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Entron EN7000 Series User Manual

Welding control for 50/60 hz spot, projection, roll-spot, seam and multi-welding applications
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EN7000
User Guide
Welding control for 50/60 Hz spot, projection, roll-spot, seam and multi-welding
applications.
For firmware versions 1.18 and 2.18

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Summary of Contents for Entron EN7000 Series

  • Page 1 EN7000 User Guide Welding control for 50/60 Hz spot, projection, roll-spot, seam and multi-welding applications. For firmware versions 1.18 and 2.18...
  • Page 2 ENTRON's trademarks and trade dress may not be used in connection with any product or service that is not ENTRON's, in any manner that is likely to cause confusion among customers or in any manner that disparages or discredits ENTRON. All other trademarks not owned by ENTRON are the property of their respective owners, who may or may not be affiliated with, connected to, or sponsored by 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 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 ENTRON.

  • Page 4: Table Of Contents

    EN7000 User Guide Table of Contents Section Page Introduction ........................7 1.1. Part numbers ......................7 1.2. Features ........................8 1.3. Weld schedule parameters................... 9 1.4. Programming options ..................10 1.4.1. NetFlash ......................10 1.4.2. WSP3 Pendant ....................10 1.4.3. Built-in touch screen ..................
  • Page 5 EN7000 User Guide 2.9. Analog control ...................... 27 Multi-weld operation ....................28 3.1. Multi-Electrode operation ................... 30 3.2. Cascade operation ..................... 31 Electrode management ..................... 32 4.1. Steppers ......................... 32 4.2. Counters ........................ 33 4.3. Current calibration ....................34 4.4. Force calibration ....................
  • Page 6 EN7000 User Guide 6.4.2. Electrode parameters .................. 51 6.4.3. Calibration parameters ................52 6.4.4. Configuration parameters ................53 EtherNet/IP ........................55 7.1. Functionality ......................55 7.2. Ports ........................55 7.3. Status LEDs (MS & NS) ................... 55 7.4. Cyclic I/O (class 1 connection) ................56 7.5.
  • Page 7 EN7000 User Guide Tutorials ........................70 13.1. Setting up a constant current weld ..............70 13.2. Testing the weld current ................... 71 13.2.1. Current monitor ..................... 71 13.2.2. Conduction monitor (C-Monitor) ..............71 13.3. Using the Valves to control a multi-head machine ........72 13.4.

  • Page 8: Introduction

    EN7000 User Guide 1. Introduction The EN7000 is a Single-phase AC and 3-phase DC constant current and proportional force controller for 50/60 Hz spot, projection and seam welding applications. The controller is available in two formats:  EN7000: welding control with pre-heat, main heat and post-heat intervals, force profile, multi-gun, multi-air valve, multi electrode manager and expansion port.

  • Page 9: Features

    EN7000 User Guide 1.2. Features Model EN7000 EN7000-TS NetFlash   programming WSP3 programming    Built-in programmer Panel mounting  Gear-plate mounting  Ethernet   EtherNet/IP   RS232   RS485   MODBUS TCP/IP  ...

  • Page 10: Weld Schedule Parameters

    EN7000 User Guide 1.3. Weld schedule 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 11: Programming Options

    EN7000 User Guide 1.4. Programming options 1.4.1. NetFlash This PC-compatible program displays and allows editing welding parameters status information. In addition to programming, 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 12: Communications

    EN7000 User Guide 1.5. Communications...

  • Page 13: Applications

    EN7000 User Guide 1.6. 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 14 EN7000 User Guide 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 15 EN7000 User Guide 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 16: Weld Control

    EN7000 User Guide 2. 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. 2.1.

  • Page 17: Program Options

    EN7000 User Guide 2.2. Program 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 Pulsations 1 - 99 The number of times the Main heat – Cool2 interval is repeated Link on/off The next welding program will be started automatically if the...

  • Page 18: Current Control

    EN7000 User Guide 2.3. 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 Pre-heat 0.0 – 99.9 The % heat used during the Pre-heat interval in PHA mode Pre-current 0 –...

  • Page 19: Timing Diagrams

    EN7000 User Guide 2.4. Timing diagrams 2.4.1. Spot weld Pre-heat = 0, Cool1 = 0, Upslope = 0, Downslope = 0, Post-heat = 0, Pulsations = 1, Force profile = Off. START I/P EOS O/P WAV O/P Force O/P Current 2.4.2. Spot pulsation Pre-heat = 0, Cool1 = 0, Post-heat = 0, Pulsations = 3, Force profile = off. START I/P EOS O/P WAV O/P...

  • Page 20: Spot Repeat

    EN7000 User Guide 2.4.3. Spot repeat Pre-heat = 0, Cool1 = 0, Upslope = 0, Downslope = 0, Post-heat = 0, Pulsations = 1, Force profile = Off. START I/P WAV O/P Force O/P Current 2.4.4. Seam Extended START I/P MOTOR O/P WAV O/P Force O/P Current The position of rising edge of the MOTOR output depends on the selection of the Second Stage configuration parameter.

  • Page 21: Roll-Spot

    EN7000 User Guide 2.4.5. Roll-spot Extended Pre-heat = 0, Cool1 = 0, Upslope = 0, Downslope = 0, Post-heat = 0, Pulsations = 1, Force profile = off. START I/P MOTOR O/P WAV O/P Force O/P Current To use Roll-Spot, set Seam welding in configuration, then select the Roll-Spot option in the weld program.

  • Page 22: Second Stage

    EN7000 User Guide 2.4.6. Second stage The second stage configuration parameter allows the user to select where in the sequence the second-stage test is to be performed. Second Stage = Off The input is not used. The MOTOR output will not be driven. Second Stage = Before Squeeze The input is checked before the squeeze time runs.

  • Page 23: Retract

    EN7000 User Guide 2.4.7. Retract 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 24 EN7000 User Guide 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 25: Force Control

    EN7000 User Guide 2.5. 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 26: Valve Control

    EN7000 User Guide 2.6. Valve control EN7000 has eight discrete outputs (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 27: Multi-Electrode Operation

    EN7000 User Guide 2.7. Multi-Electrode operation Extended Each welding program can be assigned an electrode: Parameter Units Range Description Electrode 0 - 7 The electrode number When a program is run, the EN7000 will automatically trigger the correct transformer by referencing the electrode/transformer assignment.

  • Page 28: Analog Control

    EN7000 User Guide 2.9. Analog control Extended If the ‘Analog control’ configuration parameter is set to ‘ON’, then the output current can be controlled by applying a 0 to 10 Volt signal to P4 pins 3(+) and 1(-). The program will track the analog input, allowing the user to create custom current profiles.

  • Page 29: Multi-Weld Operation

    EN7000 User Guide 3. Multi-weld operation Extended There are two methods available for multi-welding:  Multi-Electrode operation allows each welding program to be triggered independently but allows for selection of a transformer and electrode.  Cascade operation allows welding programs to be linked together and triggered from a single start command.
  • Page 30 EN7000 User Guide Example: the diagram below 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...

  • Page 31: Multi-Electrode Operation

    EN7000 User Guide 3.1. Multi-Electrode 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 signal can use a different output for each program...

  • Page 32: Cascade Operation

    EN7000 User Guide 3.2. Cascade operation Different electrodes and transformers can still be selected but the welding programs are linked together and started by a single Start command. Cancelling the Start command at any time will abort the cascade sequence. Start input EOS output WAV output...

  • Page 33: Electrode Management

    EN7000 User Guide 4. Electrode management Electrode management is provided via a combination of stepper, counter and calibration 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 34: Counters

    EN7000 User Guide 4.2. Counters A counter is programmed by entering values related to the electrode maintenance and lifetime. Parameter Units Range Description Enable on/off Enables or disables the counter counter Count welds 0 - 9999 The number of welds that have been done since the last reset End count welds...

  • Page 35: Current Calibration

    EN7000 User Guide 4.3. 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 36: Force Calibration

    EN7000 User Guide Calibration is not required if a toroid is being used for secondary feedback. In this situation only the toroid sensitivity is required. If using analog control mode, set the calibration parameters and use PHA mode to verify that the control is measuring current correctly.

  • Page 37: Input/Output (I/O)

    EN7000 User Guide 5. Input/Output (I/O) Inputs and output signals which are used to operate the control can be taken from a number of sources:  Discrete connections  Modbus messages  EtherNet/IP The I/O Source configuration parameter selects which interface is active. 5.1.

  • Page 38: Outputs

    EN7000 User Guide The discrete connection for this input is always required, even when the I/O source is Modbus or EtherNet/IP. The signal from the discrete interface is always used, even when the I/O source is Modbus or EtherNet/IP where there is no equivalent signal. Momentary operation will reset all expired counters.

  • Page 39: Analog Signals

    EN7000 User Guide 5.4. Analog signals Signal X4 pin Toroid Toroid Ground (screen) Signal X5 pin Analog Output (0...10V) Analog Input (0…10V) Ground (screen) 5.4.1. CT Spot or Seam welds. A CT (current transformer) is used to measure the current (normally on the primary side of the power transformer).

  • Page 40: Discrete Interface

    EN7000 User Guide 5.5. Discrete interface 24V DC only. Do not connect to 110V AC! 5.5.1. Inputs Current sinking. Connect input to 24V DC to activate. Input X3 pin Start Weld on Stop Thermal stage Retract Reset fault Reset counter / tip dress acknowledge Reset stepper P64 / Edit enable...

  • Page 41: Led Indicators

    EN7000 User Guide 5.6. LED indicators An array of LEDs, visible on the side of the control indicate activity: EtherNet/IP FUNCTION EtherNet/IP module status EtherNet/IP network status Heartbeat (Flashes at 1 Hz) Synchronised to ac mains (Flashes at 1Hz) Sequence initiated Weld current COM4 Data receive COM0/4...

  • Page 42: Modbus

    EN7000 User Guide 6. Modbus Both MODBUS TCP/IP (Ethernet) and MODBUS RTU (RS485) protocols are supported. Modbus TCP/IP uses port 502. To have the Modbus connection activate the inputs to the welding control, access the control configuration parameters (using WSP3, touch- screen or NetFlash) and select I/O SOURCE: COMn where n = desired port (see table below).

  • Page 43: Inputs To En7000

    EN7000 User Guide 6.2. Inputs to EN7000 Variable Channel Address Type Description Write inputs %QW0 WORD Write multiple registers ARRAY [0..1] Write inputs [0] %QW0 WORD WRITE 16#8000 (= 32768) Start Bit 0 %QX0.0 BOOL Weld on Bit 1 %QX0.1 BOOL Stop Bit 2...

  • Page 44: Outputs From En7000

    EN7000 User Guide 6.3. Outputs from EN7000 Variable Channel Address Type Description Read outputs %IW0 WORD Read holding registers ARRAY [0..23] Read outputs [0] %IW0 WORD READ 16#9000 (= 36864) Bit 0 %IX0.0 BOOL Bit 1 %IX0.1 BOOL Fault Bit 2 %IX0.2 BOOL Ready...
  • Page 45 EN7000 User Guide 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] %IW12...
  • Page 46 EN7000 User Guide 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 47 EN7000 User Guide 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 48: Parameter Mapping

    EN7000 User Guide 6.4. Parameter 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)

  • Page 49: Weld Program Parameters

    EN7000 User Guide 6.4.1. Weld program parameters Variable Channel Address Type Description offset Weld program %IW0 WORD ARRAY [0..63] Attributes Weld %IW0 WORD program [0] Pre heat Bit 0 %IX0.0 BOOL 0 = off, 1 = on Post heat Bit 1 %IX0.1 BOOL 0 = off, 1 = on...
  • Page 50 EN7000 User Guide Post-current Weld %IW19 DWORD 0 – 500000 program [19] Hold time Weld %IW21 WORD 0 – 99 program [21] Off time Weld %IW22 WORD 0 – 99 program [22] Upslope time Weld %IW23 WORD 0 – 99 program [23] Downslope time Weld...
  • Page 51 EN7000 User Guide Downslope force Weld %IW41 WORD 0 – 32767 program [41] Post-heat force Weld %IW42 WORD 0 – 32767 program [42] Hold force Weld %IW43 WORD 0 – 32767 program [43] Off force Weld %IW44 WORD 0 – 32767 program [44] Force low limit Weld...

  • Page 52: Electrode Parameters

    EN7000 User Guide 6.4.2. Electrode parameters Variable Channel Address Type Description offset Electrode %IW0 WORD ARRAY [0..63] Attributes Electrode [0] %IW0 WORD Enable counter Bit 0 %IX0.0 BOOL 0 = off, 1 = on Enable tipdress Bit 1 %IX0.1 BOOL 0 = off, 1 = on Enable stepper Bit 2...

  • Page 53: Calibration Parameters

    EN7000 User Guide 6.4.3. Calibration parameters Variable Channel Address Type Description offset Calibration %IW0 WORD ARRAY [0..63] Power factor Calibration [0] %IW0 WORD 0 – 86 (x100) A out X1 Calibration [1] %IW1 WORD 0 – 10000 mV A out Y1 Calibration [2] %IW2 WORD...

  • Page 54: Configuration Parameters

    EN7000 User Guide 6.4.4. Configuration parameters Variable Channel Addres Type Description s offset Configuration %IW0 WORD ARRAY [0..63] Weld type Configuration[0] %IW0 WORD 0 = spot 1 = seam Second stage Configuration[1] %IW1 WORD Bit 0 %IX1.0 BOOL 00 = none Bit 1 %IX1.1 BOOL...
  • Page 55 EN7000 User Guide Analog output Configuration[17] %IW17 WORD 0 = force function 1 = waveform Analog output Configuration[18] %IW18 DWORD 0 – 500 kA scale (10 V =) Security Configuration[20] %IW20 WORD 0 = off 1 = key-switch 2 = PIN on WSP3 3 = PIN on touchscreen 4 = PIN on both...

  • Page 56: Ethernet/Ip

    EN7000 User Guide 7. EtherNet/IP EN7000v2 and EN7000v2-TS include integrated EtherNet/IP. For EN7000 and EN7000-TS, EtherNet/IP can be provided via an optional plug-in adapter board. 7.1. Functionality  Cyclic I/O control using EtherNet/IP implicit messaging (class 1 connection).  Parameter programming using EtherNet/IP explicit messaging. 7.2.

  • Page 57: Cyclic I/O (Class 1 Connection)

    EN7000 User Guide 7.4. Cyclic I/O (class 1 connection) To have the EtherNet/IP connection activate the inputs to the welding control, access the control configuration parameters (using WSP3, touch- screen or NetFlash) and select I/O SOURCE: COM6-E/IP then restart the control. This setting only affects the inputs and outputs.

  • Page 58: Parameter Programming

    EN7000 User Guide 7.5. Parameter programming This is achieved through the use of the EtherNet/IP explicit messaging service. The following services are implemented: Service Code Get attribute single 0E (hex) Set attribute single 10 (hex) With each of these services, the following objects are available: Parameters Class ID Instance...

  • Page 59: Configuration

    EN7000 User Guide 8. Configuration Parameter Value Description Standard Selects standard features. Features Extended Selects extended features. Spot Selects spot welding features. Weld type Seam Selects 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: Status Messages

    EN7000 User Guide 9. Status messages NetFlash, WSP3 and the Touch-screen all show these status messages. They are also available on the bus outputs – See Modbus and EtherNet/IP sections. 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...
  • Page 61 EN7000 User Guide 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 End of count 6...

  • Page 62: History Log

    EN7000 User Guide Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved History log EN7000 stores the results of the last 6000 spot welds in a history log. Each record contains the following information: Parameter Description...

  • Page 63: Programming

    EN7000 User Guide Programming EN7000 supports several programming methods:  NetFlash PC program (Ethernet)  WSP3 pendant (RS232)  MODBUS (Ethernet or RS485)  Built-in touch screen (EN7000-TS only) – see separate touch-screen programming guide document.  EtherNet/IP (Integrated on EN7000v2/EN7000v2-TS, via optional adapter card on EN7000/EN7000- 11.1.

  • Page 64: Programming With Wsp3 Pendant

    EN7000 User Guide 11.2. Programming with WSP3 pendant When parameters are changed in NetFlash 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. The WSP3 uses RS232 to communicate with the EN7000 and should be connected to COM3:...

  • Page 65: Keypad

    EN7000 User Guide 11.2.1. 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. Return. Access the selected function.

  • Page 66: Menus

    EN7000 User Guide 11.2.3. Menus The functions of the EN7000 are arranged into a set of menus and screens as follows: Diagnostic screen Ready    |‐‐     0  A         prog  7  ‐ |‐  11.7 kA     5.66 kN  ‐‐ |     0  A         ~30.5 %  <<<  MAIN MENU   >>>  <<<  configure  >>>  USE program 7  01 sep 2016 12.00.00  Edit program   stage:off  Edit electrode  Sensor:ct  Select the first or the last line of the Main Menu…...

  • Page 67: Backup/Restore

    EN7000 User Guide 11.2.4. 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 68: Programming With The Touch-Screen

    EN7000 User Guide 11.4. Programming with the Touch-screen EN7000-TS models have a touch screen display that can be used to access all parameters and diagnostic information. Please consult the separate document EN7000-TS Touch-screen programming User Guide for full details. 11.5. Programming with MODBUS Please see the Modbus section of this manual.

  • Page 69: Dimensions And Mounting

    EN7000 User Guide Dimensions and Mounting 12.1. Gear plate mounting 12.1.1. EN7000 Note: If an adapter board is fitted then the depth increases to 59.5 mm 12.1.2. EN7000v2...

  • Page 70: Front Panel Mounting

    EN7000 User Guide 12.2. Front panel mounting 12.2.1. EN7000-TS Note: If an adapter board is fitted then the depth increases to 58 mm 12.2.2. EN7000v2-TS...

  • Page 71: Tutorials

    EN7000 User Guide Tutorials This section is a series of application notes which discuss some specific topics in detail. 13.1. Setting up a constant current weld Phase Angle (PHA) heat control sets the heat of a weld by specifying a fixed conduction angle. The minimum and maximum conduction angles are termed 0% and 100% Heat respectively.

  • Page 72: Testing The Weld Current

    EN7000 User Guide 13.2. Testing the weld current 13.2.1. Current monitor 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 73: Using The Valves To Control A Multi-Head Machine

    EN7000 User Guide 13.3. 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...
  • Page 74 EN7000 User Guide 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 75 EN7000 User Guide 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 76: Controlling A Multi-Welder

    EN7000 User Guide 13.4. Controlling a multi-welder A multi-welder can use different transformers for each welding head. The welding heads can be controlled as described in the previous tutorial. Choose the transformers that will be assigned to the electrodes. The procedure is described in the Multi-welding section.
  • Page 77 EN7000 User Guide 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 78: Controlling An Air Over Oil System

    EN7000 User Guide 13.5. Controlling an Air over oil system An ‘Air over Oil’ system (also referred to as OHMA) uses compressed air to open and close the electrodes plus a hydraulic intensifier to apply the weld force. This type of system can easily be controlled by the EN7000 by making use of the programmable AUX valves feature.

  • Page 79: Setting The Power Factor

    EN7000 User Guide 13.6. 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. The following procedure involves running the machine at maximum output.

  • Page 80: Resetting Faults

    EN7000 User Guide 13.7. Resetting Faults Fault conditions and error messages can be reset in several ways. 13.7.1. Touch-screen Status LOW MAIN CURRENT Pre-heat Program Tap the centre of any title bar to access the Status menu then tap the error message Main Force 10.1 kA...

  • Page 81: Setting The Ip Address

    EN7000 User Guide 13.8. Setting the IP address 13.8.1. EN7000v2 and EN7000v2-TS These models have an integrated Ethernet sub-system for Ethernet and EtherNet/IP communications on COM4, COM5 and COM6. The IP address may be set in the configuration with NetFlash, WSP3 or the touch-screen on the TS model. 13.8.2.
  • Page 82 EN7000 User Guide  Select the EN7000/xPort AR device then select Assign IP:  Select ‘Assign a specific IP address’ and then select Next:...
  • Page 83 EN7000 User Guide  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 84: Updating The Firmware

    . The following screen is shown:  Select the flash file . This will be a file with a .hex extension supplied by ENTRON.  Select connect to the EN7000 . NetFlash will connect to the target control and report the current firmware status.

  • Page 85: Terminology

    EN7000 User Guide 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. See Current transformer.
  • Page 86 Weld transformer Electrical component for converting mains voltage input to low voltage, high current output. Entron Controls LLC. USA. Entron Controls De Mexico. BF Entron Ltd. England. Tel: 864-416-0190 Tel:...

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