700120S EN1000/EN1001 SERIES CONTROLS

1 INSTRUCTION MANUAL. 700120S . EN1000/EN1001 . SERIES CONTROLS . MICROPROCESSOR BASED. Weld Sequence CONTROLS With Solid State Thyristor Contactors INCLUDES: Appendix E EN1000/EN1001 Bench CONTROLS Appendix F EN1003 CONTROLS Wiring Diagrams Cabinet Style en1000 en1001 . S 421180 421270. T/D/LS/LF/FP 421210 421269. E 421212 421268. D/T 421387 421377. C 421498 421499. IMU 421424 421423. Intended for use with firmware versions 619016-002Z and higher ENTRON CONTROLS , LLC. 1402 S. Batesville Road Greer, South Carolina 29650. (864) 416-0190. FAX: (864) 416-0195. ENTRON CONTROLS , LLC. 700120S Page 1. THIS PAGE IS. INTENTIONALLY. BLANK. Page 2 700120S ENTRON CONTROLS , LLC. ENTRON CONTROLS , LLC.

2 MICROPROCESSOR BASED WELDING CONTROLS . INSTALLATION AND OPERATION MANUAL FOR: Model SERIES EN1000/EN1001 . NEMA Type: ALL. CAUTION . READ THIS MANUAL COMPLETELY BEFORE ATTEMPTING. TO INSTALL OR OPERATE THIS control . ENTRON CONTROLS , LLC., reserves the right to alter the contents of this manual without previous notice. ENTRON CONTROLS , LLC. Greer, South Carolina 29650. ENTRON CONTROLS , LLC. 700120S Page 3. TABLE OF CONTENTS. general DESCRIPTION .. 9. STANDARD FEATURES .. 10. control PANEL LAYOUT .. 11. PROGRAMMABLE FUNCTIONS .. 12. control FUNCTIONS .. 12. SEQUENCE TIMED PARAMETERS .. 14. OTHER PROGRAMMABLE SEQUENCE PARAMETERS .. 15. INSTALLATION .. 17. INSTALLATION AND MOUNTING DIAGRAMS S CABINET.

3 17. INSTALLATION AND MOUNTING DIAGRAMS E CABINET .. 18. INSTALLATION AND MOUNTING DIAGRAMS T/D AND L CABINET .. 19. INSTALLATION AND MOUNTING DIAGRAMS C CABINET .. 20. INSTALLATION AND MOUNTING DIAGRAMS FLAT PLATE AND IMU .. 21. WELDING TRANSFORMER PRIMARY WIRING .. 23. EXTERNAL SCR CONTACTOR WIRING .. 23. CONTACTOR SPECIFICATIONS .. 25. COOLING REQUIREMENTS FOR CONTACTORS .. 27. general OPERATING REQUIREMENTS .. 28. OPERATING VOLTAGE .. 28. FUSING AND SAFE OPERATION .. 30. TERMINAL STRIP DIAGRAMS AND CONNECTIONS .. 31. TERMINAL STRIP TS1/PCB2 .. 31. TERMINAL STRIP CONNECTIONS .. 33. TERMINAL STRIP TS1 INSIDE THE CABINET .. 35. INITIATION .. 36. SINGLE STAGE PILOT INITIATION.

4 36. TWO STAGE PILOT INITIATION .. 36. OTHER TERMINAL STRIP INPUTS .. 36. NON-VOLATILE MEMORY ERROR .. 38. ISOLATION CIRCUITRY DESCRIPTION .. 40. INTRODUCTION TO DATA PROGRAMMING .. 42. general PROGRAMMING .. 42. PROGRAM LOCKOUT OPTIONS .. 43. PROGRAM LOCKOUT KEY SWITCH OPTION .. 43. USING PROGRAM LOCKOUT KEY SWITCH FOR ERROR CLEARING .. 43. SEQUENCE (SCHEDULE) PARAMETERS PROGRAMMING .. 44. USING PROGRAMMING SHORTCUTS .. 45. EXTENDED FUNCTIONS .. 46. IDENTIFICATION NUMBER .. 47. SEAM WELDING MODE .. 47. SCHEDULE SELECT .. 50. AUTOMATIC VOLTAGE COMPENSATION AND MONITORING .. 57. CLEAR ALL FUNCTIONS .. 59. BACK-STEP / TEMPERATURE LIMIT SWITCH .. 60. PROCESS OUTPUTS .. 61. BEAT OPERATION INITIATION MODES.

5 66. 87 DELAY .. 68. MANUAL POWER FACTOR PROGRAMMING .. 69. POWER FACTOR MEASURING .. 69. SQUEEZE DELAY .. 70. BLOCKING DELAY .. 70. TURNS RATIO .. 70. CONSTANT CURRENT MODES .. 71. RANGE .. 72. CURRENT OFFSET .. 73. PIN LOCKOUT MODE .. 76. Page 4 700120S ENTRON CONTROLS , LLC. TABLE OF CONTENTS (cont.). general OPERATING 77. WELD SEQUENCE EXAMPLE .. 77. CYCLE MODES .. 78. NON-REPEAT .. 78. REPEAT .. 79. CHAINED .. 79. SUCCESSIVE .. 81. CONDITIONAL SUCCESSIVE .. 82. WAIT-HERE .. 83. SLOPE MODES .. 84. NO SLOPE .. 85. UPSLOPE .. 85. DOWNSLOPE .. 85. VALVE MODES .. 86. STEPPER ON EN1000/EN1001 SERIES CONTROLS .. 87. SCHEDULE MAP .. 88. STEPPER PROGRAMMING .. 89. EXTENDED FUNCTION PROGRAMMING.

6 89. WELD SEQUENCE PROGRAMMING .. 89. STEP COUNTS PROGRAMMING .. 89. LAST STEP AND LAST COUNT PROGRAMMING .. 90. QUICK SETUP INSTRUCTIONS FOR STEPPER .. 91. SEQUENCE (SCHEDULE) INITIATION IN STEPPER MODE .. 92. SCHEDULE SELECT OPTIONS FOR STEPPER MODE .. 92. SCHEDULE SELECT OPTIONS FOR STEPPER MODE .. 92. STEPPER OPERATION .. 93. OPERATION ALGORITHM FOR STEPPER MODE .. 93. STEPPER OPERATION FOR STEPPER MODE .. 94. STEPPER RESET .. 95. MANUAL STEPPER RESET .. 95. AUTOMATIC STEPPER RESET .. 95. STEPPER RESET USING EXTERNAL SWITCH INPUT .. 96. USING STEPPER AS A COUNTER .. 96. DISPLAYING STEPPER COUNT DURING OPERATION .. 96. END OF STEPPER .. 96. CONSTANT CURRENT OPERATION ( en1001 only).

7 97. HARDWARE SETUP .. 97. SOFTWARE PARAMETERS SETUP .. 98. SECONDARY PRESET-RANGE COMPENSATION OR MONITORING MODE. WITH ROGOWSKI COIL .. 99. PRIMARY PRESET-RANGE COMPENSATION OR MONITORING MODE. WITH CURRENT TRANSFORMER .. 99. SECONDARY AUTO-RANGE COMPENSATION OR MONITORING MODE. WITH ROGOWSKI COIL .. 100. PRIMARY AUTO-RANGE COMPENSATION OR MONITORING MODE. WITH CURRENT TRANSFORMER .. 100. DISPLAYING CURRENT AFTER WELD SEQUENCE .. 101. USING CONSTANT CURRENT PROCESS OUTPUTS .. 102. SETTING LIMIT WINDOW FOR CONSTANT CURRENT .. 103. LEARNING-TYPE SETUP PROCESS FOR AUTO-RANGE WORKING MODE .. 103. SETTING UP CURRENT REGULATOR .. 104. SETTING UP CURRENT REGULATOR BOARDS W/PROMS.

8 BEFORE 619016-001R .. 105. APPLICATIONS AND PROGRAMMING EXAMPLES .. 106. SPOT MODE EXAMPLES .. 106. SPOT WITH REPEAT MODE .. 106. PULSATION WITH SUCCESSIVE MODE .. 106. QUENCH-TEMPER WITH CHAINED MODE .. 107. ENTRON CONTROLS , LLC. 700120S Page 5. TABLE OF CONTENTS (cont.). UPSLOPE AND DOWNSLOPE WITH CHAINED MODE .. 107. BUTT WELD WITH CHAINED MODE .. 108. FORGE DELAY WITH CHAINED MODE .. 108. SEAM MODE EXAMPLES .. 110. CONTINUOUS SEAM MODE .. 110. INTERMITTENT SEAM MODE .. 110. WELD CURRENT DELAY .. 110. SEAM MODE 06 .. 111. BRAZING APPLICATION .. 112. AUTOMATIC BRAZING MODE .. 112. MANUAL BRAZING MODE .. 112. SQUEEZE DELAY APPLICATION .. 113. SQUEEZE DELAY OPERATION .. 113.

9 SQUEEZE DELAY PROGRAMMING .. 113. RETRACTION APPLICATION .. 114. MOMENTARY CLOSURE .. 114. MAINTAINED CLOSURE .. 115. AIR OVER OIL RETRACTION .. 117. MULTIPLE SCHEDULE OPERATION .. 122. PROCESS OUTPUT 26 .. 123. VALVE 1 WELDING HEAD SOLENOID OUTPUT FOR ELECTRODES .. 123. VALVE 2 MAGNETIC ISOLATION CONTACTOR OUTPUT CR1 .. 124. VALVE 3 ALARM OUTPUT CR2 .. 124. HALF CYCLE CURRENT 125. ENABLE HALF CYCLE WELDING .. 125. PROGRAM A HALF CYCLE WELD .. 125. ENABLE CURRENT MONITORING .. 125. OPTIONS FOR en1000 AND en1001 SERIES CONTROLS .. 126. MM2 MEMORY MODULE .. 126. INTEGRATED PRESSURE SENSE AND control SYSTEM .. 126. 24 VDC VALVE OUTPUTS .. 127. CURRENT SENSORS .. 127. PROGRAM LOCKOUT KEY SWITCH.

10 127. 1 OF 7 VALVE EXTENSION BOARD .. 127. SCHEDULE SELECT S49 OPTION .. 127. RS485 OPTIONS .. 127. ENLINK 1000/1001 SOFTWARE .. 128. REMOTE TERMINAL RT4jr.. 128. ISOLATED ADAPTERS S485 AND U485 .. 128. RS232 OPTIONS .. 128. HALF-CYCLE OPTION .. 128. ERROR CODES AND TROUBLESHOOTING .. 129. ERROR CODES .. 129. TROUBLESHOOTING .. 131. TROUBLESHOOTING GUIDE .. 134. WELD control WITH OPTIONS BLOCK DIAGRAM .. 136. WARRANTY AND SERVICE .. 137. APPENDICES. APPENDIX A ERROR CODES .. 138. APPENDIX B PROGRAMMING AND SETUP .. 139. APPENDIX C S49 SCHEDULE SELECT OPTION INSTALLATION .. 146. APPENDIX D WELDSAFE 5000 .. 149. APPENDIX E EN1000/EN1001 BENCH CONTROLS .. 154. APPENDIX F EN1003 THREE PHASE DC CONTROLS .