Entron EN1000 Series Instruction Manual
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Entron EN1000 Series Instruction Manual

Microprocessor based welding control with solid state thyristor contactors
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  • Page 1 ,16758&7,210$18$/ & (16(5,(6&21752/6 1(0$7<3($// 0,&52352&(6625%$6(' :HOG6HTXHQFH&RQWUROV :LWK 6ROLG6WDWH7K\ULVWRU&RQWDFWRUV :LULQJ'LDJUDP 5&DELQHW  6&DELQHW 7'/6/)&DELQHW (&DELQHW  (17521&RQWUROV,QF (DVW5DQG\5RDG &DURO6WUHDP,OOLQRLV   )$;  ...
  • Page 2 (17521&RQWUROV,QF 0,&52352&(6625%$6(':(/',1*&21752/ :,7+62/,'67$7(7+<5,6725&217$&7256 ,167$//$7,21$1'23(5$7,210$18$/)25 0RGHO6HULHV(11(0$7\SH$// CAUTION READ THIS MANUAL COMPLETELY BEFORE ATTEMPTING TO INSTALL OR OPERATE THIS CONTROL (17521&RQWUROV,QFUHVHUYHVWKHULJKWWRDOWHUWKHFRQWHQWVRI WKLVPDQXDOZLWKRXWSUHYLRXVQRWLFH (17521&RQWUROV,QF &DURO6WUHDP,OOLQRLV Page 1 710228A...
  • Page 3 7$%/(2)&217(176 7$%/(2)&217(176                              *(1(5$/'(6&5,37,21                             67$1'$5')($785(6                              (1&21752/3$1(//$<287                     &21752/)81&7,216                             ...
  • Page 4 7$%/(2)&217(176 FRQWLQXHG 6/23(02'(&21752/                           126/23(                                     836/23(                                      '2:16/23(                                  6(77,1*6/23(%27720&855(17                 ...
  • Page 5 *(1(5$/'(6&5,37,21 The EN1000 is a microprocessor based resistance welding control. It can store as many as 11 parameters in each of 50 unique schedules. These are held in non-volatile memory for storage. It can perform Up Slope, Down Slope, Quench, Temper, Pulsation, Seam, and Spot, all of which can be combined to provide for any possible welding schedule imaginable.
  • Page 6 (0(5*(1&<6723 - This is a terminal strip connection that allows all control functions to be reset upon opening of the EMERGENCY STOP switch. Control will not be re-initiated automatically upon release of the switch and must be re-initiated through the normal initiation circuit.
  • Page 7 (1&21752/3$1(//$<287 FIGURE 1 :(/'12:(/'6:,7&+ ,1',&$725/('6/23(02'()81&7,21 ,1',&$725/('12:(/'02'( ,1',&$725/('6/23(&2817)81&7,21 ,1',&$725/(':(/'02'( ,1',&$7251(210$,132:(5 '$7$',63/$< ,1&5(0(176&+('8/(6(/(&7 6386+%87721 ,1&5(0(17'$7$ 6386+%877216:,7&+ ,1&5(0(176&+('8/(6(/(&7 6386+%87721 6&+('8/(6(/(&7',63/$< ,1&5(0(17'$7$ 6386+%877216:,7&+ ,1',&$725/('648((=()81&7,21 ,1',&$7251(21:(/' ,1',&$725/(':(/')81&7,21 352*5$0/2&.2876:,7&+ ,1',&$725/('3(5&(17&855(17)81&7,21 ,1',&$725/('&21752/,123(5$7(02'( ,1',&$725/('+2/')81&7,21 352*5$023(5$7(386+%87721 ,1',&$725/('2)))81&7,21 ,1',&$725/('&21752/,1352*5$002'( )81&7,216(/(&7,21386+%877216:,7&+ ,1',&$725/('9$/9( (17(5386+%877216:,7&+ ,1',&$725/(',038/6(6)81&7,21 ,1',&$725/('&22/)81&7,21 ,1',&$725/('9$/9( ,1',&$725/('9$/9(02'()81&7,21 ,1',&$725/('9$/9( ,1',&$725/('&<&/(02'()81&7,21 *For operator convenience, the codes for these mode and selection functions are printed on the left side of the control panel, adjacent to Push Buttons (1) and (26).

  • Page 8: Schedule

    &21752/)81&7,216 - See Figure 1, CONTROL PANEL LAYOUT. 32:(521/,*+7 - The red POWER (19) lamp on the light panel, at the top of the R cabinet door or bottom of the S cabinet dialplate, indicates when power is applied to the control.

  • Page 9: Squeeze Count

    6&+('8/(180%(56(/(&7,21: Displayed by (22). There are two possible ways to select the SCHEDULE to be initiated. Schedules can be selected internally or externally. INTERNAL: If EXTENDED FUNCTION, SCHEDULE SELECT [SS] is set to INTERNAL [00], use Push Button switches (20) and (21) to select the desired SCHEDULE.
  • Page 10 6/23(&2817(18) - The number of cycles during which the percent current increases or decreases cycle by cycle to achieve a slope function (gradual increase or decrease in current). 27+(5352*5$00$%/()81&7,216 ,038/6(6 (13) - In multiple impulse welding this counter counts the number of predetermined Heat Impulses.
  • Page 11 9$/9( 02'( (15) - The three solenoid valves are activated based on the code programmed as shown in Table 1 below. 7$%/( CODE TS1-SV1 TS1-SV3 TS1-SV5 -------------------------------------------------------------------- -------------------------------------------------------------------- -------------------------------------------------------------------- -------------------------------------------------------------------- -------------------------------------------------------------------- -------------------------------------------------------------------- -------------------------------------------------------------------- -------------------------------------------------------------------- -------------------------------------------------------------------- When in the PROGRAM mode and selection of a valve code is being made, the valve LED indicators (28,30,31) will indicate the selected valve /s (the valve /s output will not be energized while in program mode).
  • Page 12 ,1,7,$7,217:267$*(3,/27 This control may be initiated by the closure of a two stage pilot. First stage is connected to TS1-FS1 and TS1-GND, second stage is connected to TS1-FS3 and TS1-GND. The first stage only activates the selected solenoid valve for the selected schedule, and does NOT initiate a sequence.
  • Page 13 &217$&7257(03(5$785(/,0,76:,7&+: If the Temperature Limit Switch is activated (open), the control cannot be initiated. The initiation will remain inactive until the Temperature Limit Switch cools (resets). If the Temperature Limit Switch is activated (opened) during WELD Time, the firing pulses to the contactor will continue until the end of WELD Time.
  • Page 14 92/7$*(352*5$00,1* &$87,21 :+(17+(:(/',1*&21752/$1'25:(/',1*0$&+,1(:$6 6+,33('7+(92/7$*($7:+,&+,7:$66(7:$60$5.(' 217+(7$*$77$&+('727+(&21752/7(50,1$/%/2&. 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.
  • Page 15 &$87,21 :KHQH[WHUQDOYDOYHSRZHULVXVHG 9$& 9DOYHWUDQVIRUPHUPXVW EHGLVFRQQHFWHGDW769/DQG769/&DXWLRQPXVWEHXVHGWR SURSHUO\LQVXODWHWKHZLUHVIURP;DQG;OHDGVDIWHUUHPRYLQJIURP76 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 firing board is 1 AMP per valve. If more current is desired, the valve circuit should be wired to a relay having a suitable contact rating to switch the desired valve.
  • Page 16 &86720(57(50,1$/675,3',$*5$06 TERMINAL STRIP TS1/PCB1 SEE CUSTOMER WIRING DIAGRAM 421189 R/T CABINET OR 421180 S CABINET Page 15 710235A...
  • Page 17 TERMINAL STRIP TS1 SEE CUSTOMER WIRING DIAGRAM 421189 R/T CABINET OR 421180 S CABINET Page 16...
  • Page 18 +22.83(;7(51$/,*1,752178%(&217$&725 SEE CUSTOMER WIRING DIAGRAM 421189 R/T CABINET OR 421180 S CABINET Page 17 710236A...
  • Page 19 +22.83(;7(51$/6&5&217$&725 SEE CUSTOMER WIRING DIAGRAM 421189 R/T CABINET OR 421180 S CABINET Page 18...
  • Page 20 &86720(57(50,1$/675,3&211(&7,216 See diagram on page 15. TS1-FS1 Used to connect one side of the First Stage of a two Stage Pilot Switch. Use a single pole, normally open, momentary type Switch. Connect the First Stage of a TWO Stage pilot Switch between TS1-FS1 and TS1-GND terminals.
  • Page 21 TS1-FS7/SS1 along with TS1-FS11/SS3 can also be used for a set of initiations configured for anti tie down. When programmed via the EXTENDED FUNCTIONS [SS] ANTI-TIE DOWN [02] TS1-FS7/SS1 and TS1-FS11/SS3 become inputs for ANTI-TIE DOWN. Use single pole normally open switches connected from TS1-FS7/SS1 to GND and TS1-FS11/SS3 to GND.
  • Page 22 TS1-ES1 Used to connect one side of an Emergency Stop Switch. When used remove jumper between TS1-ES1 and TS1-GND terminals and install a single pole, normally closed Emergency Stop Switch. It is possible to install several Emergency Stop Switches in series. Activation of any one switch will put the control into the Emergency Stop condition.
  • Page 23 5()(5(1&(7(50,1$/675,376',$*5$0VHFWLRQ Used to properly jumper for input voltages to the control TS1-CTHA,L1,CTH1,CTH3, transformer. L1 is internally connected to control fuse F1. CTH2,CTH4/L2 For 208/240 VAC operation - jumper CTH1 to CTH3 and CTH2 to CTH4/L2. For 480 VAC operation - jumper CTH3 to CTH2 only. Used also for connections to external SCR or IGNITRON CONTACTORS.
  • Page 24 35,0$5<:,5,1*72:(/',1*&217$&725 6&525,*1,752178%(&217$&7256 &$87,21 :KHQSRZHULV21DOOH[WHULRUVXUIDFHVRI WKHLJQLWURQWXEHVDQG6&5 VFDUU\OLQH YROWDJHVRI9RU9&RQWDFWZLWKWKHVH GHYLFHVPD\FDXVHVHULRXVRUIDWDOLQMXULHV 1. For your convenience, many electrical and mechanical connections have been performed at the factory. Check ALL electrical connections to assure that all connections are tight. Connections may loosen during shipping. 2. Connect the L1 lead from incoming power to the L1 connection located on the contactor assembly.
  • Page 25 &22/,1*5(48,5(0(176)25&217$&7256 SOLID STATE MANUFACTURER'S COOLING RECOMMENDATIONS 600 AMP SCR Solid State Contactor 1200 AMP SCR Solid State Contactor 1800/2200 AMP SCR Solid State Contactor 1 GPM at 104(F (40(C) maximum inlet temperature. TUBE MANUFACTURER'S COOLING RECOMMENDATIONS This chart shows typical cooling requirements at 500VAC operation in GPM. Maximum water temperature 50(C (122(F) IGNITRON TUBE SIZE WATER INLET...
  • Page 26 ,167$//$7,21',$*5$066&$%,1(7 Page 25 710240...
  • Page 27 ,167$//$7,21',$*5$06(&$%,1(7 300/600A CONTACTOR ‘E’ CABINET See Page 28 for mounting information. 1800/2200A CONTACTOR ‘E’ CABINET Page 26...
  • Page 28 ,167$//$7,21',$*5$067$1'/&$%,1(76 $&217$&725 ¶7·&$%,1(7 See Page 28 for Mounting Information $&217$&725 ¶7·&$%,1(7 Page 27 710241...
  • Page 29 0(&+$1,&$/02817,1*',$*5$06 "E" CABINET "T" CABINET Page 28...
  • Page 30 *(1(5$/23(5$7,1*,16758&7,216 4. For your convenience, many electrical and mechanical connections have been performed at the factory. Refer to CUSTOMER WIRING DIAGRAM for other connections. 5. Be sure all electrical connections are properly made and that all fittings are securely tightened. Loose electrical connections can cause faulty or erratic operation of the control or welding machine.
  • Page 31 &$87,21 .((3+$1'6$50627+(53257,2162)7+(%2'<&/27+,1* $1'722/6$:$<)5207+(029,1*3$5762)7+(0$&+,1( 10. Program the schedule for the part to be welded as recommended by the machine manufacturer or to RWMA standards for the work to be performed. Place the work in the machine and set the WELD/NO WELD switch (both on control panel and any EXTERNAL WELD/NO WELD switches) to the WELD position.
  • Page 32 ,1752'8&7,2172352*5$00,1*7+((1 The EN1000 is capable of storing and accessing up to 50 unique welding Schedules. This makes the EN1000 particularly suitable for complex welding operations, as well as automated machinery. Programming allows the operator to enter or change parameters of weld SCHEDULES and the subsequent storing of those parameters in non-volatile memory.
  • Page 33 STEP 5. Press the ENTER Push Button (29) to enter the data in the DATA DISPLAY into non-volatile memory. As the ENTER key is pressed the DATA Display will blink and then remain steady. Repeat STEPS 2, 3, 4 and 5 as required. Any or all Functions may be programmed depending on the final Welding Schedule desired.
  • Page 34 (;7(1'(')81&7,216 The EN1000 Series controls extend their versatility and cost effectiveness through use of EXTENDED FUNCTIONS. The EXTENDED FUNCTIONS are intended to give more versatility to the advanced applications without encumbering casual applications. Most of the default (factory shipped mode) settings of the EXTENDED FUNCTIONS are set for the more common uses and may need to be programmed before EXTENDED FUNCTIONS are used.
  • Page 35 6($0:(/',1* The EN1000 Series controls can be programmed for SEAM welding operation. To program the control for SEAM welding, the EXTENDED FUNCTION [SE] mode must be selected. See section 7.3. EXTENDED FUNCTIONS. Use the SCHEDULE SELECT Push Buttons (20 & 21) and SCHEDULE DISPLAY (22) to select [SE]. With the control in the PROGRAM MODE enter a 01 into the DATA Display (4) using DATA Push Buttons (5 &...
  • Page 36 NOTE: When the EN1000 series controls are used for SEAM WELDING, RESISTANCE BRAZING, or other high duty cycle applications, additional surge resistors must be installed in accordance with instructions on the wiring diagram. These resistors may be obtained through your resistance welder dealer or directly from ENTRON CONTROLS INC.
  • Page 37 TS1-FS7/SS1 and TS1-FS11/SS3 can also be used for a set of initiations configured for ANTI-TIE DOWN. When programmed via the EXTENDED FUNCTIONS [SS] ANTI-TIE DOWN [02] these terminals become inputs for ANTI-TIE DOWN. Use two single pole normally open Push Button Switches connected from TS1-FS7/SS1 and TS1-FS11/SS3 to TS1-GND.
  • Page 38 $9& The EN1000 controls are shipped with the automatic voltage compensation feature disabled. Under conditions of poor line voltage regulation, its use will provide consistently good quality welds in spite of varying line voltage. To enable the AVC, the EXTENDED FUNCTION [CC] Mode must be selected.
  • Page 39 7(03(5$785(/,0,76:,7&+%$&.67(3 To add versatility to SUCCESSIVE, an EXTENDED FUNCTION [bS] is provided to decrement the selected schedule by one. The TS1-TLS1/AUX1 on the terminal strip is used as a BACK STEP input. The BACK-STEP input is used to decrement the SCHEDULE display by one, except when the SCHEDULE number displayed is the first in a SUCCESSIVE sequence.
  • Page 40 352&(662873876 PROCESS OUTPUTS may be implemented through the use of EXTENDED FUNCTIONS [EF]. This feature can be used to communicate specific process statuses or error conditions to machine controls, shunt trips, or an indicator lamp. Please note that in this mode, valve three can no longer be used for a valve output.
  • Page 41 When the WELD PROCESS OUTPUT (01) is chosen, the third valve output will turn on upon the application of welding voltage to the welding transformer. The output remains on until the voltage is turned off to the weld transformer, at the completion of the schedule. In SEAM Mode the output will turn on for WELD/HEAT and COOL Time.
  • Page 42 ,1,7,$7,2102'(6121%($7 The EN1000 Series of controls can provide several INITIATION Modes. The default Mode is NON BEAT. In the NON BEAT Mode, once the sequence is initiated by a momentary closure, it cannot be stopped other than use of EMERGENCY STOP.
  • Page 43 To program the control to BEAT INITIATION DURING SQUEEZE and WELD, the EXTENDED FUNCTION [bE] Mode must be selected. See section 7.3 EXTENDED FUNCTIONS. Use the SCHEDULE SELECT Push Buttons (20 & 21) and SCHEDULE Display (22) to select [bE]. With the control in the PROGRAM Mode enter a 02 into the DATA Display (4) using DATA Push Buttons (5 &...
  • Page 44 0$18$/32:(5)$&725352*5$00,1* (1) Select EXTENDED FUNCTION [PP]. See section 7.3 EXTENDED FUNCTIONS. Use the SCHEDULE SELECT Push Buttons (20+21) and SCHEDULE Display (22) to select [PP] (2) Using DATA Entry Switches (5+6) and DATA DISPLAY (4) enter the machine POWER FACTOR determined in section 7.13 step (2). When desired to return to AUTOMATIC POWER FACTOR Mode, enter 00 as in steps (1) and (2) above.
  • Page 45 23(5$7,1*02'(6 For the instruction manual discussion on Operating Modes, the following abbreviations will be used: SQ . . . SQUEEZE TIME WE . . WELD TIME CO . . . COOL TIME HO . . . HOLD TIME OF . . . OFF TIME IMP .
  • Page 46 5(3($7 : CODE [01] IN CYCLE MODE FUNCTION. If the control is initiated and the initiation remains closed the sequence will be as shown in FIGURE 3 below. FIGURE 3. The operations achieved in each SCHEDULE are the same as in NON REPEAT. See section 7.3 EXTENDED FUNCTIONS.
  • Page 47 FIGURE 4. While SCHEDULE "N" is sequencing, the times and parameters will be in accordance with those stored in SCHEDULE "N". When it ends, the sequence jumps to SCHEDULE "N+1". SCHEDULE "N+1" is then performed and so on until the sequence encounters a [00],[01],[02], or [03] in the CYCLE MODE FUNCTION.
  • Page 48 When HO, OF (SCHEDULE "N") and SQ (SCHEDULE "N+1") are all programmed to 00 cycles, the sequence will jump directly from the end of WELD Time (SCHEDULE "N") to the beginning of WELD Time (SCHEDULE "N+1"), without any interval between the two WELD Times (continuous weld current).
  • Page 49 6/23(02'(&21752/ The EN1000 Series of weld controls standardly offer UP SLOPE, DOWN SLOPE, and UP/DOWN SLOPE for applications that require its use. Up-Slope Control provides a means of gradually increasing weld current by automatically phase shifting each cycle of welding current from a low preset current level to a higher preset current level within a specific time.

  • Page 50: Table Of Contents

    6/23(02'( :[02] - DOWN SLOPE. When [02] is selected and the control initiated, DOWN SLOPE will occur after WELD. If the control is in PULSATION MODE, the DOWN SLOPE will only occur after the last WELD IMPULSE. For example, if the SCHEDULE calls for 5 cycles of DOWN SLOPE and 15 cycles of weld, the DOWN SLOPE will start after WELD.

  • Page 51: Percent Current

    In this example, using the default SLOPE BOTTOM CURRENT the current will slope down, after weld count, from 95% to 50% of 95 % over a 10 cycle period of time. The total length of time current would be on is 31 cycles (5 cycles upslope, 16 cycles weld, and 10 cycles downslope).

  • Page 52: Hold Count

    Forge delay is defined as the delay from the beginning of the weld and the activation of the forging solenoid valve. To accomplish a FORGE DELAY operation on EN1000 series controls, it is necessary to chain together 2 or more SCHEDULES as outlined below.

  • Page 53: Impulses

    SCHEDULE 01 SQUEEZE count ... . 00 cycles. WELD/HEAT count ..desired WELD count that occurs after forging takes place. PERCENT CURRENT ..desired PERCENT CURRENT for WELD during forge. HOLD count .
  • Page 54 08/7,3/(6&+('8/(23(5$7,21 3C/3C (TRIPLE count/TRIPLE current) can be accomplished on the EN1000. EXTENDED FUNCTION [SS] must be set to INTERNAL mode. A switch closure between TS1-FS3 and TS1-GND then will initiate SCHEDULE 00. A switch closure between TS1-FS7 and TS1-GND will initiate SCHEDULE 10. A switch closure between TS1-FS11 and TS1-GND will initiate SCHEDULE 20.
  • Page 55 (5525&2'(6 Please refer to other manual pages and wiring diagrams for location of fuses, terminal strips, etc. Please refer to Wiring & Logic Diagrams for Bills of Material. 7528%/( 3266,%/(&$86( 5(0('< ___________________________________________________________________________________ Data/Schedule Display 3. Error Code #01. Temp. Limit 1.
  • Page 56 7528%/(6+227,1* Please refer to other manual pages and wiring diagrams for location of fuses, terminal strips, etc. Please refer to Wiring & Logic Diagrams for Bills of Material. TROUBLE POSSIBLE CAUSE REMEDY ___________________________________________________________________________________ Power On Light will Fuse F1, type BBS 6/10, 1.
  • Page 57 TROUBLE POSSIBLE CAUSE REMEDY ____________________________________________________________________________________ Control does III. Mis-wired for single stage Check pilot switch between initiate, but welder operation. FS3 and GND head or arms close. Second stage pilot switch open. Check for proper operation of pilot switch. Be sure first stage closes before second stage.
  • Page 58 TROUBLE POSSIBLE CAUSE REMEDY ____________________________________________________________________________________ External Weld/No-Weld Switch, 1. Check both for proper operation Control sequences but will not weld. or Weld/No-Weld Switch on and/or loose wires on NW1 & front panel of control. 2. If no external Weld/No-Weld Switch is used, connect jumper. II.

  • Page 59: Percent Current

    TROUBLE POSSIBLE CAUSE REMEDY ____________________________________________________________________________________ Half cycle during weld One ignitor circuit open. 1. Check connections to ignitor time. resistor. 2. Check ignitor lead connection to NOTE: Ignitor Fuses tubes. resistors l o c a t e d t h e 3.
  • Page 60 TROUBLE POSSIBLE CAUSE REMEDY ____________________________________________________________________________________ Inconsistent Welds Varying air pressure. 1. Check air supply and accessories. Work not square with elec- 1. Check welding fixtures set-up or trodes. electrode alignment. III. Poor part fit-up. 1. Check parts for proper fit-up. IV.
  • Page 61 ENTRON control panels are covered by a limited warranty from the original manufacturer other than ENTRON and if these parts fail because of a manufacturing defect they will not be repaired or replaced by ENTRON, but will be returned by ENTRON to the original manufacturer in accordance with said manufacturer's warranty.

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