Entron EN7000-TS User manual

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

EN7000 Technical Manual
2
EN7000 Technical Manual
Copyright © 2019 BF ENTRON Ltd. and/or its affiliates. All rights reserved.
The information in this manual is subject to change.
BF ENTRON assumes no responsibility for any errors that may appear in this manual.
BF ENTRON assumes no responsibility for any injury, loss or damage caused by improper installation,
use or application of the EN7000 welding control
The reproduction, transmission or use of this document or contents is not permitted without express
authority from BF ENTRON
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.
BF ENTRON Ltd.
Building 80 Bay 1
First Avenue
The Pensnett Estate
Kingswinford
West Midlands DY6 7FQ
Phone [phone] • Fax [phone]
www.entroncontrols.com
Issue
Date
Comment
1.00
27/02/17
Added parameter descriptions and % conduction parameter.
1.02
23/05/17
Increased weld programs from 128 to 256. New options for SCR select and CT calibration.
New options for valves. New tutorial (resetting faults). Issue number corresponds to
EN7000 firmware.
1.04
26/09/17
Updated issue number.
1.05
30/11/17
Added seam welding features.
1.07
09/04/18
Models 5 and 6 discontinued. Seam welding features added to Models 3 and 4.
1.08
12/09/18
Added note to reset stepper/counter inputs. Updated status codes.
1.09
15/01/19
Revised description of force control.
1.10
12/02/19
Data log contains 6000 records
1.11
27/02/19
Models 1 and 2 discontinued. Model 3 is referred to as EN7000 and model 4 as EN7000-
TS. EN7000 and EN7000-TS can emulate the functionality of Models 1 and 2.

EN7000 Technical Manual
3
IMPORTANT SAFETY INSTRUCTIONS
READ ALL INSTRUCTIONS BEFORE USING THE EN7000
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.
Only apply the specified power. Application of a voltage or current beyond the specified range can
cause electric shock or fire.
Do not use damaged plugs or connecting cables.
Keep water and water containers away from the EN7000. Water ingress can cause a short circuit,
electric shock, or fire.
Do not insert objects into openings. Do not use with any opening blocked; keep free of dust and debris.
Do not install the EN7000 in any of the following environments
odamp environments where humidity is 90% or higher.
odusty environments.
oenvironments where chemicals are handled.
oenvironments near a high-frequency noise source.
ohot or cold environments where temperatures are above 40°C or below 0°C, or environments
where water will condense.

EN7000 Technical Manual
4
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
History log…………………..…….…………………………………………………………………..…47
Section 10
Multiwelding…………………..…….……………………………………………………..…………..48
Section 11
Seam welding………………..…….……………………………………………………..…………..52
Section 12
Configuration…………………..…….……………………………………………….………………59
Section 13
Programming…………………..…….………………………………………………………….……61
Section 14
Tutorials…………………..…….………………………………………………………………………...80
Section 15
Appendix…………………..…….……………………………………………………………….…….…91
Section 16
Terminology……………..…….…………………………………………………………………….…95

Section 1 Introduction
5
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: core welding control with single air-valve, electrode manager and expansion port.
Pre-heat and main heat intervals. Extended features include post-heat interval, force
profile, multi-gun, multi-air valve, multi electrode manager and seam welding. 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.
Short-circuit proof outputs and a guided-contact pilot relay provides enhanced safety. Connection to the
power system is via a single ribbon cable. Analog inputs and outputs can be used to drive a proportional
air regulator valve for force control.
Operation in Standard mode provides a basic set of features for simple applications. Extended mode
adds advanced features for more demanding applications. Choose between Standard or Extended
features (Section 12 Configuration). EN7000 must be restarted after changing this setting.

Section 1 Introduction
6
Features
Model
EN7000
EN7000-TS
Netflash programming


WSP3 programming


Built-in programmer 1

Panel mounting

Gear-plate mounting

Ethernet 2


RS232


RS485


MODBUS TCP/IP


MODBUS RTU


Analogue inputs 3
1
1
Analogue outputs 3
1
1
Discrete inputs
16
16
Discrete outputs 4
16
16
Weld programmes
256
256
Pre-heat


Main heat


Post-heat 5


Slope


Constant current


Power factor adjust


Cascade/Mux 5
8
8
Multi air valve 5, 6
8
8
Aux valves
7
7
Force profile 5


Electrodes/SCRs 5
8
8
Real-time clock


Data log (spot welds)
6000
6000
Expansion


Seam weld sequence 5


1Colour touch-screen display
2Two simultaneous connections
30 to 10 V
424 V dc, short-circuit proof, monitored
5Extended feature
6Guided contact safety relay, monitored
The extended features can be enabled for greater flexibility or more demanding applications.

Section 1 Introduction
7
Weld parameters
EN7000/EN7000-TS
Presqueeze

Squeeze

Pre-heat

Cool1

Upslope

Main heat

Cool2

Downslope

Pulses

Post-heat 1

Hold

Off

WAV selection 1

Aux valve control

Retract/Hi-lift

Electrode selection 1

Force profile 1

SCR selection 1

Current monitor

Force monitor

Spot weld

Roll-spot weld 1

Seam weld 1

1Extended feature
Part numbers
Model
Part number
EN7000
01-07-03
EN7000-TS
01-07-04

Section 1 Introduction
8
Programming options
NetFlash
This PC-compatible program displays and allows editing of all
welding parameters and 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.
WSP3 Pendant
EN7000s work with the same WSP3 pendant that is used with
iPAK and WS2003. Access to all parameters is provided, plus
diagnostic indication.
MODBUS
A PLC or HMI MODBUS master can be used to program, control
and monitor 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.

Section 1 Introduction
9
Communications

Section 1 Introduction
10
Applications
Standard machines, portable/manual guns, robot guns, multi-welders and seam welders.
Standard machine.
Multi-head machine. Up to eight cylinders. Cascade or independent firing.
Program 1
I1 = 17.0 kA H1 = 23.5% PHA
PSQ = 0 ~ SQZ = 10 ~
W1 = 12 ~ C1 = 0 ~
W2 = 12 ~ C2 = 0 ~
HLD = 10 ~
EditP rogram
12.5 kA Prog 01 Low curren t W 2
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 ~
Edit Program
12.5 kA Prog 01 Low cu rrent W 2
BF701 V1.01
1 2 8

Section 1 Introduction
11
Multi-welder. Up to 8 transformers and cylinders. Cascade or independent firing.
Program 1
I1 = 17.0 kA H1 = 23.5% PHA
PSQ = 0 ~ SQZ = 10 ~
W1 = 12 ~ C1 = 0 ~
W2 = 12 ~ C2 = 0 ~
HLD = 10 ~
Edit Program
12.5 kA Prog 01 Low current W 2
BF701 V1.01
1
2
8
8
2
1

Section 1 Introduction
12
Program 1
I1 = 17.0 kA H1 = 23.5% PHA
PSQ = 0 ~ SQZ = 10 ~
W1 = 12 ~ C1 = 0 ~
W2 = 12 ~ C2 = 0 ~
HLD = 10 ~
Edit Program
12.5 kA Prog 01 Low current W 2
BF701 V1.01
Seam welder with one transformer.
Program 1
I1 = 17.0 kA H1 = 23.5% PHA
PSQ = 0 ~ SQZ = 10 ~
W1 = 12 ~ C1 = 0 ~
W2 = 12 ~ C2 = 0 ~
HLD = 10 ~
Edit Program
12.5 kA Prog 01 Low current W 2
BF701 V1.01
Seam welder with a multi-tap transformer.

Section 1 Introduction
13
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.
Section 13 Programming: switch on then use the ‘Initialise all data’ function to clear the
EN7000’s memory.
Section 12 Configuration: set the Configuration parameters appropriately for the application.
Section 7 Electrode management: edit the calibration file.
Section 13 Programming: edit program 0 to set up a basic weld sequence e.g. Squeeze = 10,
Main heat = 10, Hold = 10, Pulses=1, and Main mode = PHA.
Section 13 Programming: a welding operation should be possible at this stage. Begin by using
the gun short-circuit. The EN7000 should report the measured current on the diagnostic
display.
Section 7 Electrode management: perform the calibration operation for the toroid sensitivity.
Observe the current with an external meter. Set the program heat to give a typical value of
welding current on the meter. Adjust the sensor sensitivity until the EN7000 measurement
corresponds with the meter.
Make any other adjustments which may be required and set up other programmes for welding.

Section 1 Introduction
14
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Section 2 Mounting
15
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.
Gear plate mounting
The mounting arrangements for EN7000 are shown below. All dimensions are in mm.

Section 2 Mounting
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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

Section 3 Inputs and outputs
17
Inputs and outputs
EN7000 uses a number of inputs and outputs to control and monitor the weld sequence.
Inputs
Input
AWS designation
Description
Start
FS1
When this input is activated a weld sequence begins. If the input is
removed during the Squeeze interval the sequence is aborted. If the input
is maintained through the Squeeze interval but switched off subsequently,
the sequence terminates normally.
Weld on
NW1
This input enables the weld current. If this input is inactive a weld
sequence will not produce any current.
Stop
ES1
Sequencing is inhibited or aborted if this input is not active.
Thermal
TT1
This input is usually connected to a normally closed thermal contact
attached to the weld transformer. Sequencing is inhibited if this input is not
active.
2nd stage
PS1
If enabled, EN7000 checks that the 2nd Stage signal is present before
proceeding to weld. The checking is programmable to take place either
before or after the Squeeze interval. If the signal is not present EN7000
waits for the signal before it proceeds. If the Start signal is removed while
waiting, the sequence is aborted.
Retract
RT1
This input is used to control the Retract function.
Reset fault
FR1
This input resets the Fault output and clears the status messages. Only
momentary application is required (minimum time 40ms).
Reset
counter/tip
dress
acknowledge1
Used to reset the counter(s) or acknowledge a tip dress request.
Reset
stepper2
SR1
Used to reset the stepper(s).
P1
BP1
Program select inputs. Weld program selection is made by applying the
binary code for the required program. Programs 0 to 127 can be selected
(programs 128 to 255 can be selected internally or via the fieldbus).
P2
BP2
P4
BP4
P8
BP8
P16
BP16
P32
BP32
P64
BP64
CT
Input for the current transformer.
Toroid
Input for the toroid.
Analog
0 to 10 V analog input. Can be used to monitor a proportional air regulator
valve output or other sensor for force control and monitoring.

Section 3 Inputs and outputs
18
Outputs
Output
AWS designation
Description
EOS
EH1
This output switches on to indicate the end of the weld sequence.
HAV
RV1
Used in conjunction with the Retract input to control the welding head.
Fault
FT1
This output indicates a fault condition.
Ready
This output is active if EN7000 is ready to weld. The output switches off
under some fault conditions.
Contactor
MC1
This output can be used to control an isolation contactor.
Counter/tip
dress request
This output indicates that the counter has reached its limit or that a tip
dressing operation is required.
Stepper
This output indicates that the stepper has reached its limit.
Pre-warn
This output indicates that the stepper is close to its limit.
AV1
Additional outputs that can be used during the weld sequence.
AV2
AV3
AV4
AV5
AV6
AV7
AV8
Analog
0 to 10 V analog output. Can be used to drive a proportional air regulator
valve for force control
1Momentary operation will reset all expired counters. If maintained for more than 5 seconds all counters will be
reset, regardless of status.
2Momentary operation will reset all expired steppers. If maintained for more than 5 seconds all steppers will be
reset, regardless of status.

Section 4 Discrete i/o
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 mm2
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.

Section 4 Discrete i/o
20
EN7000
Outputs are rated 500 mA @24 V dc
AWS designations in parenthesis
1 inputs must be linked if not required
1. Heartbeat
2. Synchronised to ac mains
3. Sequence initiated
4. Weld current
5. Data receive COM0
6. Data send COM0
7. Data receive COM1
8. Data send COM1
9. Data receive COM2
10. Data send COM2
11. Data receive COM3
12. Data send COM3
1. CT input
2. CT input
3. Toroid input
4. Toroid input
5. Gnd
1. 0 V
2. Output (0 to 10 V)
3. Input (0 to 10 V)
4. Gnd
MODBUS-RTU
NetFlash
MODBUS-TCP/IP
Power