot welds can be used in applications where a motor drive output is required between welds. The following example shows how this type of sequence may be implemented. Parameter Setting Description Sequence timing Repeat Sets roll-spot mode when configured for seam welding Squeeze cycles The time between the initial application of the electrode force and...

  • Page 59: Configuration

    Section 12 Configuration Configuration The Configuration parameters affect the operation of the EN7000. Parameter Value Description Standard Use standard features Features Extended Use extended features Spot Use spot welding features Weld type Seam Use seam welding features Use a Current Transformer (CT) for primary current monitoring Sensor Toroid Use a measuring coil (Toroid) for secondary current monitoring...
  • Page 60 Section 12 Configuration After Squeeze The 2 stage input is checked after the Squeeze interval. The motor output is activated when the 2 stage input is confirmed Start input stage input Motor output Sequence Sequence begins Squeeze continues   Simple Hilift + Retract...

  • Page 61: Programming

     NetFlash PC program (Ethernet)  WSP3 pendant (RS232)  Built-in touch screen (EN7000-TS only)  MODBUS (Ethernet or RS485) NetFlash NetFlash is a PC-compatible program which provides a graphical user interface to program and monitor one or more EN7000s. In addition NetFlash provides backup/restore functions for control data, live data logging to a file and a utility for updating the firmware in the EN7000.
  • Page 62 Section 13 Programming Connection NetFlash uses 10/100 Base-T Ethernet to communicate with the EN7000. Ensure that the PC has an appropriate Ethernet adapter and that a network connection is in place. Use COM0/1 to connect the EN7000 to the network PC + NetFlash Hub or switch EN7000...
  • Page 63 Section 13 Programming Initialisation Run the NetFlash.exe program. The home screen is shown: Displays ENTRON UK contact details Edit EN7000 parameters. Allows access to the EN7000 parameters via the network or from a file. Network configuration. Locates welding controls on the network Flash programming tool.
  • Page 64 Section 13 Programming Select Network Configuration . The following screen is shown: Edit timer location. Welding controls that have been detected on the network can be assigned descriptive names and locations. This function allows the names and locations to be edited. Add a welding control to the network Remove a welding control from the network Scan for welding controls on the network...
  • Page 65 Section 13 Programming Select Scan network for timers. NetFlash will show the compatible welding controls on the network: Select an IP address and then select OK. NetFlash will ask if the address should be used as the target welding control for editing: If Set as target IP address is selected the IP address will be shown as the target IP address: Alternatively, the target address can be set by using the Edit button: To add a descriptive name and/or location for the welding control, use the Add welding control function.
  • Page 66 Section 13 Programming Parameters Caution: when parameters are changed in NetFlash they are changed immediately in the EN7000. Select the Edit weld parameters function from the home screen. Select Load from timer. Data will be loaded from the target welding control: The Program screen is shown.
  • Page 67 Section 13 Programming WSP3 Caution: when parameters are changed with the WSP3 they are changed immediately in the EN7000. The WSP3 is a hand-held programming pendant with a 20x4 character display and a sealed keypad. The WSP3 can be used to access diagnostic information in addition to all parameters. eady prog - - 11.7...
  • Page 68 Section 13 Programming Keypad Return to the previous screen or move between menu screens. Select a different function or parameter. The selected function or parameter will flash and the visible window will scroll if required. Access the selected function. Alter the selected parameter. Press both keys together to set the parameter to 0 or to its minimum value.
  • Page 69 Section 13 Programming Menus The functions of the EN7000 are arranged into a set of menus and screens as follows: Diagnostic screen eady prog 11.7 5.66 ~30.5 % <<< MAIN MENU >>> <<< configure >>> USE program 7 01 sep 2016 12.00.00 Edit program stage:off Edit electrode...
  • Page 70 Section 13 Programming Backup/Restore The WSP3 allows the data in one EN7000 to be transferred to another by using the Backup and Restore functions.  Use the Backup function to make a copy of all the EN7000’s settings. The copy is held within the WSP3.
  • Page 71 Section 13 Programming Touch screen EN7000-TS models have a touch screen display that can be used to access all parameters and diagnostic information. The touch screen uses a number of elements to navigate and edit the parameters. Tap the element to access the function.
  • Page 72 Section 13 Programming Menus The menus of the EN7000 are arranged as follows: Main menu Use program Discrete I/O Program Bus I/O Electrode Analog I/O History log System Configure Program menu Program Link to program Electrode Time Current Force Valves Options Copy START...
  • Page 73 Section 13 Programming Main menu Use program Discrete I/O Program Bus I/O The Main menu allows access to all other menus, the input/output Electrode Analog I/O status and system information. History log System Configure Status Ready Pre-heat Program The Status menu shows diagnostic information and the results of the last weld.
  • Page 74 Section 13 Programming MODBUS A PLC or HMI MODBUS master can be used to program EN7000. All parameters are directly mapped to MODBUS registers for easy access. Both MODBUS-TCP/IP (Ethernet) and MODBUS-RTU (RS485) protocols are supported. Write the data using MODBUS function 16 Read the data using MODBUS function 3 MODBUS access types Write data...
  • Page 75 Section 13 Programming MODBUS mapping Variable Address Type Description Weld programs 256 x 64 WORDS Weld program 0 16#0000 (= 0) WORD ARRAY [0..63] Weld program 1 16#0040 (= 64) WORD ARRAY [0..63] Weld program 2 16#0080 (= 128) WORD ARRAY [0..63] Weld program 3 16#00C0 (= 192) WORD ARRAY [0..63]...
  • Page 76 Section 13 Programming Weld program parameters Variable Channel Address offset Type Description Weld program %IW0 WORD ARRAY [0..63] Attributes Weld program [0] %IW0 WORD Pre heat Bit 0 %IX0.0 BOOL 0 = off, 1 = on Post heat Bit 1 %IX0.1 BOOL 0 = off, 1 = on...
  • Page 77 Section 13 Programming Weld program parameters (continued) Variable Channel Address offset Type Description 0 – 32767 Squeeze force Weld program [35] %IW35 WORD 0 – 32767 Pre-heat force Weld program [36] %IW36 WORD 0 – 32767 Cool1 force Weld program [37] %IW37 WORD 0 –...
  • Page 78 Section 13 Programming Calibration parameters Variable Channel Address offset Type Description Calibration %IW0 WORD ARRAY [0..63] 0 – 86 (x100) Power factor Calibration [0] %IW0 WORD 0 – 10000 mV A out X1 Calibration [1] %IW1 WORD 0 – 32767 A out Y1 Calibration [2] %IW2...
  • Page 79 Section 13 Programming Configuration parameters Variable Channel Address offset Type Description Configuration %IW0 WORD ARRAY [0..63] Weld type Configuration[0] %IW0 WORD 0 = spot 1 = seam Second stage Configuration[1] %IW1 WORD 0 = none 1 = before Squeeze 2 = after Squeeze Retract Configuration[2] %IW2...

  • Page 80: Tutorials

    Section 14 Tutorials Tutorials EN7000 has a number of features that can improve weld quality, diagnostics and maintenance. Before each tutorial:  Section 12 Configuration: ensure the Configuration parameters are set appropriately for the application.  Section 7 Electrode management: if a CT is being used to measure current, ensure the Calibration parameters are set.
  • Page 81 Section 14 Tutorials Testing the weld current The current for each weld can be tested against upper and lower limits. In the weld program, enable the Test current option for each weld to be tested. Set the Low limit and High limits appropriately. The limits correspond to a percentage of the required current.
  • Page 82 Section 14 Tutorials Using the Retract functions The Retract function allows the welding head to open in two stages.  The fully open position allows the work piece to be positioned between the electrodes.  The middle position allows the electrodes to close onto the work piece in order to weld. EN7000 has four Retract modes that can be used depending on the application.
  • Page 83 Section 14 Tutorials Hi-lift - A pulse on the Retract Input causes the High Lift Air Valve to switch off and close the electrodes to the mid position. Welding can proceed in this case. Whilst the High Lift Air Valve is off, a pulse on the Retract Input causes the valve to switch on and the electrodes go to the fully open position.
  • Page 84 Section 14 Tutorials Using the valves to control a multi-head machine EN7000 can be used with welding machines that have multiple welding heads. By assigning one of the EN7000s AV outputs, each head can be operated individually. 12.5 kA Prog 01 Low current W 2 Edit Program BF701 V1.01...
  • Page 85 Section 14 Tutorials The diagram shows the operation in multi-gun mode: Start input EOS output AV1 output AV2 output AV3 output AV4 output Program select Current (Program 0) Current (Program 1) Current (Program 2) Current (Program 3)
  • Page 86 Section 14 Tutorials The operation is similar when the programs are linked together in multi-gun cascade mode: Start input EOS output AV1 output AV2 output AV3 output AV4 output Program First program # select Current ( Program 0) Current ( Program 1) Current ( Program 2) Current...
  • Page 87 Section 14 Tutorials Controlling a multiwelder A multiwelder can use different transformers for each welding head. 12.5 kA Prog 01 Low current W 2 Edit Program BF701 V1.01 Program 1 I1 = 17.0 kA H1 = 23.5% PHA PSQ = 0 ~ SQZ = 10 ~ W1 = 12 ~ C1 = 0 ~ W2 = 12 ~ C2...
  • Page 88 Section 14 Tutorials For example: Electrode SCR/Transformer Description Electrodes 0, 1 and 2 are assigned to transformer 0 Electrodes 3 and 4 are assigned to transformer 1 Electrode 5 is assigned to transformer 2 Electrodes 6 and 7 are assigned to transformer 3 The electrodes can then be assigned to weld programs: Weld program Electrode...
  • Page 89 Section 14 Tutorials Setting the power factor An AC welding machine will have a power factor which is determined by the physical properties and geometry of the electrical system. Linear control of the machine over the full heat/current range can be achieved by programming the correct value for the power factor.
  • Page 90 Section 14 Tutorials NetFlash to select the Metrics window then select the reset button Discrete input Input Pin number Description Reset fault X3.7 This input resets the Fault output and clears the status messages. Only momentary application is required (minimum time 40ms). The discrete i/o is described in Section 4 Discrete i/o.

  • Page 91: Appendix

    Section 15 Appendix Appendix Updating the firmware The functionality of EN7000 is determined by firmware stored in reprogrammable memory. EN7000 has three memories: Memory Description Memory A Memory B BIOS BIOS memory The firmware can be transferred to one or more of the memories and then activated when EN7000 starts. In this way it is possible to retain different firmwares and activate them without having to reprogram EN7000.
  • Page 92 Section 15 Appendix  Select the flash file . This will be a file with a .hex extension supplied by ENTRON UK.  Select connect to the EN7000 . NetFlash will connect to the target control and report the current firmware status.
  • Page 93 Section 15 Appendix  Select the EN7000/xPort AR device then select Assign IP:  The IP address can be set manually or automatically. Select the most appropriate method for your network. To set the address manually, select Assign a specific IP address and then select Next:...
  • Page 94 Section 15 Appendix  Enter the IP address, subnet mask and gateway then select Next:  Select Assign to complete the assignment. Device Installer will show the progress of the operation:  Select Finish to return to the main screen.

  • Page 95: Terminology

    Section 16 Terminology Terminology Term Description Constant current regulation. See Constant Current. Conduction The % of the mains waveform during which current is flowing. Constant current Closed loop control of weld current resulting in the weld current being regulated to a programmed value.
  • Page 96 Section 16 Terminology the work piece, and a working position for welding. Retract air valve For use on a gun where the electrodes can be opened and closed in two stages. This is an electrically operated valve for admitting air to the air cylinder that controls the electrode movement.

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