Download instruction manual 700151 en1501 series controls

INSTRUCTION MANUAL
700151
EN1501 SERIES CONTROLS
MICROPROCESSOR BASED
Weld Sequence Controls
With
Solid State Thyristor Contactors
EN1501 Series Controls
Wiring Diagram
421361 FPX (SCR)
421365 T/D/LS/LF Cabinet
465 East Randy Road
Carol Stream, Illinois 60188
(630) 682-9600
FAX# (630) 682-3374
ENTRON Controls, Inc.
MICROPROCESSOR BASED WELDING CONTROL
WITH SOLID STATE THYRISTOR CONTACTORS.
INSTALLATION AND OPERATION MANUAL FOR:
Model Series EN1501
CAUTION
READ THIS MANUAL COMPLETELY BEFORE ATTEMPTING
TO INSTALL OR OPERATE THIS CONTROL
ENTRON Controls, Inc., reserves the right to alter the contents of
this manual without previous notice.
ENTRON Controls, Inc.
Carol Stream, Illinois, 60188
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TABLE OF CONTENTS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
UNIQUE FEATURES . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD FEATURES . . . . . . . . . . . . . . . . . . . . .
EN1501 CONTROL PANEL LAYOUT . . . . . . . . . . . .
CONTROL FUNCTIONS . . . . . . . . . . . . . . . . . . . . .
WELD SCHEDULE PARAMETERS . . . . . . . . . . . . . . .
INITIATION PILOT INPUTS . . . . . . . . . . . . . . . . . .
OTHER CHARACTERISTICS . . . . . . . . . . . . . . . . . .
NON-VOLATILE MEMORY ERROR . . . . . . . . . . . . . .
VOLTAGE PROGRAMMING . . . . . . . . . . . . . . . . . . .
FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CUSTOMER TERMINAL STRIP DIAGRAMS . . . . . . . .
CUSTOMER TERMINAL STRIP CONNECTIONS . . . . .
PRIMARY WIRING TO WELDING CONTACTOR . . . . .
COOLING REQUIREMENTS FOR CONTACTORS . . . .
INSTALLATION DIAGRAMS FLAT PLATE RETROFIT .
INSTALLATION DIAGRAMS “S” CABINET . . . . . . . .
INSTALLATION DIAGRAMS “E” CABINET . . . . . . . .
INSTALLATION DIAGRAMS “T/D & L” CABINET . . . .
MECHANICAL MOUNTING DIAGRAMS . . . . . . . . . .
EXTENDED FUNCTIONS . . . . . . . . . . . . . . . . . . . . .
SEAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC VOLTAGE COMPENSATION . . . . . . . .
CLEAR ALL FUNCTIONS . . . . . . . . . . . . . . . . . . . . .
87° DELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL POWER FACTOR PROGRAMMING . . . . . .
PROCESS OUTPUTS . . . . . . . . . . . . . . . . . . . . . . .
POWER FACTOR MEASURING . . . . . . . . . . . . . . . .
CONSTANT CURRENT REGULATION . . . . . . . . . . . .
CURRENT RATIO MAXIMUM SCALE . . . . . . . . . . . .
BEAT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .
CONSTANT CURRENT MODE . . . . . . . . . . . . . . . . .
CONSTANT CURRENT SETUP . . . . . . . . . . . . . . . . .
CONSTANT CURRENT LIMITS . . . . . . . . . . . . . . . .
EN1501 CONSTANT CURRENT CONTROL
SECONDARY SENSING APPLICATIONS . . . . . . . . . .
8.1
SETTING UP FOR CONSTANT CURRENT OPERATION
9.0
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
TROUBLE-SHOOTING . . . . . . . . . . . . . . . . . . . . . . .
10.0
WARRANTY AND SERVICE . . . . . . . . . . . . . . . . . .
APPENDIX “A” INITIATION COMBINATIONS . . . . . . . . . . . . . . . . . .
APPENDIX “B” ISOLATION CIRCUITRY DESCRIPTION . . . . . . . . . . .
1.0
1.1
1.2
2.0
2.1
3.0
4.0
4.1
4.2
5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
6.0
6.01
6.02
6.03
6.04
6.05
6.06
6.07
6.08
6.09
6.10
7.0
7.1
7.2
8.0
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.2
.3
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12
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20
20
21
22
23
24
25
26
26
27
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29
29
30
30
31
31
32
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. 33
. 35
. 36
. 39
A-1
B-1
1.0 GENERAL DESCRIPTION
The EN1501 control is a microprocessor based seam welding constant current resistance
welding control. It has been designed specifically for Seam Welding Applications or any
application where Preheat, Up Slope, Weld Heat, Down Slope and Post Heat are necessary.
One outstanding feature of the EN1501 control is its ability to allow the operator concurrent
adjustment of weld heat percent current during the “Weld” portion of an initiated sequence
via the (optional) rotary input board adjustment knob. The EN1501 can store weld sequence
parameters in each of 40 unique schedules. Weld schedule parameters are held in nonvolatile memory for storage. Pilot initiations trigger specific sequences tailored to the
intended application. Despite the need for complex weld schedules to provide different heats
at specific times, the EN1501 is automatically preprogrammed to execute a chain of events
making the control simple to program and operate. Constant Current is possible through
sensing either welding transformer primary or secondary current.
CONTROL SEQUENCE
The EN1501 control is preprogrammed for “Beat During Squeeze” operation. This feature
allows the sequence to be canceled if the initiation switch is opened before a weld has been
started, the control cannot be re-initiated until the previous sequence is completed, or the
sequence has been terminated (interrupted) using Emergency Stop.
Continued closure will keep the control in the weld state until opening the initiation pilot
switch. The control will then advance to Down Slope, Post Heat, and Hold to end the
sequence. (See Initiation Flow Chart).
The EN1501 is a “Seam Welding” control which is able to perform Seam or Roll-Spot
welds. If any value is entered into “Cool” a Roll-Spot weld will occur by alternating
between the number of “Weld” and Cool” cycles programmed in the initiated schedule.
1.1 - UNIQUE FEATURES
FS3, FS7 and FS11 are weighted initiation inputs allowing the control to automatically jump
to the parameters stored for “Weld” of the schedule associated with the higher order
initiation switch. Release of the higher order pilot switch will automatically revert to the
schedule associated with lower order (previous) pilot switch if it is still closed.
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1.1 UNIQUE FEATURES - (cont.)
INITIATION ON FS3
Closure of a switch between FS3 and GND will initiate the schedule shown on the control
display.
INITIATION ON FS7
Closure of a switch between FS7 and GND will initiate Schedule 10.
INITIATION ON FS11
Closure of a switch between FS11 and GND will initiate Schedule 20.
1.2 STANDARD FEATURES
DIGITAL CURRENT CONTROL is possible via micro processor driven circuitry allowing
precise firing on each half cycle of alternating current being delivered to the welding
transformer. Accurate phase shift firing makes this control adjustable in 1 percent
increments of available current.
FUNCTION TIMING of sequence parameters relates to all programmed parameters except
“Weld” which is a function of how long the pilot initiation is held closed.
Cycle timing is achieved by counting each cycle of the line current directly. This method
of timing allows this control to be used on either 60 or 50 Hz operation without special
adjustments. See Control Functions and Terminal Strip Connection for further information.
NO ADJUSTMENT is required for power factor or timing to
change from 60 to 50 Hz operation.
87° DELAY OF FIRST CYCLE FIRING The purpose of the 87° delayed firing of each
weld sequence is to prevent the build-up of a dc component in the welding transformer. This
feature is most widely used in conjunction with wound core transformers.
MANUAL ADJUSTABLE HEAT (Optional) A knob located on the control display panel
can adjust the Weld % Current while the control is in the Program mode, or during a weld.
The new value of percent current is automatically stored in memory in the schedule being
executed during the adjustment only.
OPERATING CONDITIONS - Temperature Range: 0°C to 70°C (32°F to 158°F).
Page 4
2.0 EN1501 CONTROL PANEL LAYOUT
FIGURE 1
1 - “WELD/NO WELD” SWITCH
2 - INDICATOR LED NO WELD MODE
3 - INDICATOR LED WELD MODE
4 - DATA DISPLAY
5 - “DATA 10'S” PUSH BUTTON SWITCH
6 - “DATA 1'S” PUSH BUTTON SWITCH
7 - INDICATOR LED SQUEEZE
8 - INDICATOR LED, PREHEAT
9 - INDICATOR LED, PREHEAT% CURRENT
10 - INDICATOR LED, UPSLOPE
11 -“SELECT FUNCTION” PUSH BUTTON SWITCH
12 -INDICATOR LED, WELD
13 -INDICATOR LED, WELD % CURRENT
14 -INDICATOR LED, COOL
15 - INDICATOR LED, DOWNSLOPE
16 - INDICATOR LED, POSTHEAT
17 - INDICATOR LED, POSTHEAT % CURRENT
18 - INDICATOR LED, HOLD
19 - INDICATOR NEON, MAIN POWER (RED)
20 - SCHEDULE SELECT 1'S PUSH BUTTON
21 - SCHEDULE SELECT 10'S PUSH BUTTON
22 - SCHEDULE SELECT DISPLAY
23 - INDICATOR NEON, WELD (WHITE)
24 - MANUAL CURRENT ADJUST KNOB (OPTIONAL)
25 - PROGRAM LOCKOUT SWITCH (OPTIONAL)
26 - INDICATOR LED, OPERATE MODE
27 - PROGRAM/OPERATE PUSH BUTTON
28 - INDICATOR LED, PROGRAM MODE
29 - ENTER PUSH BUTTON SWITCH
30 - END OF SEQUENCE LED (VALVE 3)
31 - VALVE 1 LED
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2.1 CONTROL FUNCTIONS - See Control Panel Layout, Figure 1.
WELD/NO-WELD SWITCH (1) - This push-button is active at all times. It puts the
control in the WELD MODE (enables the contactor to fire) or NO-WELD MODE (disables
firing). This function is accessible while in operate mode or while welding with few
exceptions (generally during error conditions).
WELD (3)/NO-WELD (2) INDICATOR LED’s - These lights indicate the weld output
status of the control. The LEDs toggle whenever the WELD/NO-WELD SWITCH is
pressed.
DATA DISPLAY (4) - The Data Display shows the value of any parameter that can be
selected and/or programmed.
DATA PUSH-BUTTONS (5) & (6) (Non-Constant Current mode) - The right button
increments or decrements the DATA by one, and the left button increments or
decrements DATA by ten.
When either digit reaches the maximum, it resets to zero. Pressing either Data Pushbutton for more than 1 second will decrement rather than increase the data viewed on
the numeric display. These Push-buttons are only active in the program mode.
Example:
Press and release of either push-button will increment the data (7,.. 8.., 9.., 0 ..etc.)
Hold and release of either push-button will decrease the data (2,..1,..0,..etc.)
DATA PUSH-BUTTONS (5) & (6) - (Constant Current mode).
When function data is shown on FOUR digits (percent Current), the Data push-buttons
(5)&(6) have a different function.
The right button selects a DIGIT, and the left button increments that DIGIT by ONE,
when in the CONSTANT CURRENT MODE.
The four digit display is only active in the Constant Current modes of operation.
It is not necessary to press the ENTER (29) push-button to save the four digit display.
INDICATOR LEDs (7- 10, and 12-18) - LED's adjacent to each programmable function
will light when selected. When in the Program Mode the LED indicates which function is
being edited.
SELECT PUSH-BUTTON (11) - Use the SELECT push-button in the PROGRAM Mode
to choose any programmable function. When selecting a function, the indicator LED's will
light to indicate the selected function. Data pertaining to the selected function will appear
in the Data Display. Tapping the Select Push-button will select the function below the one
currently being displayed. Pressing the Select Push-button for more than 1 second will cause
Function Indicator LED's to change direction and select the previously displayed function.
Page 6
2.1 CONTROL FUNCTIONS (cont.) - See Control Panel Layout, Figure 1.
EXTENDED FUNCTIONS is a section of memory dedicated as a second layer of
parameters that apply to all the schedules, and can modify the way the control
operates. This section of memory can be found by pressing the SELECT push buttons and
paging through the functions until [ EF ] appears in the Data display window. Then use the
SCHEDULE push buttons to find the needed [EF].
POWER LIGHT (19) - The red POWER lamp indicates when power is applied to the
control.
SCHEDULE DISPLAY (22) - The SCHEDULE DISPLAY shows the number of the active
SCHEDULE. The EN1501 can store up to 40 schedules [ 00 to 39 ].
SCHEDULE PUSH-BUTTONS (20) & (21) - The right button increments or
decrements the SCHEDULE by one, and the left button increments or decrements the
SCHEDULE by ten. When either digit reaches the maximum, it resets to zero.
Press and release of either SCHEDULE push-button will increase the Schedule Display
readout to the next integer. Press and hold of either SCHEDULE push-button will decrease
the schedule display to the previous integer selecting a lower schedule.
Schedule Push-buttons are active in both the Program and Operate modes.
WELD LIGHT (23) - The white WELD lamp is connected directly across the welding
transformer primary and will light when voltage is present at the welding transformer. The
brilliance of the WELD lamp is an indication of the programmed PERCENT CURRENT and
therefore, provides a visual indication of the percent of RMS voltage supplied to the welding
transformer.
PROGRAM/OPERATE PUSH-BUTTON (27) - This push-button will put the control in
the PROGRAM or OPERATE modes.
PROGRAM is the mode in which the individual schedules can be entered or modified.
Welding parameters (times, valves, etc.) can only be changed in the PROGRAM mode. If
the control is fitted with a Manual Adjustment knob, the Weld (Heat) parameter can be
adjusted in the PROGRAM mode or via the Manual Adjustment knob (24).
OPERATE is the normal operating mode for the control. This is the only mode in which the
control can initiate a weld. When the control is in OPERATE mode, the control is in a
"Ready" (to initiate) state.
PROGRAM LOCKOUT SWITCH (25) (optional) - Allows the operator to lock the
control in the OPERATE mode only. A key is necessary to place the control in the
PROGRAM mode.
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2.1 CONTROL FUNCTIONS (cont.)- See Control Panel Layout, Figure 1.
To put the control in the PROGRAM mode using the PROGRAM LOCKOUT Switch:
1. Rotate the key 45 degrees clockwise.
2. Hold the key in this position and press the PROGRAM/OPERATE push-button.
3. Release the PROGRAM/OPERATE push-button and release the key.
The OPERATE LED will now turn off and the PROGRAM LED will turn “on”, indicating
ability to program all functions.
To put the control back in the OPERATE mode:
Press the PROGRAM/OPERATE push-button again. The control will return to the
OPERATE Mode without rotating the key.
END OF SEQUENCE LED (30) - When the control is in the OPERATE mode this LED
is momentarily lit when indicating the sequence has ended.
ENTER PUSH-BUTTON (29) - The ENTER push-button is used to store the data shown,
from the DATA Display into the non-volatile memory. (The non-volatile memory retains
data with the power OFF).
If the ENTER push-button is not pressed before other DATA is viewed (by pressing the
SELECT push button) or before returning to the OPERATE mode, the new DATA will
not be stored and the previous data will be retained. This statement is not true when
changing the Weld Percent Current using the manual adjust knob.
VALVE 1 LED (31) - When the control is in the OPERATE mode, during an initiated
sequence, this LED is lit when the valve output is active.
NOTE: INDICATOR LEDs (7- 10, and 12-18) - LED's adjacent to each programmable
function will light when selected. When in the Program Mode the LED indicates which
function is being edited.
SQUEEZE LED (7) - When the control is in the OPERATE mode, during an initiated
sequence, this LED is lit when the valve output is active for the time interval entered in this
parameter.
PREHEAT LED (8) - When the control is in the OPERATE mode, during an initiated
sequence, this LED is lit indicating preheat current is passing through the welding
transformer for the time interval entered in this parameter.
PREHEAT % CURRENT LED (9) - When the control is in the Program mode this
indicator is lit indicating a value representing the percentage of available current is being
entered or changed in the selected schedule. This magnitude of current will be present
during PREHEAT time.
Page 8
2.1 CONTROL FUNCTIONS (cont.) - See Control Panel Layout, Figure 1.
UP SLOPE LED (10) - When the control is in the OPERATE mode, during an initiated
sequence, this LED is lit indicating UP SLOPE time is elapsing for the programmed time
interval.
WELD LED (12) - When the control is in the OPERATE mode, during an initiated
sequence, this LED is lit indicating the contactor (SCR) is activated.
WELD % CURRENT LED (13) - When the control is in the Program mode this indicator
is lit indicating a value representing the percentage of available current is being entered or
changed in the selected schedule. This magnitude of current will be present during WELD
time.
COOL LED (14) - When the control is in the OPERATE mode, during an initiated
sequence, this LED is lit indicating an impulse sequence is active and an intermittent seam
is in process.
DOWN SLOPE LED (15) - When the control is in the OPERATE mode, during an initiated
sequence, this LED is lit indicating DOWN SLOPE time is elapsing.
POST HEAT LED (16) - When the control is in the OPERATE mode, during an initiated
sequence, this LED is lit indicating Post Heat time is elapsing.
POST HEAT % CURRENT LED (17) - When the control is in the Program mode this
indicator is not lit indicating a value representing the percentage of available current is
being entered or changed in the selected schedule. This magnitude of current will be present
during POST HEAT time.
HOLD LED (18) - When the control is in the OPERATE mode, during an initiated
sequence, this LED is lit indicating HOLD time is elapsing.
MANUAL ADJUST KNOB (24) (optional)- Allows the increase or decrease of the
percent current in both Program and Operate Mode, during an initiated sequence. Non
functional with a Program Lockout Switch option.
Page 9
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3.0 WELD SCHEDULE PARAMETERS
WELD* (BEAT OPERATION) . . . . . . . . “Beat” (“On” with initiation switch closed)
ALL OTHER PARAMETERS . . . . . . . . . . 0 to 99 cycles (1 cycle = 1/60 sec.)
SQUEEZE - The number of cycles (1 cycle = 1/60 sec.) that the valve output is turned “on”
prior to the PREHEAT portion of the sequence unless the initiation pilot input is opened
before PREHEAT time begins.
PREHEAT - The number of cycles (1 cycle = 1/60 sec.) that current will be transferred to
the weld transformer at the Preheat percent current unless the initiation pilot input is opened
before WELD time begins.
PREHEAT PERCENT CURRENT - The amount of available current that will be available
to the weld transformer for the programmed number of PREHEAT cycles.
UP SLOPE - The number of cycles that will occur after Preheat causing a gradual increase
in heat until reaching the programmed Weld percent current.
WELD TIME (CONTINUOUS SEAM) - One or more cycles programmed into this
parameter will produce a continuous weld (Note: COOL time = 00) while the pilot switch
is closed.
WELD TIME* (INTERMITTENT SEAM) - A value programmed into this parameter, with
a value stored in COOL time, will produce a intermittent seam weld by alternating WELD
and COOL as long as the initiation pilot is held closed.
WELD PERCENT CURRENT - The EN1501 control has the ability to display weld current
in two modes.
CONSTANT CURRENT
NON-CONSTANT CURRENT
78 percent Weld Current has been programmed in both cases.
CONSTANT CURRENT MODE - The Data Display will read-out in four digits in the
Constant Current Mode. See Extended Functions (Section 6.07 and 6.08).
The EN1501 can not be programmed below 20 percent weld percent current using either the
DATA push buttons, or the optional Manual Current Adjust knob when in the constant
current mode.
NON-CONSTANT CURRENT MODE - The Data Display will read-out in two digits in
the Non-Constant Current Mode.
Page 10
* - Weld time in an intermittent seam weld is in cycles (1 cycle = 1/60 sec.)
3.0 WELD SCHEDULE PARAMETERS - (cont.)
SETTING UP SLOPE and DOWN SLOPE BOTTOM CURRENT - Up Slope will begin
at the percent current stored in Preheat percent current and Downslope will stop at the
percent current stored in POSTHEAT percent current..
COOL - The interval of time between weld pulses in an intermittent Seam Weld sequence.
Weld and Cool time will alternate while the pilot initiation is held closed. If [00] is stored
in this parameter, the Seam Weld will be continuous.
DOWN SLOPE - The number of weld cycles that will occur immediately after “Weld” time.
The percent of current decreases from the programmed “Weld” percent current to the level
of current stored in POSTHEAT.
POSTHEAT - The number of cycles immediately following DOWN SLOPE, that current
will be transferred to the weld transformer at the POSTHEAT percent current.
POSTHEAT PERCENT CURRENT - The amount of current that will be available at the
weld transformer for the programmed number of POSTHEAT cycles.
HOLD - The number of cycles that the valve output will stay on after the Weld (Down Slope
or Weld/Cool, etc) portion of an initiated sequence has elapsed.
4.0 INITIATION PILOT INPUTS
TWO STAGE INITIATION
STAGE 1 INITIATION FS1 - Connect a normally open pilot switch between TS1-FS1
and TS1-GND. Closure of this switch will energize the valve output on the Terminal
Strip/Firing Board (SV1 and SV2).
STAGE 2 INITIATION - FS3 or FS7 or FS11 to GND (same functionality as single stage
initiation See single stage initiation)
SINGLE STAGE INITIATION
SINGLE STAGE INITIATION - Connect a normally open pilot switch between TS1-FS3
or FS7 or FS11 and TS1-GND.
Closure of this switch will execute a welding schedule as follows:
FS3 Initiates the schedule shown in the Schedule Display.
FS7 Initiates Schedule 10.
FS11 Initiates Schedule 20.
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4.0 INITIATION PILOT INPUTS (cont.)
CAUTION
DO NOT connect TS1-GND to Earth Ground.
May cause irregular operation.
Use Chassis Ground Lug
Initiation of this control is very versatile in that it may allow several individual heat levels
to be introduced during the welding process depending on what parameters are stored in
Schedules 10 and 20 and the manner in which the “FS” initiation switches are operated.
For further clarification on various heat initiations refer to Appendix A of this manual.
4.1 OTHER CHARACTERISTICS
CONTACTOR TEMPERATURE LIMIT SWITCH - This feature is used to block welding
if the TEMPERATURE of the CONTACTOR is above the rated operating temperature.
If the Temperature Limit Switch is active (open) the control cannot be initiated until the
temperature limit switch cools (resets). If the Temperature Limit Switch becomes active
(OPEN) during a weld, the firing pulses to the contactor will continue until the end of
WELD Time. A new sequence cannot be initiated until the Temperature Limit Switch cools
and resets (closes).
In either of the above cases, the DATA Display will show ERROR Code [ 01 ] until the
Temperature Limit Switch recovers its normally closed state. The control will then return
to normal operation. If the Temperature Limit Switch is not used, place a jumper between
PCB2-TLS1 /AUX1 and GND. Temperature Limit Switches are standard on ALL supplied
contactors.
PRESSURE SWITCH - This feature is used to make the control wait if the required
pressure has not been reached while in the SQUEEZE interval as follows:
After initiation, the control advances through SQUEEZE. If the pressure switch is not
active, (pressure not sufficient), the control waits, and the SQUEEZE LED flashes at the end
of squeeze. When the pressure switch closes (pressure is sufficient), the flashing stops and
the control continues the sequence.
If the Pressure Switch interrupts the sequence for an extended period, the display will flash
the ERROR Code # [15]. This error will not terminate the sequence. Once the pressure
switch closes, the sequence will continue on through PREHEAT, and UPSLOPE to
WELD and then complete the sequence. See section 5.2 CUSTOMER TERMINAL
STRIP CONNECTIONS.
NOTE:
If a pressure switch is not used, place a jumper (factory installed) between TS1-PS1 and
TS1-GND. Pressure Switch is not furnished with the control.
Page 12
4.1 OTHER CHARACTERISTICS (cont.)
WATER FLOW SWITCH (optional) - This feature is used to inhibit welding if WATER
FLOW is not sufficient for proper cooling of the contactors as follows:
The Water Flow Switch (normally closed) contact can be connected to TS1- NW1 and TS1GND. If the Water Flow Switch is open because of insufficient flow, the control will not
allow weld current to pass to the welding transformer until there is sufficient water flow to
close the switch. See Section 5.5 for CONTACTOR COOLING requirements. If the switch
is activated during an initiated sequence the control will open EXTERNAL No Weld. The
LED directly above TS1-NW1 will turn off indicating that an EXTERNAL No Weld has
activated.
EMERGENCY STOP - The Emergency Stop operates as follows:
When the Emergency Stop switch is active (open), the control stops all processes. All
valves and the contactor are turned off.
While in the Emergency Stop condition, the control will flash ERROR Code [ E.S. ] on the
DATA Display until the condition has been cleared.
If the execution of a schedule was interrupted by means of the Emergency Stop Switch, the
control cannot be re-initiated automatically (after the emergency condition is removed).
Upon release of the switch, it must be re-initiated by closing the pilot switch.
NOTE:
If the Emergency Stop Switch is not used, place a jumper between TS1-ES1 and TS1-GND
(factory installed). Emergency Stop Switch is not supplied with the control.
INTERLOCKING DOOR SOLENOID (IDS) - The Control may include an IDS to prevent
entry to the control when power is applied. An IDS is included (unless otherwise specified)
in S and E style cabinets. T/D, L and other NEMA 12 style cabinets DO NOT include
interlocking door solenoids.
WARNING:
The IDS is protected by fuse F1 (6/10A). If the fuse is blown or
missing the IDS will not operate and will not prevent entry to cabinet.
4.2 NON-VOLATILE MEMORY ERROR (ERROR CODE 14)
The EN1501 Series of controls make extensive use of Non-Volatile memory devices. These
devices are sometimes susceptible to corruption due to electrical disturbance present in some
systems.
To detect effects of electrical disturbance on the control, upon power-up or return from
Emergency Stop, the control executes a diagnostic test that reads all memory locations
within the
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4.2 NON-VOLATILE MEMORY ERROR (ERROR CODE 14) - (cont.)
SCHEDULE STORAGE areas. If the microcontroller finds invalid data, it displays the
ERROR [ 14 ] condition alternated with the schedule number where the invalid data is
stored. The invalid data may also be found in the Extended Function memory area; in
this case the alternate flash displays [ EF ].
Physically isolating high voltage wires from low voltage wires will avoid the introduction
of electrical disturbance into the control.
If an ERROR [14] occurs, the following procedure should be performed to clear this error
condition:
1.
Press the SELECT push-button to stop the flashing.
2.
Using the Program/Operate push button, place the control in the PROGRAM MODE.
The operator can use SELECT to find the invalid Parameter in the schedule displayed
during the flashing.
3.
Use the DATA push-buttons to correct the DATA.
4.
Press ENTER.
5.
Return the control to the OPERATE MODE.
If more than one location has been affected, it may be necessary to use the CLEAR ALL
command in the EXTENDED FUNCTIONS to erase all the memory locations and restore
the default settings. (See Section 6 of this manual for factory settings )
If [ER 14] persists, you may need to isolate “High Voltage” (valve outputs, etc) from “Low
Voltage” (initiation inputs) wires. Re-routing each type wires to a separate grounded conduit
may restore the control to normal operation.
If [ER 14] is NOT flashing or appears in the “Program” mode the Main Control board may
need repair.
Page 14
5.0 VOLTAGE PROGRAMMING
CAUTION
THE WELDING CONTROL AND/OR WELDING MACHINE WAS
SHIPPED CONFIGURED FOR A SPECIFIC VOLTAGE. A TAG ATTACHED
TO THE CONTROL TERMINAL BLOCK SPECIFIES THIS VOLTAGE.
THE 1501 IS A MULTI-VOLTAGE UNIT WHICH CAN BE CHANGED FROM ONE
OPERATING VOLTAGE TO ANOTHER BY RE-ARRANGING JUMPERS ON THE
TERMINAL STRIP INSIDE THE UNIT. OPERATING THE CONTROL AT A VOLTAGE
OTHER THAN THAT PRESCRIBED BY THE VOLTAGE CONFIGURATION JUMPERS
MAY CAUSE SERIOUS DAMAGE.
This control can be configured to operate at 208, 240, 380, 480, and 575 VAC. If operation
at 380 or 575 VAC is required, please consult the factory.
Control Transformer
Jumpers on TS1-L2/CTH4, CTH2, CTH3, and L1/CTH1 must be configured to match the
line voltage. Refer to the wiring diagram shipped with the control.
Sense Transformer
Jumpers on TS1-H4, TS1-H2, TS1-H3, and TS1-H1 must be configured to match the line
voltage. Refer to the wiring diagram shipped with the control.
Valve Transformer
Jumpers on the transformer H1, H3, H2, and H4 must be configured to match the line
voltage. Refer to the wiring diagram shipped with the control.
5.1 FUSING
CONTROL - This fuse, a BBS 6/10 AMP, is used to protect the control circuits.
VALVE -
These fuses, a 2AG 1 AMP, are used to protect the valve circuits. The fuses
are located on the TERMINAL STRIP PCB, PCB2 Assembly Number
410319 or 410319-001.
INSTALL PROPERLY SIZED FUSES IN SERVICE DISCONNECT SWITCH. CHECK
WELDING MACHINE MANUFACTURER'S RECOMMENDATIONS.
Page 15
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5.2 CUSTOMER TERMINAL STRIP DIAGRAM
Page 16
TERMINAL STRIP TS1
SEE CUSTOMER WIRING DIAGRAM 421365 T/D-L/LS CABINET OR 421361 FLAT
PLATE.
NOTE: For complete instructions refer to the Wiring Diagram that came with the
control
Page 17
710483
5.3 CUSTOMER TERMINAL STRIP CONNECTIONS (Ref. Appendix B)
TS1-GND Used as the Common Connection/Return Path for initiation connection.
There are six GND terminals provided on TS1. Do Not use as Earth Ground!
TS1-FS1
Used to connect the first stage of a Two Stage Pilot. Connect a Single Stage
Pilot between TS1-FS1 and TS1-GND terminals. Use a single pole, normally
open, momentary type switch. This input can be used as a first stage for FS3,
FS7 and FS11.
TS1-FS3* Used to connect a Single Stage Pilot or second stage of a Two Stage Pilot.
Connect a Single Stage Pilot between TS1-FS3 and TS1-GND terminals. Use
a single pole, normally open, momentary type switch.
-ORUsed to connect one side of a Two Stage Pilot. Connect the Second Stage of
a Two Stage Pilot between TS1-FS3 and TS1-GND terminals. Use a single
pole, normally open, momentary type switch.
When initiated via TS1-FS3 the weld control will begin execution at the
schedule actively shown in the Schedule Display. See also Appendix A.
TS1-FS7* Used to connect a Single Stage Pilot or second sage of a Two Stage Pilot for
direct initiation of Schedule 10. Connect a Single Stage Pilot between TS1-FS7
and TS1-GND terminals. Use a single pole, normally open, momentary type
switch.
-ORUsed to connect one side of a Two Stage Pilot. Connect the Second Stage of
a Two Stage Pilot between TS1-FS7 and TS1-GND terminals. Use a single
pole, normally open, momentary type switch.
When initiated via TS1-FS7 the weld control will begin execution of
schedule 10. See also Appendix A.
TS1-FS11* Used to connect a Single Stage Pilot or second stage of a Two Stage Pilot for
direct initiation of Schedule 20. Connect a Single Stage Pilot between TS1-FS11
and TS1-GND terminals. Use a single pole, normally open, momentary type
switch.
-ORUsed to connect one side of a Two Stage Pilot. Connect the Second Stage of
a Two Stage Pilot between TS1-FS11 and TS1-GND terminals. Use a single
pole, normally open, momentary type switch.
When initiated via TS1-FS11 the weld control will begin execution of
schedule 20. See also Appendix A.
TS1-PS1
Used to connect a Pressure Limit Switch. When used, remove jumper and
install a single pole, normally open (closed when set pressure is met) Pressure
Limit switch between TS1- PS1 and TS1-GND terminals.
TS1-ES1
Used to connect an Emergency Stop Switch. When used, remove jumper and
install a single pole, normally closed Emergency Stop switch between ES1 and
TS1-GND terminals. (Open switch = Emergency Stop)
Page 18
* When initiated the pilot switch MUST remain closed beyond the Up Slope time of the scheduled sequence for
Seam weld current to flow. Upon release of the switch the control will automatically proceed to Down Slope , etc.
5.3 CUSTOMER TERMINAL STRIP CONNECTIONS - (cont.)
TS1-NW1 Used to connect an External No Weld Switch. When used, remove jumper and
install a single pole, normally closed switch between TS1- NW1 and TS1-GND
terminals. (Open switch = No Weld)
TS1-TLS1 Used to connect a Temperature Limit Switch. When used, remove jumper and
install a single pole, normally closed Temperature Limit switch between TS1
-TLS1/AUX1 and TS1-GND terminals. (Open switch = No Weld)
TS1-VL1
External Valve Power Input Line 1. This terminal can be used to supply
power to the control valve circuit from an external power source. When used
by customer, external power is connected between TS1-VL1 and TS1SV2/SV4/VL2. Reference Appendix B. Note: Internal valve power supply on
TS3-VL1 & VL2 must be disconnected and isolated when present.
TS1-SV2/SV4
/VL2
External valve power input Line 2 and Valve 1 & 2 solenoid output common
connection. This terminal can be used to supply power to the control valve
circuit from an external power source. When used by customer, external power
is connected between TS1-VL1 and TS1-SV2/SV4/VL2. This terminal may be
grounded by customer if allowed or required by the application. Reference
Appendix B. Note: Internal valve power supply on TS3-VL1 & VL2 must be
disconnected and isolated when present.
TS1-SV1
Valve 1 output. This output is active during any schedule for which V1 has
been programmed. (Squeeze time, Hold time etc.) Connect Valve to TS1-SV1
and TS1-SV2. Reference Appendix B. Note: Internal valve power supply on
TS3-VL1 & Vl2 must be disconnected and isolated when present.
TS1-SV3
Not used in this control. No connection is necessary to this terminal. Reference
Appendix B.
TS1-SV5
End Of Process output. Reference Appendix B.
TS1-SV6
/VL2
End Of Process output common connection. Note: Jumper position JB on TS3.
Reference Appendix B.
REFERENCE TERMINAL STRIP DIAGRAM section 5.1
NOTE: For complete instructions refer to the Wiring Diagram that came with the control.
TS1-CTHA, L1, CTH1
CTH3,CTH2,CTH4/L2
Used to configure the Control Transformer for different Line Voltages.
L1 is internally connected to control fuse F1.
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 CONTACTORS. When
required connect wire (minimum 18 AWG) L1 To L1 side of external
contactor.
TS1-CTHA is a tap on the Control Transformer T1 typically used to
power an Interlocking Door Solenoid (IDS) (when used). TS1-CTHA
can also be used for 120 or 380 volt operation (see wiring diagram)
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710484
5.3 CUSTOMER TERMINAL STRIP CONNECTIONS - (cont.)
TS1-CTH4/L2
L2 is used to provide control power. Connect wire (minimum 18 AWG)
from common to the L2 welding transformer lead. On controls furnished
with integrally installed isolation switch or circuit breaker, L2 is factory
installed.
TS1-H1,TS1-H3,
TS1-H2,TS1-H4/XH1
Used to configure the Sense Transformer for different Line Voltages.
For 208/240 VAC operation - Jumper H1 To H3 and H2 to H4.
For 480 VAC operation - Jumper H3 to H2 only.
Used also for connections to external SCR CONTACTORS. When
required, connect wire (minimum 18 AWG) H4/XH1 to H1 side of
external contactor.
5.4 PRIMARY WIRING TO WELDING CONTACTOR
For your convenience, many electrical and mechanical connections have been performed at
the factory. Check ALL electrical connections to insure integrity. Connections may loosen
during shipping.
64444444444444444444444444444444444444444444444444444444444444447
DANGER
When power is ON, all exterior surfaces of the ignitron tubes
and SCR's carry Hazardous Voltage. Contact
with these devices may cause serious or fatal injuries.
94444444444444444444444444444444444444444444444444444444444444448
Note:
Size and style of SCR may differ from that shown above.
Only customer primary wiring connections to the EN1501 are shown in this diagram.
Connect the L1 lead from incoming power to the L1 connection located on the contactor
assembly. Connect the H1 lead from the welding transformer to the H1 connection located
on the contactor assembly.
Connect an 18 AWG wire from L2/CTH4 to the H2 side of the welding transformer primary.
Since this manual is a multipurpose manual, consult Wiring Diagram supplied with Welding
Control.
Page 20
5.5 COOLING REQUIREMENTS FOR CONTACTORS
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.
WATER OFF - POWER OFF
POWER ON - WATER ON
Be sure power to an electronic contactor is turned off when water is turned off.
With a voltage applied, most water will ionize and begin to conduct current between points.
of high differential voltages. This current is sufficient to heat the water past the boiling
point, creating steam and possibly causing the rubber hose to burst. The water spraying over
the high voltage circuit can cause considerable damage to the contactor and, most likely , the
control circuitry as well. Never use metallic or other conductive tubing to plumb a water
cooled resistance welding contactor. Heater hose has a very high carbon content and should
not be used for contactor plumbing. A low carbon, reinforced hose (such as the hose
originally supplied with the unit), no less than 18" long, must be used to connect the heat
sinks to each other and to the bulkhead fitting on the inside wall of the cabinet, see plumbing
instructions on wiring diagram.
The 600 and 1200 Ampere water cooled heat sinks are electrically isolated from the
electrical circuit within the contactor. An 18" hose length is recommended for consistency
only. It is still recommended to turn power off when the control is not in use.
For all water cooled contactors, be sure water is turned ON before placing welder in
operation. An open drain is recommended for best operation. If a closed return system is
used, be sure return line is properly sized so that back pressure will not reduce water flow
below recommendations. A sight flow indicator is recommended.
5.6 INSTALLATION DIAGRAM “11 X 11 FLAT PLATE RETROFIT”
For more information on installation of the EN1501
FP (SCR) retrofit package, refer to wiring diagram
421361 shipped with that model.
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710485
5.7 INSTALLATION DIAGRAMS "S" CABINET
Page 22
5.8 INSTALLATION DIAGRAMS "E" CABINET
300/600/1200 Amp CONTACTOR
“E” CABINET
See page 25 for mounting information.
1800/2200 Amp CONTACTOR
“E” CABINET
Page 23
710486
5.9 INSTALLATION DIAGRAMS "T/D AND L" CABINETS
600/1200 Amp CONTACTOR
T/D CABINET
See page 25 for mounting information.
1800/2200 Amp CONTACTOR
T/D CABINET
Page 24
5.10 MECHANICAL MOUNTING DIAGRAMS
"T/D or L" CABINET
"E" CABINET
Page 25
710487
6.0 EXTENDED FUNCTIONS
To change settings of the EXTENDED FUNCTIONS, put the control in PROGRAM mode.
Use the SELECT push button to step ONCE past HOLD. All function indicator LEDs will
turn off and the DATA display will read [ EF ]. This indicates that the control is in the
EXTENDED FUNCTION mode. EXTENDED FUNCTIONS can now be viewed or altered.
To view all of the EXTENDED FUNCTIONS, press the SCHEDULE push-buttons and step
through the available EXTENDED FUNCTIONS in either direction. When a desired
function is shown in the SCHEDULE display, the DATA display will read the current value
programmed for that function. To exit the EXTENDED FUNCTIONS mode, press SELECT
once to advance the function indicator one more time.
The table below lists the available EXTENDED FUNCTIONS; They will be described in
the sections to follow:
DESIGNATION
SE
CC
CA
87
PP
PO
PF
rA
Cr
BE
DESCRIPTION
Seam Mode
AVC
Clear All
87° Delay
Manual Power Factor Programming
Process Outputs
Power Factor Measuring
Ratio/Kilo Amps Maximum Scale
Current Regulation
Beat Operation
SECTION
6.01
6.02
6.03
6.04
6.05
6.06
6.07
6.08
6.09
6.10
6.01 SEAM [ SE ]
The EN1501 Seam Welding control is shipped from the factory set to SE=[01].
Note: Modes [02] and [03] are reserved for future applications
SE = [04] is primarily used in applications having DC transformers. This mode allows
several Weld cycles to be ignored by the current compensation circuit.
Example:
Page 26
If a value of 64 were entered into Seam Mode, the first (6) cycles of
weld current would be ignored by the compensation circuit. Likewise,
a value of 74 would ignore the first (7) cycles of weld. This will avoid
over compensation which may occur due to the natural Up Slope
inherent with a DC transformer.
6.02 AVC [ CC ]
The EN1501 controls are shipped with the automatic voltage compensation feature disabled.
Under conditions of poor line voltage regulation, AVC will allow for consistently good
quality welds in spite of varying line voltage.
To enable AVC:
1. Put the control in PROGRAM MODE.
2.
Use SELECT to find [ EF ].
3.
Use the SCHEDULE push-buttons and find [ CC ].
4.
Enter a value for CC that corresponds to the operating voltage being used via the
DATA push-buttons.
5.
Press the ENTER push-button.
NOMINAL LINE VOLTAGE
DISABLE
120
240
380
480
575
CC CODE VALUE
00
01
02
03
04
05
The AVC must be enabled when the line voltage is nominal. Also, when using AVC, select
a percent current not higher than 85% to allow the AVC circuit "operating space".
NOTE: This control was primarily designed to correct for current losses due to various
conditions including line voltage. It is not necessary to enable AVC. AVC will not work
concurrently with constant current.
6.03 CLEAR ALL FUNCTIONS [ CA ]
It is sometimes desirable to CLEAR ALL previous schedules and extended functions from
the memory and return the programmed control parameters to factory defaults.
To use the CLEAR ALL feature:
1.
2.
3.
4.
Where:
5.
Put the control in PROGRAM MODE.
Use SELECT to find [ EF ].
Use the SCHEDULE push-buttons to find [ CA ].
Enter a value for CA of:
[ 01 ] or [ 02 ] or [ 03 ] into the data display using the DATA push-buttons.
CA = [ 01 ], Clears SCHEDULE data.
CA = [ 02 ], Clears EXTENDED FUNCTION data.
CA = [ 03 ], Clears HI, CU, and LO variables for all schedules.
Press the ENTER push-button.
NOTE: Erased Data can only be restored by reprogramming the control.
Page 27
710488
6.04 87° DELAY [87]
The 87° Delay helps to prevent the build-up of a DC component in the welding transformer.
A DC component may be damaging.
1.
2.
3.
4.
Put the control in PROGRAM MODE.
Use SELECT to find [ EF ].
Use the SCHEDULE push-buttons to find [ 87 ].
Use the DATA push-buttons and make [ 87 ] = [ 00 ] or [ 01 ].
Where:
00 = 87° DELAY DISABLE
01 = 87° DELAY ENABLE DEFAULT (factory default setting)
5.
Press ENTER.
6.05 MANUAL POWER FACTOR PROGRAMMING [ PP ]
If required the EN1501 Control can be placed in the MANUAL POWER FACTOR Mode
as follows:
1.
Place the control in the PROGRAM MODE.
2.
Use SELECT and find [ EF ].
3.
Use the SCHEDULE push-buttons to find [ PP ].
4.
Use the DATA push-buttons to enter the Machine's Power Factor.
Where:
If [ PP = 00 ] The control is in Automatic Power factor mode.
If [ PP = XX ] If XX is not 0, the control is in Manual Power factor mode and the
Programmed Power factor is XX.
5.
Press ENTER.
6.06 PROCESS OUTPUTS [ PO ]
PROCESS OUTPUTS [ PO ] - The EN1501 provides a 120 VAC output on TS1-SV5 and
TS1-SV6 that can be programmed. (See the list for programming options).
To use any PROCESS OUTPUT Modes:
1.
2.
3.
4.
5.
Put the control in PROGRAM MODE.
Use SELECT to find [ EF ].
Use the SCHEDULE push-buttons to find [ PO ].
Use the table below as a guide for the necessary process.
Press the ENTER push-button.
Page 28
6.06 PROCESS OUTPUTS [ PO ] (cont.)
To enable the End of Sequence Valve Output, a jumper on the EN1501 Terminal Strip Firing
Board (410319) on TS3 (see page 13) MUST be moved from the “JA” position to the “JB”
position. Reference Appendix B.
NOTE:
Since this valve output (TS1-SV5 - TS1-SV6) is no longer isolated through the control
relay, caution must be exercised in what this output is connected to and the results of
its being energized. Also the jumper on terminal strip TS3 on circuit board #2 (410319)
must be moved connecting terminal #1 to VL1 as indicated by "JB" printed on the
board. This is necessary in order to bypass the Valve Control Relay normally
incorporated into the normal operation of this output. Reference Appendix B.
CODE
[00]
[01] - [05]
[06]
[07] - [11]
PROCESS
Process Output Disabled
Reserved for future applications
“On” for .5 second after the end of a sequence (default setting)
Reserved for future applications
[ PO ] = [ 06 ] Process output (TS1-SV5 - TS1-SV6) will turn on for one half second
after the sequence is complete.
6.07 POWER FACTOR MEASURING [ PF ]
When the Schedule Display reads [PF] and a sequence is executed, the Data Display will
show the measured power factor of the machine.
6.08 CONSTANT CURRENT REGULATION [ Cr ]
The EN1501 Constant Current control can be programmed for CONSTANT CURRENT
operation.
To program the control for CONSTANT CURRENT:
1. Put the control in PROGRAM MODE.
2.
Use SELECT to find [ EF ].
3.
Use the SCHEDULE push-buttons to page through the Extended Functions to [ C.r.
].
4.
Enter a value for [ C.r. ] using the DATA push-buttons.
[ C.r. = 00 ]
[ C.r. = 10 ]
[ C.r. = 11 ]
[ C.r. = 20 ]
[ C.r. = 21 ]
5.
CONTROL NOT IN CONSTANT CURRENT MODE
PRIMARY SENSING Percent Emulation/Measured Max
SAME AS MODE 10 Monitoring only
SECONDARY SENSING & COMPENSATION
SAME AS MODE 20 with NO COMPENSATION
Press the ENTER push-button.
Page 29
710489
6.09 CURRENT RATIO MAXIMUM SCALE [ rA ]
The EN1501 Can operate in various CONSTANT CURRENT modes.
1. Put the control in PROGRAM MODE.
2. Use SELECT to find [ EF ].
3. Use the SCHEDULE push-buttons to page through the extended functions and find
[C.r.]. There must be a valid [ C.r. ] value enabling constant current before [ r.A. ] can
be programmed.
If the control is in [ C.r. = 00 ], [ r.A. is not programmable ].
If the control is in [ C.r. = 10 ], [ r.A.= 00.99 ] / [r.A=XX.XX], OR
If the control is in [ C.r. = 11 ], [ r.A.= 00.99 ] / [r.A=XX.XX]
The control can be programmed in percent current steps 00.00 to 00.99 / The control can be
programmed in steps proportional to a maximum measured current on the secondary of the
welding transformer.
If the control is in [ C.r. = 20 ], [ r.A.= 00.99 ] / [r.A=XX.XX], OR
If the control is in [ C.r. = 21 ], [ r.A.= 00.99 ] / [r.A=XX.XX]
4. Use the SCHEDULE push-buttons to page through the extended functions and find
[ r.A. ].
5. Enter a value for [ r.A. ] of: [ 00.99 ] (see table for available modes) using the DATA
push-buttons
6.10 BEAT OPERATION [ BE ]
By definition, a Seam Welding Control works in a Beat Mode during the Weld or Weld/Cool
portion of the sequence. Beat Operation allows an initiated sequence to be terminated.
BE = [00] (factory default setting) allows sequence termination during Squeeze, Preheat, and
Upslope time if the pilot initiation is opened prior to the start of WELD time.
BE = [01] allows sequence termination during Squeeze time ONLY.
BE = [02] Reserved for future applications.
Page 30
7.0 CONSTANT CURRENT MODE
The purpose of the EN1501 Current Compensation feature is to maintain constant weld
current, to a preset level, despite influencing factors that would otherwise cause the weld
current to vary.
Operating the control in Constant Current Mode allows the control to compensate for
varying voltage, inductive power losses caused by movement of ferrous metals within the
machine secondary, or changes in material resistance.
The constant current feature should not be expected to correct for electrode wear, electrode
size, changes in force, or other problems caused by improper machine setup or maintenance.
Whenever there is any inconsistency in the electrode seam wheel pressure, contact area, or
anything that changes the CURRENT DENSITY (current/electrode area) through the work,
the inconsistency should be cleared first and a new SETUP procedure performed to
reestablish the proper weld data in the control memory.
7.1 CONSTANT CURRENT SETUP
The EN1501 will scale the weld current for a 99% output to allow adjustment when welding
conditions vary. To configure the control scaling data follow the steps outlined in the
following procedure.
1.
Enter a value of [10] in Extended Functions [Cr] for primary sensing, or [20] when the
control is to be configured for sensing the machines secondary current. Program [rA]
in Extended Functions to [00.99]. The control is now in the Constant Current Mode.
2.
Program [CA] in Extended Functions to [04] Do not disable the motor that drives the
welding wheels. Allow the welding wheels to revolve during setup. Allow he wheels
to reach proper weld pressure.
3.
Do NOT place any material between the electrodes. Initiate the welding machine using
a switch closure between TS1-FS3 and TS1-GND. HOLD the switch closed. The
welding transformer will pulse several times and the Display will begin counting down
from 99 to 20.
4.
The control Display will then read ER = [05]
5.
Release the pilot initiation switch and the Error will clear.
6.
The control is now calibrated for the machine and is ready to use.
Page 31
710490
7.2 CONSTANT CURRENT LIMITS [HI], [CU], and [LO]
[PO = 12, 13, and 14]
The EN1501 can be programmed to toggle the process output valve when constant current
limits have been exceeded. [PO] is programmed in Extended Functions [EF].
Establishing limits is only possible in the Constant Current Mode.
Example: [HI] = [00.83] = 83% = High Limit
[CU] = [00.78] = 78% = Welding Current.
[LO] = [00.72] = 72% = Low Limit
PO=[12] When in the Constant Current mode the control will flash the current value at the
end of the initiated sequence.
PO=[13] When in the Constant Current mode the control will flash HI or LO when weld
current is outside the established limits. The controls will also toggle Valve three for 0.5
seconds at the end of an initiated sequence.
PO=[14] When in the Constant Current mode the control will interrupt a sequence at the
end of weld if the control cannot compensate within the preset limits. HI or LO will remain
on the Display until any button is pressed to clear the error. If no limits are programmed the
control will maintain its default settings. (CU+ 10% for the HI limit and CU-10% for the LO
limit)
8.0 EN1501 CONSTANT CURRENT CONTROL
SECONDARY SENSING APPLICATIONS
The EN1501 Constant Current control can be used with an optional secondary sensing unit.
To program the control using the secondary sensing unit, follow the instructions below.
Installation.
The secondary sensing unit should be plugged into the connector provided in the back or
side of the control as applicable.
Mount the sensing unit on a stationary part of the current path on the secondary of the
welding transformer.
To help in the alignment and mounting, screw holes have been provided.
Before affixing the unit permanently, screw only one end of the unit first and if
possible, mark its position as a reference, because a different mounting angle may be
needed.
This is a HALL EFFECT TRANSDUCER.
For proper functioning, the device needs to be placed so that the current path on the
secondary of the transformer is aligned with the arrow drawn on the factory supplied
sensor. On larger KVA units, the sensing unit may need to be skewed at a slight angle
to the current path of the secondary of the welding transformer. This will be
determined as follows, while making the CONSTANT CURRENT SETUP as outlined
below.
Page 32
8.1 SETTING UP FOR CONSTANT CURRENT OPERATION
To operate the control with constant current mode, it is necessary to be familiar with the
operation of the control in non-constant current mode. Then follow the steps outlined below
in CONSTANT CURRENT [ C.r. = Current regulation ].
Upon completing setup procedures, first make sample welds to establish the correct welding
machine transformer tap switch setting, control percent current and weld time setting. Make
necessary pull tests to determine that control and transformer settings provide sufficient
current to provide the correct weld nugget diameter and strength.
It is recommended to set the welding machine transformer tap and weld time to allow the
weld to be made with a percent current setting between 70 % and 80 % to allow a proper
range for current compensation for low welding currents.
1. Program [ C.r ] for a constant current mode of operation. See section 7.3 for available
modes or [ C.r = 20 ] for the quickest setup possible. Program [ r.A.] for the
corresponding value of ratio. See section 7.3 for allowable values or [r.A. = 00.99 (if C.r
= 20) for percent emulation, the quickest possible].
2. Program [ C.A. = 04 ]. This presets Schedule 39 with the parameters shown below. Use
SELECT to review these parameters. CHANGE ONLY THE SQUEEZE TIME OR THE
VALVE MODE , in order to adjust to the machine's proper operation. If operating a
seam welder, stop the motor from turning the wheels. Run the setup without any
material between the electrodes. This will provide the control with a good basis for gain
adjustment and for recording the machine's characteristics.
SQUEEZE count . . . . . . . . . . . . . 30
WELD /HEAT count . . . . . . . . . . 04
PERCENT CURRENT . . . . . . . . Not Applicable (Disregard this Value)
HOLD count . . . . . . . . . . . . . . . . . 10
OFF count . . . . . . . . . . . . . . . . . . 00 cycles.
IMPULSES . . . . . . . . . . . . . . . . . 01 (no impulses).
COOL count . . . . . . . . . . . . . . . . . 00 cycles.
VALVE MODE . . . . . . . . . . . . . . 01 (valve #1).
CYCLE MODE . . . . . . . . . . . . . . 01 (repeat).
SLOPE MODE . . . . . . . . . . . . . . . 00 (no slope).
SLOPE COUNT . . . . . . . . . . . . . . 00 cycles.
3. Initiate the control using FS3 and hold this switch in a closed position until the front
panel displays error 05 [ E.r. 05 ].
If the control only makes one gain stop (only one firing pulse), followed by countdown
on the front panel 99,98,...20 , the sensor has too much gain.
Page 33
710491
8.1 SETTING UP FOR CONSTANT CURRENT OPERATION - Cont.
Skew the sensor at an angle between 20 to 40 degrees to the current path.
Repeat step 3. Re-run the constant current setup. This time, the control should make
more than one gain stop. However, if the control does not begin the countdown
shown in the front panel and stops after a few pulses, the sensor needs to back down
the skew to a smaller angle so that after a few pulses, the control WILL BEGIN a
countdown and complete the setup.
At this point the control is in CONSTANT CURRENT MODE and ready to operate.
Secondary Current Sensor Detail
Page 34
9.0 ERROR CODES
TROUBLE
Data/Schedule
Display E.r. 01.
POSSIBLE CAUSE
I. Error Code #01. Temp. Limit
Sw. Open/Overheated
------------------Data/Schedule
Display E.r. 02.
------------------Data/Schedule
Display E.r. 03.
------------------Data/Schedule
Display E.r. 04.
------------------Data/Schedule
Display E.r. 05.
---------------------------------------I. Error Code #02. FS1 AND
FS7 both closed.
---------------------------------------I. Error Code #03. FS1 AND
FS11 both closed.
---------------------------------------I. Error Code #04. Attempt to
weld while in Program mode.
---------------------------------------I. Error Code #05.
FS1,FS3,FS7,FS11, closed to
GND before power “on “.
---------------------------------------I. Error Code #07. FS1 initiated
while another seq. active.
---------------------------------------I. Error Code #08. FS3 initiated
while another seq. active.
---------------------------------------I. Error Code #09. FS7 initiated
while another seq. active.
---------------------------------------I. Error Code #10. Termination of
sequence . FS11-GND
---------------------------------------I. Error Code #11. Control BD.
control relay problem.
---------------------------------------I. Error Code #12. Control BD.
hardware error.
---------------------------------------I. Error Code #13.
Full
conduction detected..
---------------------------------------I. Error Code #14. EEROM
error.
Possible electrical
disturbance causing invalid data
storage.
------------------Data/Schedule
Display E.r. 07.
------------------Data/Schedule
Display E.r. 08.
------------------Data/Schedule
Display E.r. 09.
------------------Data/Schedule
Display E.r. 10.
------------------Data/Schedule
Display E.r. 11.
------------------Data/Schedule
Display E.r. 12.
------------------Data/Schedule
Display E.r. 13.
------------------Data/Schedule
Display E.r. 14
FLASHING
E.r. 14 NONFLASHING
------------------Data/Schedule
Display E.r. 26.
-------------------
II. EERAM memory failure.
---------------------------------------I. Error Code #26. Contactor
short detected.
----------------------------------------
REMEDY
1. Wait for the Temperature Limit
Switch to cool, or check for open
circuit.
See section 4.1 and 5.2.
-----------------------------------------------1. Remove any connection to FS1
See section 4.0 and 5.2.
-----------------------------------------------1. Remove any connection to FS1
See section 4.0 and 5.2
-----------------------------------------------1. Return to Operate mode.
See section 2.1
-----------------------------------------------1. All initiations must be open at
power “on”.
See section 2.1, 4.0 and 5.2
-----------------------------------------------1. Remove any connection to FS1
See section 4.0, and 5.3
-----------------------------------------------1. Open TS1-FS3
See section 4.0, 5.2 and 5.3
-----------------------------------------------1. Open TS1-FS7
See section 4.0, 5.2 and 5.3
-----------------------------------------------1. Open TS1-FS11
See section 4.1, 5.2 and 5.3
-----------------------------------------------1. Replace Control Board.
-----------------------------------------------1. Replace Control Board.
-----------------------------------------------1. Change to higher welding
transformer tap.
-----------------------------------------------4. Follow procedure in section 4.2 and 6.2
of this manual.
1. Replace Control Board
See section 4.2
-----------------------------------------------1. Check contactor for short.
2. Check Firing Module 410319
3. Check L1 and L2 reversed or L2
missing.
------------------------------------------------
Page 35
710492
9.1 TROUBLE-SHOOTING
TROUBLE
Power On light will
not light.
-------------------------Control will not
initiate.
-------------------------Half cycle during
weld time.
POSSIBLE CAUSE
I. Fuse F1, type BBS
6/10, control
fuse blown.
REMEDY
1. Check that control is wired for
proper input line voltage. (H1,
H2, H3 and H4 and CTH1,
CTH2, CTH3 and CTH4
jumpers on customer terminal
strip).
II. Defective Power On light.
1. Replace Power On light.
III. Main welder disconnect open.
1. Check that fuse or circuit
breaker is of sufficient size for
KVA demand of welding
transformer.
IV. L2 wire to customer terminal
strip missing.
---------------------------------------I. Initiation switch(s) defective.
1. Add L2 wire
II. Loose or broken wire(s) at
initiation switch.
1. Check for loose or broken
wire(s) at initiation switch(s)
and at customer terminal
strip (FS3, FS7, etc.)
IV.
1. Replace board with another
board stamped with the same
assembly number.
----------------------------------------1. Check thyristor for open.
Replace.
Defective Control/Display
----------------------------------------I. Defective thyristor.
I.
Defective Terminal
Firing PCB.
Strip/
--------------------------------------1. Replace switch(s).
2. Check connections on PCB1-J3
and PCB2-J5 & J6.
3. Replace board. See wiring
diagram for correct assembly
number.
Page 36
9.1 TROUBLE-SHOOTING (cont.)
TROUBLE
Control sequences
but will not weld.
POSSIBLE CAUSE
REMEDY
I.
Weld/No-Weld Switch
front panel of control.
on
1. Check to see that the control is
in WELD
II.
Open Temperature Limit Switch.
1. Contactor overheated, causing
Limit Switch to open.
5. Defective Limit Switch.
Replace Limit Switch.
3. Connect jumper across TLS1 &
GND if TLS is not used.
III.
Welding transformer tap switch
in OFF position.
1. Set to “ON” or at one of the tap
positions.
IV. Welding transformer secondary
open. (Weld lamp may light.)
1. Check for corroded or open
connections. Be sure welding
electrodes close on work.
V.
Defective Terminal Strip/Firing
PCB.
1. Replace board. See wiring
diagram for correct assembly
number.
VI. Defective Control/Display PCB.
1. Replace board with another
board stamped with the same
Assembly Number.
VII. External Weld/No Weld on TS1NW1.
1. Make sure jumper exists
between TS1-NW1 and TS1GND.
VIII. No Data in Weld or % Current.
1. Put Data in Weld and/or %
Current.
Page 37
710493
9.1 TROUBLE-SHOOTING (cont.)
TROUBLE
Weld too cool or too
small.
------------------------"HOT" Welds
-------------------------Inconsistent Welds
POSSIBLE CAUSE
I.
Line voltage drop.
1. KVA demand for welding
transformer too high for input
power line.
II.
Excessive force at electrodes.
1. Check force setting.
III. Weld transformer set low.
1. Increase transformer tap setting.
IV. Weld Count too short.
1. Increase Weld Count duration.
V.
1. Increase value of Percent
Current.
Percent Current too low.
VI. Electrode face too large.
1. Select correct electrode face
diameter.
VII. Excessive electrode wear.
------------------------------------------I.
Low Force.
1. Properly dress electrodes.
------------------------------------------1. Check force at electrodes.
II.
1. Reset tap to lower setting.
Weld transformer set high.
III. Weld Count set too high.
1. Reduce Weld Count duration.
IV. Percent Current set too high.
1. Decrease value of Percent
Current.
V.
-------------------------------------------I.
Work not square with electrodes.
1. Dress or replace electrode with
proper size.
------------------------------------------1. Check welding fixtures set-up
or electrode alignment.
II.
1. Check parts for proper fit-up.
Electrode face too small.
Poor part fit-up.
III. Dirty material to be welded.
Page 38
REMEDY
1. Work should be free from excessive dirt, paint and oxides.
10.0 ENTRON LIMITED WARRANTY AND FACTORY SERVICE
ENTRON Controls, Inc., warrants that all ENTRON control panels, except silicon controlled
rectifiers (SCR's) and SCR assemblies, and circuit breakers, are free of defects for a period
of two years from the date of original purchase and, in the event of a manufacturing defect,
ENTRON will repair or replace, at its discretion, the defective part without any cost for parts
or labor.
All silicon controlled rectifiers, SCR assemblies, and circuit breakers in 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.
To obtain repairs or replacement parts under this warranty, the defective parts must be
returned to ENTRON Controls, Inc., 465 East Randy Road, Carol Stream, IL 60188.
Exclusions: This warranty does not cover damage by accident, misuse, unauthorized repair
or modification.
Use of out of Warranty repair service: To obtain service for any printed circuit board
assembly after two years from the date of purchase, send the assembly, prepaid, and $100.00
to ENTRON Controls, Inc., and ENTRON will repair the assembly and return it to you
without further warranty on its part.
Your ENTRON Controls, Inc., representative is always
available to assist you with your control or welding
problems.
Our sales representatives,
Original
Equipment Manufacturers, Dealers and Distributors are
always supported by direct factory assistance. Do not
hesitate to call for prompt, professional assistance, 630682-9600. There is no charge for this assistance.
Page 39
710494
Appendix “A”
Initiation Combinations
The control will initiate a programmed schedule when any of three initiation inputs FS3,
FS7, and FS11 is switched to GND. When closed, FS3 will initiate whatever Schedule is
shown on the control display. When closed, FS7 will initiate Schedule 10. When closed,
FS11 will initiate Schedule 20. All initiations will perform the sequence shown on page 3
of this manual, e.i. Squeeze, Preheat, Up Slope, etc.. to End Of Sequence.
Within the software of the control, these inputs are weighted (prioritized). By this we mean
if a higher order switch initiation is closed the switches weighted lower will be ignored. If
all three switches are closed, in succession, (3-11-7 or 11-7-3 or any combination) the
control will initiate the schedule associated with the highest order initiation switched, in this
case Schedule 20 (FS11), the highest order initiation.
There may be applications that require several heats being introduced to the material as the
weld progresses. An outstanding feature of the EN1501 is that the “next higher schedule”
can interrupt and replace a lower numbered initiation during the programmed Weld/Cool
time. FS3 can be interrupted by FS7 or FS11, likewise FS7 can be interrupted by FS11.
Release of a higher order switch, while the lower order switch is still made, will revert back
to the highest of the lower order initiations still closed and provide the Weld (or Weld/Cool
in the case of an intermittent seam) heat/time in the schedule associated with the closed
switch.
EXAMPLE:
If, after FS3 has been initiated and has reached the weld/cool portion of its program, the FS7
OR FS11 initiation switch is closed, the control will immediately jump to the weld/cool
portion of Schedule 10; (in the case of the FS7 initiation) or Schedule 20 (in the case of the
FS11 initiation).
If the FS3 switch is opened once the FS7 or FS11 is engaged, the control will continue
through the newly chosen schedule. If the FS3 switch is held closed the control will cycle
through the weld/cool portion of the newly chosen schedule until that switch is opened, at
which time the control will revert to the FS3 schedule and complete it.
If, after FS3 has been initiated and has reached the Weld/Cool portion of its program, and
the FS7 initiation is engaged the control will jump to and begin the weld/cool portion of
Schedule 10.
If, while the control is engaged in the Weld/Cool portion of schedule 10 and the FS11
initiation is engaged, the control will immediately jump to the weld/cool portion of the
Schedule 20 program. The control will continue to maintain the Weld/cool portion of the
FS11 (Schedule 20) until one of two things happens:
A. The FS11 initiation switch is opened, causing the control to revert to Schedule 10 (FS7,
as long as that initiation switch is being held closed), or FS3 (the schedule shown on
the display), if the FS3 initiation switch is held closed when the FS7 initiation switch
has been released.
A-1
710495
Appendix “A” - (cont.)
B. Both the FS3 and FS7 Initiation switches are opened, and FS11 switch is opened,
allowing the control to complete Schedule 20.
The flow chart below may assist in better understanding the capabilities of the control when
an application dictates the need for more than one heat.
A-2
Appendix “B”
ENTRON MICROPROCESSOR CONTROL
ISOLATION CIRCUITRY DESCRIPTION
ENTRON MODEL: EN1501 SERIES CONTROLS
The EN1501 Series of controls are microprocessor based resistance welding controls that
incorporate circuitry designed to prevent any output from the control due to "spurious"
conditions or failure of circuit components. The intent of this application note is to explain
how the circuitry accomplishes this isolation.
The main isolation is provided by electro-mechanical control relay contacts that are in series
with the solenoid valve voltage supply and the CONTACTOR firing circuitry. In a noninitiated state, the relay contacts are open and no output from these circuits is possible.
When the control is initiated by the physical closure of a normally open set of external
contacts (commonly a foot switch) across the initiation circuit, the relays are energized and
their contacts close and complete the circuits to the solenoid valve and the contactor. The
outputs are not actually energized, however, until the microprocessor reaches the point in
the sequence at which the valve or contactor outputs are to be activated.
There is no way to guarantee that any control circuit will be free of any component failure.
It is always necessary to take personal safety precautions when operating any machinery.
In addition to the relay contacts mentioned above, there are other levels of isolation. The
initiation signals first pass through a circuit comprised of opto-isolators before being passed
to the input circuitry of the microprocessor. The valve outputs are further isolated by the use
of optically coupled triac (solid state) outputs and the weld pulses are isolated by a pulse
transformer.
NOTE: Valve 3 (SV5/SV6) will not be isolated if jumper "B" is used on TS3. See diagram
on page B-2.
B-1
710496
Appendix B - (cont.)
B-2