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Transcript
INTRODUCTION OF EN1000/EN1001 SERIES CONTROLS ENTRON Controls, LLC. 1402 S. Batesville Road Greer, SC 29650 (864) 416-0190 FAX (864) 416-0195 www.entroncontrols.com [email protected] ENTRON Controls, LLC. offers over 40 years of experience in the design and manufacture of resistance welding controls to meet each customer’s application. Released 4/16/15 1 EN1000/EN1001 770015 Revision C Introduction to Series Single contactor and single phase microprocessor-based weld controls with or without constant current For firmware version 619016-002Z and Manual version 700120R 2 770015 Revision C Released 7/10/14 EN1000 Series Family Controls are part of the larger EN1000 Series Family Cascade Multiple Contactor Single Phase Controls Three Phase DC Control MFDC Control – OBSOLETE 3 EN1000/EN1001 770015 Revision C EN1000/EN1001 System RS232 Option Terminal Strip/ Firing Board 410319 – AC Valves 410319-011 – DC Valves J4 Sequence Control & Display Board 600541 – EN1000 600572-002 – EN1001 ENLINK 1000/1001 Software for PC RS232 – or – RS485 Option Initiations J2 J4 S485 – or – Pressure Switch Emergency Stop U485 J2 J3 Weld/ No Weld Valve 1-3 Outputs USB J4 J12 IPSC Option Proportional Valve J4 – or – Pressure Sensors S49 Option Control & Sense Transformers J4 Current Sense Coils SCR 50 Schedule Binary Select 4 EN1000/EN1001 770015 Revision C Introduction and Overview This slide show details the features of the EN1000/EN1001 Series Controls and shows how to properly operate the system. The EN1000/EN1001 Series Control is a microprocessor-based welding control which provides accurate, predetermined execution of welding schedules for specific number of cycles upon external command. Designed to operate in conjunction with a welding transformer rated for 60 or 50 Hz output frequency. Features Capabilities • • • • • • • • • • • • • • • Spot, Seam, Pulsation Sequences Upslope & Downslope Quench/Temper Forge Delay Multiple Weld/Multiple Current Sequence Preheat / Postheat External Schedule Select Process & Error Outputs Non-Repeat, Repeat, Chained, Successive Modes 50 Unique Schedules Weld and Valve Controls Relays 3 Valve Output Multiple Weld Programming Multiple Job Set-ups Control Panel layout permits quick access to all needed parameters • Diverse schedule capabilities provide maximum application versatility 5 EN1000/EN1001 770015 Revision C Standard Features • Digital Phase Shift Current Control – varies output waveform duty cycle from 0% to 99% in 1% increments • Function Timing – parameter timing programmed in 1 cycle steps; allows control to be used on either 50 Hz or 60 Hz power without special adjustment • Operating Conditions – Temperature Range: 0°C to 70°C (32°F to 158°F) • Power Supply Monitoring – whenever VCC power supply voltage goes below safe operating range, message displayed on DATA display • Pressure Switch Firing – Terminal Strip connection allowing initiation from Pressure Switch closure • Emergency Stop – Terminal Strip connection allowing control functions to be reset upon opening of Emergency Stop Switch • Valve Control Transformer – provides necessary voltage for powering welding machine solenoid valve(s) 6 EN1000/EN1001 770015 Revision C Control Panel Layout On EN1000 Control Panel layout, no added text for Constant Current modes Data Display Schedule Display 7 EN1000/EN1001 770015 Revision C Programmable Functions Schedules Extended Functions • Up to 50 schedules • Weld sequence may include more than one schedule • Program only desired control functions • Functions accessed using Control Panel parameters • Allow operator to change normal operation modes • Add various operating functions useful for special applications • Replaces Jumper or Dip-switch settings • Accessible from Control Panel • Visible in Schedule display See Extended Functions section for available functions and programming details 8 EN1000/EN1001 770015 Revision C Control Functions • • • • • Weld/No Weld Push Button Weld/No Weld Indicator LEDs Data Display Data Push Buttons Function Indicator LEDs o Squeeze (0 to 99 cycles) o Weld/Heat (0 to 99 cycles) o Percent Current (0 to 99%) o Hold (0 to 99 cycles) o Off (0 to 99 cycles) o Impulses (1 to 99) o Cool (0 to 99 cycles) o Valve Mode (see next slide) o Cycle Mode (see next slide) o Slope Mode (see next slide) o Slope Count (0 to 99 cycles) • • • • • • • • • • Select Push Button Power Light Weld Light Schedule Display Schedule Push Buttons Program/Operate Push Button Program/Operate Indicator LEDs Enter Push Button Valve Indicator LEDs Program Lockout Key Switch (optional) 9 EN1000/EN1001 770015 Revision C Control Functions – Modes Slope Mode Cycle Mode Valve Mode 10 EN1000/EN1001 770015 Revision C “S” Cabinet Installation 150/300 A Contactor Mounting 1200 A Contactor 11 EN1000/EN1001 770015 Revision C “E” Cabinet Installation Mounting 300 A Contactor 1200 A Contactor 1800/2200/3200 A Contactor 12 EN1000/EN1001 770015 Revision C “T/D” and “L” Cabinet Installation Mounting 1200 A Contactor 1800/2200/3200 A Contactor 13 EN1000/EN1001 770015 Revision C “C” Cabinet Installation Mounting 300 A 1200 A Contactor Contactor 14 EN1000/EN1001 770015 Revision C “B” Cabinet Installation Mounting 150/300 A Contactor EN1000 & EN1001 Controls are available in smaller “B” Cabinet. Terminal/Firing PCB and various operations are different from other cabinet styles. See Appendix E in Instruction Manual 700120 for detailed information. 15 EN1000/EN1001 770015 Revision C Flat Plate & IMU Flat Plate EN1000 & EN1001 Controls are available in component form – Flat Plate or Integrated Modular Unit (IMU). They can be used with retrofit, new or custom designs. 21x21 Flat Plate Integrated Modular Unit 11x11 Flat Plate 13x19 Flat Plate 16 EN1000/EN1001 770015 Revision C Welding Transformer Primary Wiring ! DANGER ! WHEN POWER IS ON, ALL EXTERIOR SURFACES OF IGNITRON TUBES OR SCRS CARRY HAZARDOUS VOLTAGES. CONTACT WITH THESE DEVICES MAY CAUSE SERIOUS OR FATAL INJURIES. For your convenience, many electrical and mechanical connections are performed at the factory. Check ALL electrical connections to ensure that all connections are tight. Connections may loosen during shipping. Connect L1 lead from incoming power to L1 connection located on contactor assembly. Connect H1 lead from welding transformer to H1 connection located on contactor assembly. Follow machine manufacturer’s recommended wire size for installation. A connection from L2 must be made to TS1-CTH4/L2 to provide power to control circuitry. Refer to Wiring Diagram for other connections. When control is supplied with circuit isolation device, L1 is factory installed and L2 control wire is connected to TS1-CTH4/L2. NOTICE Connect chassis ground to lug provided on right wall of cabinet and to external earth ground. A good earth ground is necessary for proper control operation. 17 EN1000/EN1001 770015 Revision C External SCR Contactor Wiring Connectors J5 and J6 are mounted on PCB2. NOTICE Do not over tighten J5 or J6. 18 EN1000/EN1001 770015 Revision C Contactor Specifications To help in selecting proper SCR contactor size for application, use following “rule of thumb” for sizing SCR contactors for various size transformers. Transformer KVA x 1000 x 3 = Maximum Current Demand AC Line Voltage Duty Cycle is percent of time weld current is on. A convenient formula for calculating Duty Cycle is: % Duty Cycle = Weld Time (in Cycles) x Number of welds per minute 36 19 EN1000/EN1001 770015 Revision C Cooling Requirements for Contactors Solid State Manufacturer’s Cooling Requirements 1200A – SCR Solid State Contactor 1800/2200/3200A – SCR Solid State Contactor } 1 GPM at 104°F (40°C) maximum inlet temperature WATER OFF – POWER OFF POWER ON – WATER ON 20 EN1000/EN1001 770015 Revision C Operating Voltage Control must be properly grounded at ground lug on the cabinet. Proper grounding is not only a safety precaution, it will lessen possibility of electrical interference being introduced into the control. ! CAUTION ! THIS WELDING CONTROL OPERATES ON SINGLE PHASE 208 VAC, 240 VAC, 380 VAC, 480 VAC OR 575 VAC. When welding control is shipped, the set voltage is marked on tag attached to control terminal block. ! WARNING ! THIS WELDING CONTROL IS MULTI-VOLTAGE UNIT WHICH CAN BE CHANGED FROM ONE VOLTAGE TO ANOTHER BY RE-ARRANGING JUMPERS ON TERMINAL STRIP INSIDE UNIT. IF CONTROL IS USED ON VOLTAGE OTHER THAN ONE FOR WHICH IT IS WIRED, SERIOUS DAMAGE CAN RESULT. 21 EN1000/EN1001 770015 Revision C Operating Voltage When control is converted from one line voltage to another, set voltage operation jumpers as shown. Jumpers on valve transformer must be configured to match line voltage. Use Jumper #1 for 480 VAC Use Jumpers #2 for 240 VAC For 380 or 575 VAC, contact factory ! CAUTION ! When external valve power is used (24-240 VAC), Valve Transformer MUST be disconnected at TS1-VL1 and TS1-VL2. Caution must be used to properly insulate wires from X1 and X2 leads after removing them from TS1. NOTICE Maximum current switched by solid state relays on Firing Board is 1A per valve. If more current is desired, valve circuit should be wired to external relay having suitable contact rating to switch desired valve. 22 EN1000/EN1001 770015 Revision C Fusing & Safe Operation CONTROL FUSE For “S”, “E”, “T/D”, and “L” Cabinets, this fuse (1/4 A) is used to protect control circuits. Fuse holder is located in upper left corner of contactor door opening or within “S” Cabinet. For “C” Cabinet, three 1.25 A fuses are used. L1, H2, and H1 connections are all protected. VALVE FUSES These fuses (2AG 1 A) are used to protect the valve circuits. Fuses are located on Terminal Strip PCB. IGNITOR FUSES These fuses (BAF 6 A – two per contactor) are used to protect ignitor circuits of ignitron tubes. Fuse holders are located on Ignitron Firing Board Module. ! CAUTION ! ! INSTALL PROPERLY SIZED FUSES IN SERVICE DISCONNECT SWITCH. CHECK WELDING MACHINE MANUFACTURER’S RECOMMENDATIONS. DANGER ! VOLTAGES PRESENT IN THIS CONTROL CAN CAUSE SEVERE OR FATAL INJURY. DO NOT SERVICE ANY COMPONENT WITH POWER ON. USE ONLY THE FUSE TYPE SPECIFIED TO MAINTAIN SAFE OPERATION. 23 EN1000/EN1001 770015 Revision C Precautionary Labels Observe the WARNING, DANGER and CAUTION labels affixed to the control to maintain safe operation. 24 EN1000/EN1001 770015 Revision C Terminal Strip TS1/PCB2 Board includes optional manufacturer of assembly with 24 VDC valves. 25 EN1000/EN1001 770015 Revision C Terminal Strip Connections Terminal Strip TS1 uses following connections: TS1-GND Common connection point for all other input connections – 6 GND terminals provided. TS1-FS1 Connect one side of First Stage of Two Stage Pilot Switch. TS1-FS3 Connect one side of Single Stage Pilot – OR – connect one side of Two Stage Pilot. TS1-FS7 When initiated via TS1-FS7/SS1, control will begin execution at schedule 10 – OR – connect one side of Two Stage Pilot – OR – along with TS1-FS11/SS3, functions as inputs to select schedules externally. TS1-FS11 When initiated via TS1-FS11/SS3, control will begin execution at schedule 20 – OR – connect one side of third Single Stage Pilot – OR – connect one side of Two Stage Pilot – OR – along with TS1-FS7/SS1, functions as inputs to select schedules externally. TS1-PS1 Connect one side of Pressure Switch. TS1-ES1 Connect one side of Emergency Stop Switch. TS1-NW1 Connect one side of External Weld/No Weld Switch. 26 EN1000/EN1001 770015 Revision C Terminal Strip Connections Terminal Strip TS1 uses following connections: TS1-TLS1/AUX1 Connect one side of Temperature Limit Switch. TS1-VL1 Connect one side of internal or external Valve Power (115 VAC internal or 24-240 VAC external*). TS1-SV2/SV4/VL2 Connect other side of Valve Power* and other side of Solenoid Valve 1 & 2 coils. TS1-SV1 Connect one side of Solenoid Valve #1 coil. TS1-SV3 Connect one side of Solenoid Valve #2 coil. TS1-SV5 Connect one side of Solenoid Valve #3 coil. TS1-SV6/VL2 Connect other side of Solenoid Valve #3 coil. ! CAUTION ! * When external valve power is used (24-240 VAC), internal Valve Transformer must be disconnected at TS1-VL1 and TS1-SV2/SV4/VL2. Properly insulate wires from X1 and X2 of Valve Transformer. 27 EN1000/EN1001 770015 Revision C Terminal Strip Connections Terminal Strip TS3 uses following connections: TS3-1 Used as other point for Jumper JA. TS3-2 Used as common point for Jumper JA or JB. TS3-VL1 Used as Valve Power Supply Input and other side of Jumper JB. TS3-VL2 Used as Valve Power Supply Input. Terminal Strip TS1 inside Cabinet 28 EN1000/EN1001 770015 Revision C Initiation EN1000 and EN1001 Controls are equipped with four weld initiation inputs and provide two basic weld initiations: Single Stage Pilot and Two Stage Pilot. Single Stage Pilot Initiation Connect Pilot Switch between TS1-FS3 and TS1-GND. Once control is initiated, switch need not remain closed. Initiation circuit is automatically latched until control has completed the sequence. Two Stage Pilot Initiation Connect First Stage between TS1-FS1 and TS1-GND; then connect Second Stage between TS1-FS3 and TS1-GND. First Stage activates solenoid valves programmed in selected schedule, but will not initiate sequence. Second Stage initiates sequence in schedule associated with chosen foot switch connection. Once control is initiated, FS1 does not need to remain closed. Initiation circuit is automatically latched to prevent re-initiation until after control has completed its sequence. 29 EN1000/EN1001 770015 Revision C Other Terminal Strip Inputs • Weld/No Weld Switch & Indicator LEDs • Pressure Switch – used to make control wait if required pressure has not been reached while in Squeeze interval. • Temperature Limit Switch – used to inhibit welding if temperature of switching circuitry is above rated operating temperature. • Emergency Stop Switch – when open, control stops any and all processes. 30 EN1000/EN1001 770015 Revision C Non-Volatile Memory Error When control is powered up or returns from Emergency Stop condition, it executes diagnostic test that reads all memory locations within schedule storage area. If invalid data is stored in memory, control will display flashing 32 in Data display and E.r. in Schedule display. Control will not sequence until error has been corrected. To recover from this condition: 1. Press SELECT push button to stop flashing. 2. Place control in PROGRAM mode. 3. Operator can use SELECT to find function containing invalid data. 4. Use DATA push buttons to correct data. 5. Press ENTER. 6. Return control to OPERATE mode. 31 EN1000/EN1001 770015 Revision C Non-Volatile Memory Error Reoccurring ERROR 32 may indicate electrical disturbances caused by improper wiring and routing of low and high voltage wires. Observe following precautions when installing welding control: 1. Make sure cabinet is properly grounded to power distribution system, nearby water pipe or other effective building ground with wire adequate for its application. 2. All wires connected to pilot input terminals on TS1 Terminal Strip should be separated as much as possible from other wires connecting to solenoid valves, welding transformers and AC line. These pilot input wires should never be run through same conduit with solenoid, welding transformer and AC line wires. NOTICE Avoid routing high and low voltage wires parallel to each other to eliminate coupling adjacent signals which may cause irregular operation. Wrong wiring and routing Better wiring and routing Best wiring and routing 32 EN1000/EN1001 770015 Revision C Isolation Circuitry EN1000 & EN1001 Series Controls incorporate circuitry designed to prevent any output from control due to spurious, unexpected, false conditions or failure of circuit components. Main isolation is provided by electro-mechanical control relay contacts in series with solenoid valve voltage supply and contactor firing circuitry. Other isolation levels include: • Initiation signals passing through circuit comprised of opto-isolators • Valve outputs isolated by use of optically coupled triac outputs • Weld pulses isolated by pulse transformer 33 EN1000/EN1001 770015 Revision C Programming The EN1000 or EN1001 Control is capable of storing and accessing up to 50 unique weld schedules. Programming allows the operator to enter and change parameters of weld schedules and subsequent storing of those parameters in non-volatile memory. Programming worksheets are available for development and documentation. Basically, programming requires selecting function to be programmed or modified, changing data (with Data display and push buttons) applicable to that function, and entering desired parameters into memory. 34 EN1000/EN1001 770015 Revision C Programming 1. Press and release PROGRAM/OPERATE push button. The PROGRAM LED will light up and the OPERATE LED will turn off. Only in PROGRAM mode does control allow changes to existing data or entering new data. 2. Select schedule to be entered or modified by using SCHEDULE push buttons until desired schedule number appears in SCHEDULE display. Left push button increments by ten, right push button increments by one. 3. Press SELECT push button to reach required function. The Function Indicator LEDs show which function may be entered or modified. DATA display shows current data stored for that function. 4. Use DATA push buttons to change data. Left push button increments by ten, right push button increments by one. For four-digit parameters, right push button affects two right-hand digits and left push button affected two left-hand digits. 5. Press ENTER push button to store data from DATA display into memory. As ENTER is pressed, DATA display will blink and then remain steady. Repeat steps above as required for remaining functions to be programmed. Remember to press ENTER push button to complete a programming step. If different function is selected before pressing ENTER, data shown in DATA display will be lost. 6. When all required functions for all required schedules have been programmed, put control in OPERATE mode by pressing PROGRAM/OPERATE push button, so that PROGRAM LED turns off and OPERATE LED turns on. 35 EN1000/EN1001 770015 Revision C Program Lockout Options A Program Lockout key switch can be ordered as factoryinstalled option or may be field-installed by customer. To install, remove key switch hole plug from Control Panel and mount switch using nut and lock-washer provided. Connect plug from switch onto mating 2-prong connector (J1) on back of Display Circuit Board. Put control in PROGRAM mode using Program Lockout key switch: Rotate key 45 degrees clockwise and hold; while holding key, press and release PROGRAM/OPERATE push button, then release key. The OPERATE LED will turn off and PROGRAM LED will turn on, indicating control can be programmed. Put control in OPERATE mode: Press PROGRAM/OPERATE push button. Control will return to OPERATE mode without necessity of rotating key. Error clearing using Program Lockout key switch: If Program Lockout key switch is installed, key is required to clear Error condition and reset control. 36 EN1000/EN1001 770015 Revision C Extended Schedule Parameters Beside standard schedule parameters, there are several extended parameters. The associated extended schedule parameters are accessed by using SELECT push button to choose main function and then clicking either SCHEDULE push button to access available extended parameters. * Available only if IPSC option is present. # See Stepper section for more detailed information. ** Available only in EN1001 Controls. See Constant Current section for more details. + See Constant Current section for programming information. 37 EN1000/EN1001 770015 Revision C Programming Shortcuts Quick Copy Schedule up to next Schedule 1. Put control in PROGRAM mode. 2. Press and hold ENTER. 3. Click SCHEDULE right push button. Displayed schedule is copied to next higher schedule. New schedule is now displayed. Clear data for displayed Schedule 1. Put control in PROGRAM mode. 2. Press and hold ENTER. 3. Click PROGRAM/OPERATE push button. Quick Copy Schedule up ten Schedules 1. Put control in PROGRAM mode. 2. Press and hold ENTER. 3. Click SCHEDULE left push button. Clear all Extended Functions 1. Remove all power to control. 2. Press and hold PROGRAM/OPERATE push button. 3. Reapply power to control. Displayed schedule is copied to that schedule number plus ten. New schedule is now displayed. 38 EN1000/EN1001 770015 Revision C Extended Functions Extended Functions allow operator to change normal operation modes and add various operating functions that are useful for special applications. 1 Extended Functions are accessed from Control Display Panel by clicking SELECT push button until Function Indicator LED reaches SLOPE COUNT, then click once more. 2 At this point, DATA display shows EF and all Function Indicator LEDs are off. This indicates control is in Extended Function mode. To exit Extended Function mode, press SELECT to advance Function Indicator LED one more time. 3 Pressing SCHEDULE push buttons will step through available Extended Functions. Programmed value of selected function is shown in DATA display. 39 EN1000/EN1001 770015 Revision C Extended Functions Available Extended Functions Designation I.d. S.E. S.S. C.C. C.A. b.S. P.O. b.E. 8.7. P.P. P.F. S.d. b.L. Description Identification Number Seam Welding Mode Schedule Select Automatic Voltage Compensation & Monitoring Clear All Functions Back-Step / Temperature Limit Switch Process Outputs Beat Operation Initiation Modes 87° Delay Manual Power Factor Programming Power Factor Measuring Squeeze Delay Blocking Delay (only if P.O.=07 ) Designation t.r. C.r. r.A. C.O. S.t. P.C. b.d. S.I. P.n. 40 Description } Available only for EN1001 using Constant Current } Available only if IPSC hardware is present Turns Ratio Constant Current Modes Range Current Offset Stepper Pressure Control Mode Background Pressure Sensor Input PIN Lockout Mode EN1000/EN1001 770015 Revision C Identification Number – I.d. Allows operator to assign unique identification number to individual controls. Programmable range is 01 to 64. Assigned identification number is shown in DATA display. Assigning unique identification number is necessary when control is equipped with RS485 Option to communicate to PC or any other device with RS485 interface. The device with RS485 interface is capable of communicating with up to 64 controls on common two-wire network. To program Identification Number for control: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find I.d. Enter desired value of I.d. using DATA push buttons. Press ENTER push button to save setting. 41 EN1000/EN1001 770015 Revision C Seam Welding Mode – S.E. This function sets control operation to either Spot or Seam mode. Following values are programmable: Value 00 01 02 03 x4 06 Description Spot Mode Seam Mode Adjust Current During Weld Seam/Spot Sequence Combination Delay Compensation Non-Beat Seam To program control for desired Seam mode: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find S.E. Enter desired value of S.E. using DATA push buttons. Press ENTER push button to save setting. 42 EN1000/EN1001 770015 Revision C Seam Mode – S.E.=01 A seam welder can be operated in one of two modes: Intermittent or Continuous. In either Seam mode, current starts synchronously upon initiation, remains on as long as pilot switch is closed, and stops synchronously when pilot switch is opened. Intermittent Seam Mode Continuous Seam Mode Weld current flows only for duration of Weld/Heat time setting and is off during Cool. Intermittent operation continues as long as initiation switch remains closed. Both Weld/Heat time and Cool time must be programmed for at least 1 cycle. Weld current flows continuously as long as pilot switch remains closed. Cool time is programmed to 00, and Weld/Heat time must be programmed for at least 1 cycle. ! WARNING ! Care MUST be taken to minimize overheating of internal components when in Seam mode. Correct transformer power dissipation (sizing) and welding control capability are essential to avoid component overheating. In Seam welding, the duty cycle is typically higher since weld current is flowing for more time. Use caution not to overheat transformer or control circuitry when in Seam mode. 43 EN1000/EN1001 770015 Revision C Other Seam Modes S.E.=02 – Adjust Current During Weld S.E.=x4 – Delay Compensation Allows change of Percent Current using DATA push buttons during welding sequence. Use DATA left push button to increase and DATA right push button to decrease Percent Current. Adds Delay before control starts to compensate or regulate current in Constant Current mode. Variable x indicates number of initial cycles during which compensation is delayed. S.E.=03 – Seam/Spot Combination S.E.=06 – Non-Beat Seam Initiation FS7 and schedule 10 will always be Spot sequence. Seam sequence is initiated with FS3 either in Continuous or Intermittent mode. Whenever FS7 is closed, control will jump from Seam to Spot sequence on schedule 10. Enables execution of fixed time weld using a number of repetitions in addition to alternating two heats within single schedule. ! Use Off function to program second Percent Heat; Impulses function is repetition factor for overall Weld time; Cool function will execute second Weld/Heat. CAUTION ! For S.E. parameter, do not enter value large than 06 except when programming Delay Compensation (S.E.=x4). 44 EN1000/EN1001 770015 Revision C Schedule Select – S.S. This function sets mode of Schedule Select and/or Initiation. Following modes are programmable: Value Description 00 Internal Schedule Select (panel-dialed) – Default 01 External Schedule Select (FS7/FS11) 03 S49 External Binary Schedule Select (optional – 50 non-panel, external schedules) To program control for desired Schedule Select mode: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find S.S. Enter desired value of S.S. using DATA push buttons. Press ENTER push button to save setting. 45 EN1000/EN1001 770015 Revision C Internal Schedule Select – S.S.=00 Dedicated Initiation Inputs for Internal Schedule Select TS1-FS3 initiates on any displayed schedule: 1.Select schedule using SCHEDULE push buttons. 2.Program selected schedule or sequence. 3.Use TS1-FS3 to initiate any schedule shown on Control Panel. TS1-FS7 automatically selects & initiates on schedule 10: NOTICE 1.Select schedule 10 using SCHEDULE push buttons. 2.Program schedule 10 (or sequence starting at schedule 10). 3.Use TS1-FS7 to initiate schedule 10 (or sequence starting at schedule 10). Regardless of schedule displayed on Control Panel, TS1-FS7 is dedicated to initiate ONLY on schedule 10. TS1-FS11 automatically selects & initiates on schedule 20: NOTICE 1.Select schedule 20 using SCHEDULE push buttons. 2.Program schedule 20 (or sequence starting at schedule 20). 3.Use TS1-FS11 to initiate schedule 20 (or sequence starting at schedule 20). 46 Regardless of schedule displayed on Control Panel, TS1-FS11 is dedicated to initiate ONLY on schedule 20. EN1000/EN1001 770015 Revision C External Schedule Select – S.S.=01 Dedicated Initiation Inputs for External Schedule Select 1. Select one of four schedules by external device or operator acting on TS1-FS7 and TS1-FS11 as shown in table. 2. Initiate selected schedule using TS1-FS3. NOTICE Operator cannot select schedules using Control Panel in OPERATE mode – can only initiate using TS1-FS3. Binary selects TS1-FS7 and TS1-FS11 must be closed before initiation of TS1-FS3 and be opened after sequence is started or completed. ! CAUTION ! When S.S. parameter is changed to S.S. =00, schedules 10 and 20 are cleared. 47 EN1000/EN1001 770015 Revision C External Schedule Select – S.S.=01 Dual Two-stage Foot Switches with External Schedule Select Use schedule 00 for foot switch #1 sequence and schedule 10 for foot switch #2 sequence. Foot switches and additional diode assembly (rated 1 A at 100 V) are connected to TS1 Terminal Strip. Multiple Two-stage Foot Switches with External Schedule Select Use schedule 00 for foot switch #1 sequence, schedule 10 for foot switch #2 sequence, schedule 20 for foot switch #3 and schedule 30 for foot switch #4. Foot switches and additional diodes are connected to TS1 Terminal Strip. 48 EN1000/EN1001 770015 Revision C External Binary Select – S.S.=03 The S49 Option must be present and connected to Control Board. Option consists of J4 ribbon cable, additional PCB with six binary schedule select inputs and Control Board. These six dry contact closure inputs make all 50 schedules remotely available to operator or machine process control system. Initiation inputs are dedicated as follows: 1. Select one of 50 schedules by external device or operator acting on TS12-SS1 through TS12-SS32. 2. Initiate sequence beginning with selected schedule using TS1-FS3. NOTICE Operator cannot select schedules using Control Panel in OPERATE mode – can only initiate sequence beginning with dialed schedule using TS1-FS3. Function of other two initiation inputs is unchanged – TS1-FS7 initiates only on schedule 10 and TS1-FS11 initiates only on schedule 20. 49 EN1000/EN1001 770015 Revision C External Binary Select – S.S.=03 Multiple Pilot Operation Allows multiple pilot switches to initiate multiple schedules using S49 Option. In External Binary Select mode, a switch closure between TS1-FS3 and TS1-GND initiates schedule externally selected via TS12-SS1 through TS12-SS32. Additional pilot circuits can be accomplished by the addition of diodes. Each pilot circuit will require at least two diodes and single pole, normally open, momentary type switch. The schedule selected by each new pilot switch is determined by adding schedule select values to which diodes are connected. Example shown in diagram uses SW7 to initiate schedule 07. Diodes are connected to SS1, SS2, and SS4. Adding together values (1+2+4) equals 7. SW15 will initiate schedule 15 as diodes are connected to SS1, SS2, SS4, and SS8. It is possible to connect more than one pilot circuit to same schedule select terminals; thus multiple pilots can initiate multiple schedules. 50 EN1000/EN1001 770015 Revision C External Binary Select – S.S.=03 Operation using Stepper When control is programmed for Stepper use, S49 Option automatically changes to select steppers directly. Schedule select inputs could be re-labeled: SS00, SS10, SS20, SS30, and SS40. Allows for automatic external selection of any of five available steppers and subsequent initiation. Only one input is necessary for each stepper as shown in table. This helps economize on PLC outputs otherwise necessary to select schedule for any of five steppers. Operation in Seam Mode S49 Option offers ability to switch from any schedule to any other schedule on the fly. Using Seam mode (S.E.=01) with External Binary Select (S.S.=03) allows control to be commanded on the fly to change heats as it welds during Seam weld sequence. This gives extreme flexibility since all 50 schedules can be selected automatically using a PLC or other dedicated input means. 51 EN1000/EN1001 770015 Revision C Automatic Voltage Compensation & Monitoring – C.C. This function sets Automatic Voltage Compensation (AVC), Automatic Voltage Monitoring (AVM), or both. There are two programmable ranges for this function available on controls with PROM firmware version 619016-002A or later. Original AVC settings (available on all controls) can be used only for compensation. Additional settings allow for monitoring and compensation or monitoring only. To program control for Automatic Voltage Compensation (AVC) or Automatic Voltage Monitoring (AVM): 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find C.C. Enter desired value of C.C. using DATA push buttons. Press ENTER push button to save setting. 52 EN1000/EN1001 770015 Revision C Automatic Voltage Compensation & Monitoring – C.C. Automatic Voltage Compensation uses a nominal set point value to determine whether line voltage is changing during idle periods between welds. AVC values must be set during a time when line voltage is at this nominal value. If nominal set point value is too low or too high compared to nominal voltage level, control will display E.r.=17 (too low) or E.r.=18 (too high). If either error occurs during programming, control will not enable AVC function. When AVC function is enabled, control monitors relative line voltage changes from nominal set point. When control is initiated, nominal relative voltage is compared to measured average values to make correction in firing angle used for weld to compensate for line voltage changes. For programmed values of 10 to 31, threshold values determine window within which error messages are not triggered. If line voltage surpasses threshold, control will display E.r.=19 (below low window) or E.r.=20 (above high window). To clear errors, simply press any push button. Several Process Outputs may be programmed for AVC and AVM. If either Error 19 or 20 occurs, control will respond depending on P.O. value: P.O.=12 Display error for 0.5 seconds and continue with sequence; Valve 3 is off P.O.=10,13,17 Display error, turn on Valve 3 for 0.5 seconds and continue with sequence P.O.=14 Display error, turn on Valve 3 and stop sequence 53 EN1000/EN1001 770015 Revision C Clear All Functions – C.A. This function clears all previously programmed Schedules and Extended Functions from memory and returns parameters to factory defaults. To use Clear All function: 1. 2. 3. 4. 5. 6. 7. 8. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find C.A. Enter value for C.A. of 01 using DATA push buttons. Press ENTER push button to clear all Schedule data. Enter value for C.A. of 02 using DATA push buttons. Press ENTER push button to clear all Extended Functions data. Press PROGRAM/OPERATE push button to return control to OPERATE mode. NOTICE ONCE CLEAR ALL FUNCTION IS EXECUTED, ERASED DATA CANNOT BE RESTORED. NOTICE After firmware updates in field, a one-time Clear All is required when upgrading to a new version of firmware on ALL older Control Boards. 54 EN1000/EN1001 770015 Revision C Back-Step / TLS – b.S. The Back-Step function adds flexibility while welding with Successive schedules. When active, this function steps back to previous schedule and allows operator to initiate on that schedule again while in midst of Successive sequence. Use normally open switch between TS1-TLS/AUX1 and TS1-GND as Back-Step input. To program control for Back-Step operation: 1. Put control in PROGRAM mode. 2. Use SELECT to find EF. 3. Use SCHEDULE push buttons to find b.S. 4. Enter value for b.S. of 01 using DATA push buttons. 5. Press ENTER push button to save setting. NOTICE If Back-Step remains active for more than 1.5 seconds, control will return to first schedule of Successive or Chained sequence and display flashing E.r.=06; Error Code will remain while Back-Step contact is held closed. 55 EN1000/EN1001 770015 Revision C Back-Step / TLS – b.S. To restore control for Temperature Limit Switch operation (default setting): 1. Put control in PROGRAM mode. 2. Use SELECT to find EF. 3. Use SCHEDULE push buttons to find b.S. 4. Enter value for b.S. of 00 using DATA push buttons. 5. Press ENTER push button to save setting. Using Both Temperature Limit Switch and Back-Step Function If Temperature Limit Switch is being used, it can be connected to TS1-NW1 and TS1-GND which is External Weld/No Weld input. If this switch is open, control will be in No Weld condition. NOTICE The Back-Step switch replaces TLS operation. Alternatively, Temperature Limit Switch should be connected in series with Water Flow Switch (WFS) or connect Temperature Limit Switch to External Weld/No Weld (NW1) while using Back-Step option. 56 EN1000/EN1001 770015 Revision C Process Outputs – P.O. Provides an output that can be used when operator or system needs feedback from specific parts of the welding sequence. Some Process Outputs may result in changes of control sequence, status, fault, or major or minor error conditions. These changes are intentional with objective of providing complete flexibility. To program any Process Output mode: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find P.O. Enter desired value using DATA push buttons (see next slide). Press ENTER push button to save setting. Valve 3 may be connected to shunt trip of circuit breaker. Using certain Process Outputs when shunt trip breaker is tripped, it is the same as removing power from control. ! WARNING ! Installation of Jumper JB between TS3-1 and TS3-VL1 will allow programming of Valve 3 output using Process Outputs. Exercise caution when programming since result of its activation could cause a personnel hazard. The Jumper between TS3-1 and TS3-VL1 is necessary to bypass the Valve Control Relay normally incorporated in standard operation of Valve 3. 57 EN1000/EN1001 770015 Revision C Process Outputs – P.O. Available Process Outputs Code Description 00 01 02 03 04 05 06 07 08 09 10 11 12 * 13 * 14 * 15 16 Process Output disabled ON during Weld ON during Weld and Hold ON during Hold ON during Off ON after Off until initiation is removed ON for 0.5 seconds after EOS Special Air-over-Oil Retraction Retraction mode Half Cycle Weld mode ON during any Error or control in No Weld or control in PROGRAM mode or control in Emergency Stop or if current out of limit window in Constant Current mode ON when Temperature Limit Switch is open Flash H.i./L.o. if current out of limit window Flash H.i./L.o. & Valve 3 ON for 0.5 seconds if current out of limit window Flash H.i./L.o. & break sequence if current out of limit window ON for Hardware Error or Control Relay Error ON for shorted SCR or L2 missing Error Code 17 18 19 20 22 * 23 * 24 * 25 * 26 * 27 * 28 * 30 31 Description ON for: TLS Error, Memory Error, AVC Errors, End of Stepper, etc. ON when SCR full conduction is detected ON during Weld only in Weld mode and closed NW1GND input on TS1 ON after Squeeze & during Weld (for welder interlock) Send HI/LO & current after out of limit window weld or last weld in sequence with RS232 or RS485 Option Send HI/LO & current if current out of limit window with RS232 or RS485 Option Flash & indicate H.i./L.o. if current out of limit window and show Current Indicate H.i./L.o. and EOS and show Current Flash H.i./L.o., stop sequence in Hold, holding part if current out of limit window Flash H.i./L.o., break sequence & Valve 3 ON for 0.5 seconds if current out of limit window Indicate EOS; Valve 3 ON for 0.5 seconds if current within limit window & control in Weld mode & closed NW1-GND input on TS1 ON if Error 36 (IPSC or IPS error) occurs ON if Error 36 (IPSC or IPS error) occurs at end of Weld * Available ONLY with EN1001 Controls 58 EN1000/EN1001 770015 Revision C Beat Operation Initiation – b.E. This function sets mode of Initiation. Following modes are programmable: Value 00 01 02 03 04 05 06 Description Non-Beat Initiation – Default Beat Initiation during Squeeze Beat Initiation during Squeeze and Weld b.E.=03 Mode – Faster Response Time Beat Initiation during Weld using NW1 Input b.E.=05 Mode – Allow programming of Cycle Mode 05 b.E.=06 Mode – External Stepper Reset To program control for desired Initiation mode: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find b.E. Enter desired value of b.E. using DATA push buttons. Press ENTER push button to save setting. 59 EN1000/EN1001 770015 Revision C Non-Beat Initiation – b.E.=00 Non-Beat Initiation is default (factory setting) mode. In this mode, once a sequence is initiated by momentary switch closure, it cannot be stopped unless Emergency Stop is opened. 60 EN1000/EN1001 770015 Revision C Beat Initiation during Squeeze – b.E.=01 Beat Initiation during Squeeze is typically used with transgun applications which may require operator or external source to terminate Squeeze time before entering Weld period, allowing operator to check tip placement before welding. If placement is not correct, initiation can be interrupted and sequence can be terminated; operator can then reposition tip. NOTICE If initiation is opened during Weld or Hold period, sequence will not be interrupted. NOTICE To emulate Two Stage Pilot, Single Stage Pilot may be used in this mode of non-interlocked Squeeze time. If Pilot is opened during Squeeze, control will immediately stop sequence. Once Weld time begins, control interlocks pilot circuit and completes sequence. Allow enough Squeeze time for operator to check alignment during Squeeze and open pilot circuit before Weld time begins, allowing operator time to reposition part if alignment is not proper. 61 EN1000/EN1001 770015 Revision C Beat Initiation during Squeeze & Weld – b.E.=02 Beat Initiation during Squeeze & Weld is typically for brazing applications. It provides same functions as Beat Initiation during Squeeze with addition of ability to terminate weld sequence before Weld time has elapsed. If operator opens initiation during Weld time, Weld time is interrupted and control immediately advances to Hold time. If initiation switch remains closed, control will weld normally until end of programmed schedule. This flexibility is required for brazing parts with differing characteristics that require different weld times. The Weld time must be set for the longest time required to bring parts to required brazing temperature. 62 EN1000/EN1001 770015 Revision C b.E.=03 Mode Using this mode, control will have faster response time after Emergency Stop or power-up, without redundant checking schedule data validity and eliminating all self-checking delays. This mode was added in PROM firmware version 619016-002J. It does not affect initiation and control will operate, after closing initiation, exactly the same as in default Non-Beat mode, except that control will be ready for initiation much faster. Faster initiation after closing Emergency Stop input may be very useful when light curtain is used. Using this mode, control will run a faster internal self-check after reset, reducing time control requires to go from Emergency Stop condition to Ready To Operate condition. This time will range from 30ms to 60ms maximum. Main reason for this mode is for machine control systems that use TS1-ES1 and TS1-GND terminals to disable weld control between initiations. Using this mode does not affect Beat operation. 63 EN1000/EN1001 770015 Revision C Other b.E. Modes Beat Initiation during Weld using NW1 Input – b.E.=04 This mode enables control to stop welding and jump immediately to Hold without executing remaining Weld part of sequence when Weld/No Weld input (NW1-GND) is open. b.E.=05 Mode This mode allows programming of Cycle Mode 05. It was added in PROM firmware version 619016-002P. Using this mode does not affect initiation and control will operate, after closing initiation, exactly the same as in default Non-Beat mode. b.E.=06 Mode This mode is used for External Stepper Reset with momentary push button-type switch connected between TS1-ES1 and TS1-GND input. It was added in PROM firmware version 619016-002S. Using this mode does not affect initiation and control will operate, after closing initiation, exactly the same as in default Non-Beat mode. 64 EN1000/EN1001 770015 Revision C 87° Delay – 8.7. This function helps prevent the build-up of a DC component in welding transformer which may be damaging. Value of 00 disables this function. Value of 01 enables this function (default setting). To program control for this function: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find 8.7. Enter desired value of 8.7. using DATA push buttons. Press ENTER push button to save setting. NOTICE 87° Delay function is only operational when control is in Manual Power Factor mode. 65 EN1000/EN1001 770015 Revision C Manual Power Factor – P.P. This function either sets Automatic Power Factor mode or allows programming of Manual Power Factor if required. Value of 00 sets control to Automatic Power Factor mode (default). Value of 01 to 99 sets control to Manual Power Factor mode and programmed Power Factor is specified value. To program control for this function: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find P.P. Enter desired value of P.P. using DATA push buttons. Press ENTER push button to save setting. NOTICE When using EN1001 Control in Constant Current mode, both Automatic Power Factor and Constant Current function will compensate current. When control operates under poor power factor and low Percent Current output situation, Manual Power Factor should be set to 99% (P.P.=99) to obtain better performance. 66 EN1000/EN1001 770015 Revision C Power Factor Measuring – P.F. EN1000 and EN1001 Controls are in Automatic Power Factor mode when shipped from factory. Calibration of automatic power factor circuit is not required, having two benefits: 1. It is not necessary to make manual adjustments when installing control, to match its circuitry to Power Factor of welding machine. 2. It assures that maximum welding current, for any welding transformer tap switch setting, will occur when selected Percent Current is 99%. For some applications, Automatic mode can be disabled and machine Power Factor can be set manually using Manual Power Factor Programming function. Machine’s Power Factor can be determined when in Automatic Power Factor mode as follows: 1. 2. 3. 4. Use SELECT to find EF. Use SCHEDULE push buttons to find P.F. Make a weld. Machine’s Power Factor will be shown in DATA display. This value can be programmed in P.P. function. NOTICE When measuring Power Factor, the displayed Power Factor corresponds to last weld made by control. 67 EN1000/EN1001 770015 Revision C Squeeze Delay – S.d. Squeeze Delay is a pre-squeeze which energizes schedules valves for programmed interval of time. It occurs after initiation and immediately before first Squeeze is executed (a form of retraction to position electrodes closer to work in Repeat sequence). The length of time added to Squeeze time is measured in cycles (60 cycles = 1 second). After initiation on any of the pilot switches, control’s display will dim slightly indicating control is in Squeeze Delay and return to regular intensity for programmed Squeeze time. To program control for this function: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find S.d. Enter desired value of S.d. using DATA push buttons. Press ENTER push button to save setting. NOTICE Squeeze Delay occurs only before first Squeeze time when in Repeat mode. 68 EN1000/EN1001 770015 Revision C Blocking Delay – b.L. This output enables user of air-over-oil gun to have programmed partial retraction in middle of sequence. The output may be turned off by momentarily opening Emergency Stop terminals TS1-ES1 and TS1-GND. Blocking Delay is interval of time that occurs immediately before (overlapping) the programmed Off time. When P.O.=07 and delays have been programmed properly, Valve 3 output will turn on during programmed Off time, starting at end of Blocking Delay time. It will remain on after current sequence until next initiation occurs. If programmed Off interval is shorter than programmed Blocking Delay interval, programmed Off will not occur. If programmed Off interval is longer than Blocking Delay, resulting Off time will be programmed Off time minus Blocking Delay time. This means that Blocking Delay overlaps Off which happens only in sequence of schedules ending with Cycle Mode of 00, 01 or 03. To program control for this function: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find b.L. Enter desired value of b.L. using DATA push buttons. Press ENTER push button to save setting. 69 EN1000/EN1001 770015 Revision C Available only for EN1001 using Constant Current Turns Ratio – t.r. This function is used to set Turns Ratio of transformer. The Turns Ratio is necessary when control is set to Primary Constant Current mode. When control is set to Primary Constant Current Compensation or Monitoring mode, control only measures primary current from sensor, and then calculates secondary current using following equation: Secondary Current = Primary Current x Turns Ratio of transformer The range of programmable values is 10 – 255. To program control for this function: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find t.r. Enter desired value of t.r. using DATA push buttons. Press ENTER push button to save setting. 70 EN1000/EN1001 770015 Revision C Constant Current Modes – C.r. Available only for EN1001 using Constant Current This function is used to select desired Constant Current mode and Current Sensor. There are two modes – Compensation (both monitoring & compensation) and Monitoring (only monitoring, no compensation). Current Sensor choices are Primary Sensing with Current Transformer and Secondary Sensing with calibrated Rogowski Coil. To program control for Constant Current operation: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find C.r. Enter desired value of C.r. using DATA push buttons. Press ENTER push button to save setting. EN1001 Controls in Constant Current mode can access H.i. and L.o. Extended parameters to set specific current limits. 71 EN1000/EN1001 770015 Revision C Available only for EN1001 using Constant Current Range – r.A. This function is used in Constant Current mode to set Range of control’s secondary current. The value of r.A. should be as close to maximum secondary current as possible. To program Range on EN1001 Control in Constant Current mode: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find r.A. Enter desired value of r.A. using DATA push buttons. Press ENTER push button to save setting. NOTICE The value of r.A. should be as close to maximum secondary current as possible. Since control will automatically adjust embedded amplifier’s gain according to value of r.A., improper setting will cause overshooting or poor compensation quality during current compensation process. 72 EN1000/EN1001 770015 Revision C Current Offset – C.O. This function provides current adjustment in either kA or % in OPERATE mode without going into PROGRAM mode. An adjustment limit window is set within which weld current can be changed. There are two Current Offset modes: 1. Current Offset for Single Displayed Schedules – Current change only affects displayed schedule. 2. Current Offset for All Schedules – Current change will affect all programmed schedules. To program Current Offset limits: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find C.O. Enter desired value of C.O. using DATA push buttons. Press ENTER push button to save setting. Next slide will explain range of programmable values for Current Offset function 73 EN1000/EN1001 770015 Revision C Current Offset – C.O. Current Offset for Single Displayed Schedules Range of programmable values: C.O.=00 C.O.=01 to 19 Current Offset is disabled Current Offset is enabled for Single Displayed Schedule Values of 01 to 19 are in units of percent and sets maximum and minimum Offset limits for programmed Current, allowing Current change within these limits while in OPERATE mode. Current Offset for All Schedules Range of programmable values: C.O.=20 C.O.=21 to 39 Current Offset is disabled Current Offset is enabled for Single Displayed Schedule Values of 21 to 39 set maximum and minimum Offset limits for programmed Current, allowing Current change within these limits while in OPERATE mode, as follows: C.O.=21 C.O.=22 C.O.=23 C.O.=24 C.O.=25 C.O.=26 C.O.=27 C.O.=28 C.O.=29 Current Offset for All Schedules ±1% Current Offset for All Schedules ±2% Current Offset for All Schedules ±3% Current Offset for All Schedules ±4% Current Offset for All Schedules ±5% Current Offset for All Schedules ±6% Current Offset for All Schedules ±7% Current Offset for All Schedules ±8% Current Offset for All Schedules ±9% C.O.=30 C.O.=31 C.O.=32 C.O.=33 C.O.=34 C.O.=35 C.O.=36 C.O.=37 C.O.=38 C.O.=39 Current Offset for All Schedules ±10% Current Offset for All Schedules ±11% Current Offset for All Schedules ±12% Current Offset for All Schedules ±13% Current Offset for All Schedules ±14% Current Offset for All Schedules ±15% Current Offset for All Schedules ±16% Current Offset for All Schedules ±17% Current Offset for All Schedules ±18% Current Offset for All Schedules ±19% 74 EN1000/EN1001 770015 Revision C Current Offset – C.O. Using Current Offset This function is very useful when a Program Lockout key switch is used. An operator may change current without changing any other welding parameters and without going into PROGRAM mode. Operator may increase operating Percent Current only up to Base Current plus Current Offset or decrease operating Percent Current down to Base Current minus Current Offset. To change programmed Current within Offset limits in OPERATE mode: 1. Click SELECT until Function Indicator LED stops at PERCENT CURRENT. 2. Use DATA push buttons to increase or decrease Percent Current by pressing or holding either push button. 3. Press ENTER only for Constant Current mode in kA. For Constant Current mode in % or for Non-Constant Current mode, data will be stored immediately after pressing either DATA push button. NOTICE If value greater than allowed by maximum Current Offset is programmed, control will store and display maximum Percent Current allowed. If value lower than allowed by minimum Current Offset in programmed, control will store and display minimum Percent Current allowed. 75 EN1000/EN1001 770015 Revision C Current Offset – C.O. Changing Base Current To change Base Percent Current, simply program schedule as done normally by switching to PROGRAM mode and following normal programming procedures. In PROGRAM mode, display will flash between Base Current and Offset Current value. Percent Current is only weld schedule parameter that is changed whenever Current Offset value is used. Current Offset Indication In PROGRAM mode, when Percent Current is displayed, control will flash if Current Offset is active. The programmed Base Current is indicated simultaneously with Schedule Number. The Offset Current is indicated simultaneously with C.O. in SCHEDULE display plus either S. (Single Displayed Schedule) or A. (All Schedules) in DATA display (when in Non-Constant Current mode) along with programmed Offset Current value. The ENTER push button can be depressed while either of the two values are displayed. Pressing ENTER will move Offset Current value into Base Percent Current value. Base Current value also may be changed by pressing or holding DATA push buttons and then pressing ENTER. 76 EN1000/EN1001 770015 Revision C Stepper – S.t. Stepper function is explained in detail during Stepper Operation section of slide show To program control to disable/enable Stepper: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find S.t. Enter desired value of S.t. using DATA push buttons. Press ENTER push button to save setting. 77 EN1000/EN1001 770015 Revision C Available only if IPSC hardware is present IPSC Hardware Functions If IPSC Hardware is installed in control, the following Extended Functions are available. Pressure Control Mode – P.C. This function activates any pressure sense control mode with rising or falling trigger: Pressure in PSI Force in lb Current in mA Background (Return) Pressure/Force/Current – b.d. This function sets background pressure/force/current required to return cylinder or return working rod. It is necessary to program this function when using IPSC or IPC system options. Sensor Input– S.I. This function shows pressure/force/current input from Pressure Sensor on DATA display. It only appears when using IPSC or IPC system options. It is not programmable. See Instruction Manual 700178 for detailed information on IPSC system options 78 EN1000/EN1001 770015 Revision C PIN Lockout Mode – P.n. This function was added in PROM firmware version 619016-002N and does not require any hardware change or additional option. Enabling PIN Lockout To enable PIN Lockout mode, a 4-digit PIN number must be programmed: 1. 2. 3. 4. 5. 6. 7. 8. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find P.n. Enter desired PIN from 0001 to 9999 using DATA push buttons. Press ENTER push button to save setting. Program all other desired Schedule or Extended Function parameters. Put control back in PROGRAM mode. After PROGRAM/OPERATE push button is released, control will flash L.o.c. on DATA display, which indicates PIN Lockout mode is enabled. Control is now locked from going into PROGRAM mode. 79 EN1000/EN1001 770015 Revision C PIN Lockout Mode – P.n. Unlocking Control Using PIN To go into PROGRAM mode when control is locked, correct PIN must be entered: 1.Use SELECT to find EF. 2.Use SCHEDULE push buttons to find P.n. DATA display will show 0000 as programmed PIN is hidden. NOTICE Whenever PROGRAM/OPERATE push button is pressed while control is locked, DATA display will flash P.i.n. for 0.5 seconds, PROGRAM LED will also flash, and control will go immediately to Extended Function parameter P.n. 3.Enter PIN using DATA push buttons. 4.Press ENTER push button. After this push button is released: • If correct PIN is entered, DATA display will flash u.L.o.c. and control will go immediately into PROGRAM mode. • If incorrect PIN is entered, DATA display will flash O.o.P.S. 5.After programming all desired Schedule or Extended Function parameters, new PIN may be entered or current PIN will be applied when control is put back in OPERATE mode. 80 EN1000/EN1001 770015 Revision C PIN Lockout Mode – P.n. Disabling PIN Lockout To disable PIN Lockout mode or delete PIN, clear all Extended Functions data by using Clear All function with C.A.=02 or by pressing and holding PROGRAM/OPERATE push button during power-up or after Emergency Stop reset. This may also be very useful whenever PIN is forgotten or lost. NOTICE Control is shipped from factory with PIN Lockout mode disabled. 81 EN1000/EN1001 770015 Revision C General Operating Instructions For customer’s convenience, many electrical and mechanical connections have been performed at factory. Refer to appropriate Wiring Diagram for other connections. Be sure ALL electrical connections are properly made and that all fittings are securely tightened. Loose electrical connections can cause faulty or erratic operation of control or welding machine. If machine is air operated, turn on air supply to machine. Set air pressure in accordance with machine manufacturer’s recommendations. Be sure that welding machine heads are fully retracted. Turn on main power. The SCHEDULE and DATA displays will turn on at this time. Place control in No Weld mode. Use either Control Panel Weld/No Weld push button or External Weld/No Weld Switch connected to Terminal Strip between TS1-NW1 and TS1-GND. 82 EN1000/EN1001 770015 Revision C Weld Sequence Example Program simple single Spot schedule as follows: Squeeze Weld/Heat Percent Current Hold Off Impulses Cool Valve Mode Cycle Mode Slope Mode Slope Count ! 30 to 60 cycles 12 to 25 cycles 50 to 60% 10 to 15 cycles 00 cycles 01 (no Impulses) 00 cycles 01 (Valve 1) 00 (Non-Repeat) 00 (no Slope) 00 cycles CAUTION ! KEEP HANDS, ARMS, OTHER PORTIONS OF BODY, CLOTHING, AND TOOLS AWAY FROM MOVING PARTS OF MACHINE. 1. Initiate control. If using Two Stage Pilot switch, depress First Stage only. Programmed valve will activate. Control will not sequence. Be sure that electrodes have closed together prior to depressing Second Stage. 2. Control will sequence but will not weld, then head or arms will retract. On Single Stage operation, closure of pilot switch will cause control to sequence. On footoperated machines only, switch on mechanical linkage will initiate sequence. 3. Program schedule for part to be welded. Place work in machine and set Weld/No Weld switches to Weld position. Machine is ready to weld. 4. If no standards have been set, it is recommended to use short Weld count for initial setup and welding. Weld count can be increased, Percent Current can be adjusted, and welding transformer tap can be increased for best weld. The most efficient use of control and welding machine will generally be at lowest welding transformer tap, highest Percent Current, and shortest Weld count. 5. For Repeat operation, program Cycle Mode to 01 and Off count to allow sufficient time to reposition part for subsequent welds. 83 EN1000/EN1001 770015 Revision C Cycle Modes Non-Repeat – Cycle Mode=00 Repeat – Cycle Mode=01 84 EN1000/EN1001 770015 Revision C Cycle Modes Chained – Cycle Mode=02 Successive – Cycle Mode=03 85 EN1000/EN1001 770015 Revision C Cycle Modes Conditional Successive – Cycle Mode=04 This mode combines benefits of both Chained and Successive sequences. Control will execute given schedule, and at end of Hold will maintain schedule valves active. Control will wait in this state indicated by blinking HOLD LED. If control is initiated a second time, when initiation input closes, control will continue by selecting next schedule and executing programmed schedule. Wait-Here – Cycle Mode=05 This mode has been implemented to satisfy additional requirements for more complicated machine sequencing. ! CAUTION ! Use Wait-Here mode with full understanding of machine and control operation. Enabling of b.E.=05 has been added to help ensure this operation is really required. Control will execute schedule sequence, wait either in Squeeze or Weld/Cool or Hold part of sequence, depending on programmed data, and maintain schedule valves active indefinitely. Sequence can be stopped by activating Emergency Stop or TLS input or can continue with FS7 or FS11 initiation. To determine where control will wait, corresponding Schedule parameter must be programmed to 99 – Squeeze, Impulses (for Weld/Cool), or Hold. 86 EN1000/EN1001 770015 Revision C Slope Modes No Slope – Slope Mode=00 In this mode, Slope is disabled. Output of welding transformer may look like natural Upslope waveform. Welding transformer secondary load characteristics will affect rate at which this occurs. Upslope – Slope Mode=01 When control is initiated in this mode, Upslope will occur before Weld. In Repeat or Pulsation mode, Upslope will only occur before first weld impulse. In Intermittent or Continuous Seam mode, Upslope will only occur when first initiated. Downslope – Slope Mode=02 When control is initiated in this mode, Downslope will occur after Weld. In Repeat or Pulsation mode, Downslope will only occur after last weld impulse. In Intermittent or Continuous Seam mode, Downslope will only occur when last initiation with programmed Downslope is removed. 87 EN1000/EN1001 770015 Revision C Valve Modes Each programmed schedule can have any one of three valve outputs (or none) enabled. When in PROGRAM mode and selection of Valve Mode is being made, the VALVE Indicator LEDs will indicate selected valve(s). The valve output(s) will not be energized while in PROGRAM mode. NOTICE The Valve Modes indicated within valve selection chart may differ with use of Process Outputs. See Process Output section when using Valve 3 as Process Output indicator. 88 EN1000/EN1001 770015 Revision C Stepper Operation The weld stepper can compensate for gradual deformation of welding machine’s electrodes which occurs because of repeated application of heat and pressure to relatively soft electrode material, resulting in broadening of electrode face (mushrooming) with continued usage. Increasing face diameter results in decreasing current density, which eventually reaches a point where satisfactory welds can no longer be made. The weld stepper increases number of satisfactory welds by increasing welding current in steps as mushrooming progresses. This maintains current density fairly constant for a relatively large number of welds. The stepper can be programmed to not only change weld current, but also weld time and even complete welding schedule if desired. Up to five steppers may be programmed on EN1000/EN1001 Controls with PROM firmware 619016001R or later. Each stepper may have up to maximum of ten steps, and each step may be programmed from 0000 to 9999 welds. The stepper can also be programmed to provide an electrical output after last step to sound an alarm to alert operator that electrodes need to be re-dressed or replaced. After end of last step, stepper can be reset manually or automatically. Each stepper may also be used as simple weld count down-counter. Counter will be decremented during welding sequence only if weld was made. 89 EN1000/EN1001 770015 Revision C Stepper Schedule Map Stepper mode 01 Since up to ten steps may be programmed per stepper, ten schedules are assigned for each stepper as shown in schedule map. Stepper mode 02 NOTICE In PROM firmware version 619016-002P, a new Stepper mode was added – S.t.=02 – for single stepper counter with multiple steps and any possible schedule sequence combination. Same schedule map is used, except that only one stepper counter exists with all schedules from 00 to 49, with maximum of 50 steps. 90 EN1000/EN1001 770015 Revision C Stepper Programming Stepper Enable Programming To program control to disable/enable Stepper: 1. 2. 3. 4. 5. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find S.t. Enter desired value of S.t. using DATA push buttons. Press ENTER push button to save setting. 91 EN1000/EN1001 770015 Revision C Stepper Programming Weld Sequence Programming 1.Put control in PROGRAM mode. 2.Using standard programming procedure, program all weld sequence parameters for first schedule for desired stepper. 3.Copy current schedule to next one and repeat as many times as number of steps needed for stepper, using Copy Schedule shortcut. 4.Percent Current and Weld/Heat must be adjusted in each step after first one. 5.Put control in OPERATE mode. 92 EN1000/EN1001 770015 Revision C Stepper Programming Step Counts Programming 1.Using SCHEDULE push buttons, set first schedule for desired stepper. 2.Put control in PROGRAM mode. 3.Use SELECT push button until WELD/HEAT parameter is reached. 4.Program required Weld time for sequence. 5.Press SCHEDULE push buttons to find first schedule for desired stepper. 6.Program required Weld Count for this step. 7.Click SELECT push button to find PERCENT CURRENT and program required Percent Current for this step. 8.Put control in OPERATE mode. 9.For programming all other steps, increase schedule number and repeat Steps 2 through 8. 93 EN1000/EN1001 770015 Revision C Stepper Programming Last Step & Last Count Programming 1.Using SCHEDULE push buttons, select any schedule from schedule map for desired stepper. 2.Put control in PROGRAM mode. 3.Use SCHEDULE push buttons to find L.S. in SCHEDULE display. 4.Program desired Last Step for this stepper. This value is first step at beginning of weld sequence. 5.Press SCHEDULE push buttons to find L.C. in SCHEDULE display. 6.Program desired Last Count for this stepper. This value is first count at beginning of weld sequence. 7.Put control in OPERATE mode. 94 EN1000/EN1001 770015 Revision C Stepper Quick Setup 1. 2. 3. 4. 5. 6. 7. Put control in PROGRAM mode. In Extended Functions (EF), set S.t.=01. Select desired starting schedule (00, 10, 20, 30, or 40). Program all Schedule parameters. Press SELECT push button, moving Function Indicator LED to WELD/HEAT parameter. Select first weld step for schedule by pressing SCHEDULE push buttons until desired weld step is displayed. Program required Weld Count for this step as follows: a. Press and hold left DATA push button to enter 1000s digit. b. Press and release quickly left DATA push button to enter 100s digit. c. Press and hold right DATA push button to enter 10s digit. d. Press and release quickly right DATA push button to enter 1s digit. e. Press ENTER and then press SELECT push button. 8. Copy this schedule by pressing and holding ENTER and right SCHEDULE push button. Repeat copying of this schedule for as many steps needed for that stepper. 9. Change each schedule’s Weld/Heat and/or Percent Current as required. 10. Return to starting schedule. Reset stepper by pressing and holding ENTER and pressing both DATA push buttons simultaneously. 11. Put control in OPERATE mode and begin welding. 12. Return to the first starting schedule. After all weld steps are complete, control will stop and display S.t. E.n.d. NOTICE When using S.t.=02 with multiple steppers, all steppers must be reset. To reset stepper, repeat steps 10 and 11. Control must be in PROGRAM mode for step 10. 95 EN1000/EN1001 770015 Revision C Schedule Select Options for Stepper Mode 01 Internal Schedule Select Each of five steppers can be initiated with FS3 initiation switch. In addition to FS3 initiation, stepper B can be initiated with FS7 and stepper C can be initiated with FS11. External Schedule Select Only four steppers can be initiated with FS3 initiation switch. This is possible only if FS7 and FS11 are used for stepper selection. External Binary Select with S49 Option Any of five steppers can be initiated with FS3 initiation switch. Stepper selection is possible with closing one of SS1, SS2, SS4, or SS8. 96 EN1000/EN1001 770015 Revision C Schedule Select Options for Stepper Mode 02 NOTICE Stepper counter will be decremented only if FS3 is used for initiation. When either FS7 or FS11 is used for initiation in Stepper mode 02, stepper counter will not be decremented, and control will execute welding sequence starting with schedule 10 or 20, respectively. When S49 Option is used for External Binary Select after FS7 initiation, control will execute any selected schedule, instead of schedule 10. 97 EN1000/EN1001 770015 Revision C Operation Algorithm Operation Algorithm for Stepper Mode 01 This algorithm explains operation for Stepper mode 01. Operation for Stepper Mode 02 Maximum number of steps is 50, which is possible only if one single schedule is used per step. If chained schedules are required in welding sequence, number of steps is determined by number of chained schedules used in each step. Algorithm for Stepper mode 02 is almost identical to one pictured, except that only one stepper counter is used and when Last Step is incremented, control will check if that number is greater than maximum number of schedules, and then show End Of Stepper message, if necessary. Also, stepper counter will be decremented only if FS3 is used for initiation. 98 EN1000/EN1001 770015 Revision C Stepper Reset Manual Stepper Reset 1. 2. 3. 4. Select any schedule from schedule map for desired stepper. Put control in PROGRAM mode. Press and hold ENTER push button. While holding ENTER push button, press both DATA push buttons at same time and hold momentarily. After this, Last Step and Last Count parameters will be initialized with appropriate values programmed for first step. Stepper will be reset only if all three push buttons are properly pressed. After reset, both initialized parameters will be displayed on SCHEDULE and DATA displays for a short period of time. These two parameters may be reprogrammed by entering desired values and pressing ENTER, at any time, without resetting stepper using all three push buttons. Put control in OPERATE mode. NOTICE Stepper Reset may be performed not only by holding ENTER and pressing both DATA push buttons at the same time, but also by manual programming of Last Step and Last Count parameters for corresponding stepper. 99 EN1000/EN1001 770015 Revision C Stepper Reset Automatic Stepper Reset Stepper can be automatically reset by adding Reset command using an additional schedule after Last Step. The Reset command is simply an empty schedule – no parameters except for Off time. If stepper counter reaches zero on Last Step, control will read next schedule. Finding Reset command, control will reload stepper automatically. Any new sequence will start again on first step. To enable automatic Stepper Reset: 1. Display next schedule after last schedule from schedule map for desired stepper. 2. Put control in PROGRAM mode. 3. Clear all parameters for that schedule. The Delete shortcut may be used by holding ENTER and pressing PROGRAM/OPERATE push button. 4. Make sure Weld Count is 0000 for this step. 5. Program Off time of 99 cycles. 6. Put control in OPERATE mode. A warning signal may be added just before Reset command. Add an additional step with very low Weld Count. This schedule may contain an additional valve output which may be used to warn operator by means of light or some other alarm device. Stepper Reset using External Switch Input Since PROM firmware version 619016-002S, it is possible to use External Reset switch (normally closed) connected between TS1-ES1 and TS1-GND terminals to cause Stepper Reset. To enable, Extended Function b.E. must be programmed to 06. Whenever momentary switch is activated (open), control will automatically reset active stepper. 100 EN1000/EN1001 770015 Revision C Stepper as Counter The stepper counter may be used as down-counter. It is simply necessary to load a schedule stepper counter with value to count down from. The maximum allowable value is 9999. 1. 2. 3. 4. 5. 6. 7. 8. 9. Select schedule to be used. Put control in PROGRAM mode. Enable Stepper by programming S.t.=01 or 02. Program weld schedule as required. Select Weld/Heat parameter again. Find a.0, b.0, etc., by pressing right SCHEDULE push button. Program desired Count from 0000 to 9999 in DATA display and press ENTER. Reset Stepper by pushing ENTER and both DATA push buttons simultaneously. Put control in OPERATE mode. NOTICE If necessary, the message S.t. E.n.d. may be shown at end of countdown. Select next schedule and clear it by using Clear Data shortcut. Program Weld time of 01 cycles and return to OPERATE mode. 101 EN1000/EN1001 770015 Revision C Displaying Stepper Counter The stepper counter may be displayed during operation. Since this is not a principal Weld function, access to displaying counter requires the following: 1. 2. 3. 4. 5. Select schedule to be used. Put control in PROGRAM mode. Select Weld/Heat parameter. Find L.C. by pressing right SCHEDULE push button. Put control in OPERATE mode. The Last Count will be shown after end of each welding sequence. 102 EN1000/EN1001 770015 Revision C End of Stepper When Last Step is reached, control will flash message S.t. E.n.d. on DATA and SCHEDULE displays. This message can be clear by pressing any Control Panel push button or by activating Emergency Stop. To avoid resetting counter value, use External Switch input. If P.O. is programmed to 10 or 17, Process Output valve or Valve 3 will be active as long as message S.t. E.n.d. is flashing on displays. 103 EN1000/EN1001 770015 Revision C Constant Current Operation Available only for EN1001 Constant Current Working Modes Secondary Preset-Range Compensation or Monitoring Primary Preset-Range Compensation or Monitoring Secondary Auto-Range Compensation or Monitoring Primary Auto-Range Compensation or Monitoring The function of Current Compensation feature is that of maintaining welding current constant at preset level, despite influencing factors which could otherwise make current vary. With Current Compensation feature in operation, current remains substantially constant regardless of line voltage variations, changes in machine power factor caused by movement of ferrous metal within secondary, changes in size or shape of secondary, changes in material resistance, or any combination of these factors. To operate control in Current Compensation mode, following steps are necessary: 1. Set up sensor selection jumper according to selected Current Sensor. 2. Software parameter setup: a. Compensation parameters – Transformer’s Turns Ratio – Constant Current mode – Range b. Process Output parameter 3. Program weld schedules. 104 EN1000/EN1001 770015 Revision C Constant Current Hardware Setup Available only for EN1001 To obtain proper signal, sensor selection jumper must be set to correct position depending on Current Sensor Primary Current Transformer – Secondary Rogowski Coil – sensor selection jumper on two pins on right sensor selection jumper on two pins on left 105 EN1000/EN1001 770015 Revision C Constant Current Software Setup Available only for EN1001 Constant Current Working Modes Secondary Preset-Range Compensation or Monitoring with Rogowski Coil – C.r.=32 or 33 Primary Preset-Range Compensation or Monitoring with Current Transformer – C.r.=12 through 19 Secondary Auto-Range Compensation or Monitoring with Rogowski Coil – C.r.=30 or 31 Primary Auto-Range Compensation or Monitoring with Current Transformer – C.r.=10 or 11 These working modes inform control which Current Sensor has been connected and which current setting will be used to input data. Control will then automatically adjust gain of embedded amplifier and control working current at desired value. Before Constant Current function is operational, operator must set control to desired working mode by programming Extended Function parameters t.r., C.r., and r.A. 106 EN1000/EN1001 770015 Revision C Constant Current Software Setup Available only for EN1001 Secondary Preset-Range Compensation or Monitoring with Rogowski Coil – C.r.=32 or 33 In these modes, a learning-type setup process is not required. However, r.A. must be programmed for desired Current range in which machine will operate. If desired range is far below or far above operating range, current overshooting or poor compensation will result. Compensation – C.r.=32 Monitoring – C.r.=33 Value of Percent Current setting in weld schedules should be input as required secondary output current in kA. Control will only display weld current after weld but will not compensate current error. Value of Percent Current setting in weld schedules should be input as percentage of maximum current output of control. 107 EN1000/EN1001 770015 Revision C Constant Current Software Setup Available only for EN1001 Primary Preset-Range Compensation or Monitoring with Current Transformer – C.r.=12 – 19 In these modes, a learning-type setup process is not required. r.A. should be set to desired secondary Current range and t.r. should be set to Turns Ratio of transformer. Maximum values of r.A. are limited by maximum value of current transformer and turns ratio of transformer. The relationship is shown by equation: Maximum r.A. = Maximum Current of current sensor x Turns Ratio of transformer Compensation – C.r.=12 / 14 / 16 / 18 Monitoring – C.r.=13 / 15 / 17 / 19 Value of Current setting in weld schedules should be input as desired secondary current in kA. Control will only display weld current after weld but will not compensate current error. Value of Current setting in weld schedules should be input as percentage of maximum current output of control. Improper choice of Current Sensor or r.A. value will cause overshooting or poor compensation quality during Current Compensation process. 108 EN1000/EN1001 770015 Revision C Constant Current Software Setup Available only for EN1001 Secondary Auto-Range Compensation or Monitoring with Rogowski Coil – C.r.=30 or 31 In these modes, a learning-type setup process is required. Control will record current values of maximum output and constant current compensation will be based on this data. Normally these modes are used only when current range of control is unavailable. Compensation – C.r.=30 Monitoring – C.r.=31 If r.A.=00.99, value of Percent Current setting in weld schedules should be input as percentage of maximum current output of control. Otherwise, r.A. should be set to assumed maximum secondary current in kA and value of Percent Current setting should be input as required secondary output current in kA value of control. Control will only display weld current after weld but will not compensate current error. Value of Percent Current setting in weld schedules should be input as percentage of maximum current output of control. 109 EN1000/EN1001 770015 Revision C Constant Current Software Setup Available only for EN1001 Primary Auto-Range Compensation or Monitoring with Current Transformer – C.r.=10 or 11 In these modes, a learning-type setup process is required. Control will record current values of maximum output and constant current compensation will be based on this data. Normally these modes are used only when current range of control is unavailable. Compensation – C.r.=10 Monitoring – C.r.=11 If r.A.=00.99, value of Percent Current setting in weld schedules should be input as percentage of maximum current output of control. Otherwise, r.A. should be set to assumed maximum output of secondary current in kA and value of Percent Current setting should be input as required secondary output current in kA value of control. Control will only display weld current after weld but will not compensate current error. Value of Percent Current setting in weld schedules should be input as percentage of maximum current output of control. 110 EN1000/EN1001 770015 Revision C Displaying Current Available only for EN1001 It is not necessary to program any special function or Process Output to display Current after weld sequence. Simply use SELECT push button to display Percent Current parameter before initiation and control will display measured Current at end of sequence. The following messages are available at end of sequence: Average RMS Current in kA – Displayed if control is operating in proper mode and weld has been made. Phase Shift in % – Selectable only if RMS Current is displayed; press DATA right push button to display Percent. To display RMS Current again, press DATA left push button. Tap Up (or Range Down) indicator (t-UP) – Shown at end of weld sequence if control is unable to compensate and maintain programmed Current. Moving tap selector to higher setting will allow control to maintain current constant. If machine already at highest tap setting, choose lower current range and reprogram r.A. value. Tap Down (or Range Up) indicator (t-dn) – Shown at end of weld sequence if control is unable to compensate and maintain programmed Current. Moving tap selector to lower setting will allow control to maintain current constant. If machine already at lowest tap setting, choose higher current range and reprogram r.A. value. 111 EN1000/EN1001 770015 Revision C Constant Current Process Outputs Available only for EN1001 Control can be programmed to always provide weld current readout at end of any weld sequence, no matter what is shown on display before beginning of sequence by using Process Outputs. End of Sequence Readout (P.O.=12) – Display value of current maintained during weld. If limit window is being monitored and control cannot maintain set Current value, control will flash L.o. or H.i. End of Sequence Readout & Valve alarm output (P.O.=13) – Display value of current maintained during weld. If limit window is being monitored and control cannot maintain set Current value, control will flash L.o. or H.i. and turn Valve on for 0.5 seconds. Interrupt Repeat sequence or stop at end of weld (P.O.=14) – Display value of current maintained during weld. If limit window is being monitored and control cannot maintain set Current value, control will display L.o. or H.i. permanently and interrupt Repeat sequence or stop control from any further initiations. Weld Current Readout without limit window monitoring (P.O.=12) – Program value in Weld Current parameter Hi=00.99 or Hi=xx.xx (close to maximum available current). Program value in Weld Current parameter Lo=00.10. Do not leave these values at zero. 112 EN1000/EN1001 770015 Revision C Setting Current Limit Window Available only for EN1001 The default (factory setting) current limit window for P.O.=12 to 14 and 22 to 27 is set at ±10% of Percent Current. If specific High or Low limits are needed: 1. 2. 3. 4. 5. 6. 7. 8. Put control in PROGRAM mode. Select desired schedule. Press SELECT push button until Function Indicator LED is at PERCENT CURRENT. Click right SCHEDULE push button once and SCHEDULE display will show L.o. to indicate Low limit. Use DATA push buttons to enter desired Low limit and push ENTER to save setting. Click right SCHEDULE push button once and SCHEDULE display will show H.i. to indicate High limit. Use DATA push buttons to enter desired High limit and push ENTER to save setting. Return control to OPERATE mode. 113 EN1000/EN1001 770015 Revision C Learning-type Setup Process Available only for EN1001 Learning-type setup process is needed for Auto-Range working modes. Control will make several weld cycles and record signal values from Current Sensor, then set gain for embedded amplifier. NOTICE Before running setup, make sure jumper on Control Board is set to proper position for Current Sensor. 1. Setup must be done in Spot mode (S.E.=00). Control must be initiated using FS3 initiation switch connected between TS1-FS3 and TS1-GND. 2. Make sample welds with Constant Current disabled (C.r.=00) to determine proper welding transformer tap switch setting. Percent Current should be between 70% and 80% and Weld time should be recommended cycles for material being welded. 3. Put control in PROGRAM mode. 4. Program Extended Function C.r. to 10 or 30, depending on current sensor option. 5. Program Extended Function r.A. to 00.99 for operating in % mode OR xx.xx for kA mode (xx.xx is maximum RMS Current). 6. Program Extended Function C.A.=04 and press ENTER. This presets schedule 49 with specific setup parameters. Control will automatically switch to OPERATE mode and flash S.e.t. on DATA display. 7. Using same material already welded, insert it between electrodes, initiate weld sequence and hold FS3 closed. Electrodes will close and control will sequence through preset test schedule. When setup is complete, control returns to schedule 00. 8. Release FS3. Control is now set up and ready to operate. Sequence parameter Current must be reprogrammed now as four-digit number. 114 EN1000/EN1001 770015 Revision C Spot Mode Operation Spot with Repeat Mode Momentary initiation results in one sequence only. If initiation is held closed, sequence will continue repeating. Pulsation with Successive Mode When first initiated schedule is completed, next schedule number flashes to indicate that it is ready to be initiated. After sequence completed, SCHEDULE display will return to first initiated schedule. 115 EN1000/EN1001 770015 Revision C Spot Mode Operation Quench-Temper with Chained Mode Two schedules are chained together to illustrate Quench-Temper operation. First schedule performs Squeeze, Weld and Quench functions (using Hold for Quench) and second schedule performs Temper and Hold functions (using Weld for Temper). WELD light gives visual indication of relative amplitude and duration of Current during Weld and Temper times. Slope with Chained Mode Four schedules are chained together to illustrate Slope operation. First schedule performs Squeeze, and establishes Percent Current at which Upslope will begin. Next schedule performs Weld function and sets Upslope time. Next schedule sets Downslope time and Percent Current it starts from. Last schedule establishes Percent Current at which Downslope will end and performs Hold function. SCHEDULE display will change as sequence progresses from one schedule to next. 116 EN1000/EN1001 770015 Revision C Spot Mode Operation Butt Weld with Chained Mode Two schedules are chained together to perform Butt Welding sequence. First schedule contains only Squeeze time with Valve 1 output, used as Clamp function. Second schedule follows Clamp function with normal Squeeze, Weld, Hold sequence with Valve 2 output. Both valves turn off at end of Hold time. Forge Delay with Chained Mode To accomplish Forge Delay operation, it is necessary to chain together two or more schedules. Program first schedule with Weld time desired before activation of forging valve. For Forge during Weld, program second schedule with remaining Weld time and unused valve output. For Forge after Weld, program time between Weld and activation of forge valve into Hold time of first schedule or into Squeeze time of second schedule. 117 EN1000/EN1001 770015 Revision C Seam Mode Operation Continuous Seam Mode Using Seam Mode S.E.=01, welding current starts when initiation contact is closed and stays on as long as it is held closed. Intermittent Seam Mode Using Seam Mode S.E.=01, intermittent operation is accomplished by programming value other than 00 for Cool. 118 EN1000/EN1001 770015 Revision C Seam Mode Operation Weld Current Delay To add Weld Current Delay to Seam sequence, program desired Squeeze time in first schedule of sequence. If sequence is programmed for Intermittent Seam or Roll Spot, programmed Squeeze time will only be in effect upon initiation. Seam Mode S.E.=06 Primarily designed as Non-Beat Seam mode, this mode enables user to execute fixed time weld using repetitions in addition to alternating two heats within single schedule. In order to obtain long series of heat patterns, schedules can be chained to execute subsequent schedules with similar set of heat patterns. 119 EN1000/EN1001 770015 Revision C Brazing Operation Automatic Brazing Mode This mode must be programmed using Beat Initiation during Squeeze & Weld (b.E.=02). Initiation must be held closed for time required to bring parts to required brazing temperature. If operator then opens initiation, brazing current turns off immediately and sequence advances to Hold time, and after Hold time electrodes retract. Control will terminate weld sequence normally at end of programmed schedule if initiation switch remains closed. Manual Brazing Mode This mode must also be programmed using Beat Initiation during Squeeze and Weld (b.E.=02). In addition, set Weld/Heat and Impulses to 99, Percent Current and Valve Mode in accordance with job requirements, and all other parameters to 00. Initiation switches are connected to TS1 as shown. When First Stage is closed, brazing electrodes close on work. When Second Stage is closed, brazing current comes on. If Second Stage opens, brazing current stops, but electrodes stay closed. Current may be turned on and off in this manner as needed. When First Stage opens, electrodes retract. 120 EN1000/EN1001 770015 Revision C Squeeze Delay Squeeze Delay is designed for use with welding guns and stationary machines incorporating standard air cylinders and valves without retraction features. Additional time provided will allow electrodes to travel a greater distance and simulate retraction function. Squeeze Delay is only active in first schedule of Repeat sequence. The Squeeze Indicator LED on Control Panel will dim slightly during programmed Squeeze Delay time. To program Squeeze Delay: 1. 2. 3. 4. 5. 6. 7. 8. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find S.d. Enter desired value of S.d. using DATA push buttons. Press ENTER push button to save setting. Select and enter Cycle Mode=01 (Repeat) Adjust Squeeze and Off times to allow electrodes to open only a short distance between repeated welding sequences. Return control to OPERATE mode. 121 EN1000/EN1001 770015 Revision C Retraction Momentary Closure – P.O.=08 Momentary closure from TS1-TLS1/AUX1 to TS1-GND toggles retraction valve from On to Off state. These contacts are normally tied to momentary type switch that is independent from initiation switch. Maintained Closure – P.O.=09 Maintained retraction uses one foot switch that has maintained/latched contact which control uses to turn on retraction valve. Air-Over-Oil Retraction – P.O.=07 This function is used on welding guns and stationary welders that incorporate special air-over-oil cylinders. This feature requires use of three solenoid valve outputs – extend, intensify, and blocking. For detailed information on Air-Over-Oil Retraction, see Section 9.5.3 of Instruction Manual 700120 122 EN1000/EN1001 770015 Revision C Multiple Schedule Operation Triple Count/Triple Current (3C/3C) can be accomplished on EN1000/EN1001 Controls. Schedules can be selected using either Internal or External Schedule Select. Internal Schedule Select – S.S.=00 1. 2. 3. Switch closure between TS1-FS3 and TS1-GND will initiate any displayed schedule. Switch closure between TS1-FS7 and TS1-GND will initiate schedule 10. Switch closure between TS1-FS11 and TS1-GND will initiate schedule 20. External Schedule Select – S.S.=01 1. 2. TS1-FS7/SS1 and TS1-FS11/SS3 become binary schedule selects, pointing to one of four schedules. Control is then initiated via TS1-FS3 for any one of four schedules. 123 EN1000/EN1001 770015 Revision C Process Output 26 Hold Part in Welder if Current Out of Limit Window This function requires EN1001 Control Board 600572 with PROM firmware version 619016-002C or later. Control will hold part just previously welded, between electrodes, if measured current is not between programmed High/Low limit window. Valve assignment must be as follows: Valve 1 Valve 2 Valve 3 TS1-SV1 TS1-SV3 TS1-SV5 ! Connects to Valve 1 for Electrodes Connects to CR1 which drives Magnetic Isolation Contactor Connects to Alarm Output CR2 WARNING ! ISOLATION CONTACTOR MUST BE CONTROLLED BY VALVE 2 SO WELD TRANSFORMER IS ISOLATED FROM WELD CONTROL WHEN PART IS HELD IN WELDER. IF ISOLATION CONTACTOR IS NOT USED, UNCONTROLLED WELD CURRENT MAY BE APPLIED TO HELD PART. This is REQUIRED as Control Relays in weld control will be held in On state until part is removed or SCRs can fail in shorted condition. NOTICE On weld controls with Program Lockout key switch, key must be rotated and error cleared before part can be removed from welder. 124 EN1000/EN1001 770015 Revision C Half Cycle Current Monitoring To enable Half Cycle Welding: 1. 2. 3. 4. Put control in PROGRAM mode. Use SELECT to find EF. Use SCHEDULE push buttons to find P.O. Program P.O.=09 to enable Half Cycle welding using DATA push buttons. 5. Make sure Extended Function S.E.=00. To program Half Cycle Weld: 1. Use SCHEDULE push buttons to select working schedule. 2. Program schedule as follows: Squeeze – meet requirements Weld=01 Hold – meet requirements Off=00 Impulses=00 Cool=00 Valve Mode – meet requirements Cycle Mode=00 Slope Mode=00 Slope Count=00 To enable Current Monitoring: Use SELECT to find EF. Use SCHEDULE push buttons to find C.r. Program C.r.=11, 31, or 33 depending on Current Sensor. 4. Program r.A. to proper Range. 5. Use SELECT to select Percent Current. 6. Program necessary Percent Current. 7. Put control in OPERATE mode. 8. Make a weld. If necessary, adjust Current. 9. After weld, control will display value of Current. 10. Put control in PROGRAM mode. 11. While in Percent Current function, use SCHEDULE push buttons to find H.i. and L.o. parameters. 12. Program appropriate value of High and Low limits. 1. 2. 3. 125 EN1000/EN1001 770015 Revision C Options • • • • • • • • MM2 Memory Module Integrated Pressure Sense & Control 24 VDC Valve Outputs Current Sensors Program Lockout Key Switch 1 of 7 Valve Extension Board Schedule Select S49 Option RS485 Options o o o ENLINK 1000/1001 Remote Terminal RT4jr. Isolated Adapters – S485 and U485 • RS232 Options o ENLINK 1000/1001 • Half-Cycle Option 126 EN1000/EN1001 770015 Revision C MM2 Memory Module • • • • Backup device for any EN1000/EN1001 Series Control Copy/download all data from one control to another Reduce programming time in critical areas Replacement Control Boards can be reprogrammed quickly by downloading backup data from Memory Module • Store different job schedules by using one or more Memory Modules and download to control when needed • Useful tool for controls where multiple schedules and multiple valves are used Two versions: MM2-RDE – for controls with RDE option MM2 – for all other controls Instruction Manual 700202 provides additional information for this option 127 EN1000/EN1001 770015 Revision C Integrated Pressure Sense and Instruction Manual 700178 provides Control System additional information for this option OPTIONS Single-ended Sensor Differential Sensor Proportional Valves 128 EN1000/EN1001 770015 Revision C 24 VDC Valve Outputs • Optional Terminal Strip/Firing Board with 24 VDC output • Incorporates use of mosfets which can switch DC voltages from 5-60 VDC at 1A • Meets European and International standards for low voltage DC operation Application Note 700189 provides additional information for this option 129 EN1000/EN1001 770015 Revision C Current Sensors Primary Coil Secondary Rogowski Coils: 6" 10" Used for Constant Current Operation on EN1001 Series Controls See Constant Current Section for further details of this option 130 EN1000/EN1001 770015 Revision C Program Lockout Key Switch • Prohibits unauthorized editing of control parameters • Physical key is required to enable programming of control • Using optional Current Offset function, operator without Program Lockout key can change current within preset limits while in OPERATE mode • Can be ordered as a factory installed option or ordered separately at later date and field installed by customer See Program Lockout Options slide for installation instructions 131 EN1000/EN1001 770015 Revision C 1 of 7 Valve Extension Board • Provides additional 7 valve output circuits • Three standard binary valves are decoded to 1 of 7 valves • Additional outputs provide unique 1 of 7 selection from first 3 valve outputs • Not intended to be used with Process Outputs Application Note 700110 provides additional information for this option 132 EN1000/EN1001 770015 Revision C Schedule Select S49 Option • Adds six binary select inputs • Allows for selection of any one of 49 schedules to begin sequence • All 50 schedules remotely available to operator or machine process control system • Enables programming of External Binary Schedule Select – 50 non-panel, external schedules See External Binary Select (S.S.=03) Section for further details of this option Application Note 700182 also provides additional information for this option 133 EN1000/EN1001 770015 Revision C Communication Options • Control can be simply interfaced to RS485 or RS232 • Works with ENLINK 1000/1001 • Documentation available for communication procedures 134 EN1000/EN1001 770015 Revision C RS485 Options • Communication with Remote Terminal RT4jr. or PC or other devices with RS485 interface over two-wire RS485 network (ENBUS) • Field installable • Link multiple controls together • Works with ENLINK 1000/1001 Instruction Manual 700171 provides additional information for this option 135 EN1000/EN1001 770015 Revision C Software • Available for use with any EN1000 or EN1001 Control • Offers ability to upload, download, store, retrieve, monitor and backup weld schedules • Controls connected to PC via RS232 or RS485 converters • Available on CDROM, and works with Microsoft Windows™ 136 EN1000/EN1001 770015 Revision C Schedule 137 EN1000/EN1001 770015 Revision C Properties 138 EN1000/EN1001 770015 Revision C Error Log 139 EN1000/EN1001 770015 Revision C Data Dump 140 EN1000/EN1001 770015 Revision C Parameters 141 EN1000/EN1001 770015 Revision C Copy 142 EN1000/EN1001 770015 Revision C Remote Terminal RT4jr. • • • • • • • Multiple networked control access Long-distance programming of control parameters Work group error monitoring Work group constant current monitoring Small remote design Easily switch between up to 64 controls Simple bus structure networking RT4jr. is part of complete networking system Instruction Manual 700171 provides additional information for this option 143 EN1000/EN1001 770015 Revision C Isolated Adapters – S485 & U485 S485 Serial Adapter U485 USB Adapter • RS232 to RS485 converter • Optically isolates and surge suppresses RS485 line • With power supply • No driver required • USB to RS485 converter • Adds isolation protection against ground loops and voltage spikes • No power supply • Required driver Instruction Manual 700171 provides additional information for this option 144 EN1000/EN1001 770015 Revision C RS232 Options • Communication with a PC, PLC, or other devices with RS232 interface • RS232 interface is full duplex and operates in ASCII mode • Works with ENLINK 1000/1001 • Field installable Instruction Manual 700140 provides additional information for this option 145 EN1000/EN1001 770015 Revision C Half-Cycle Option • Allows programming of either unipolar or antipolar operation and polarity of halfcycle in unipolar mode • Unipolar produces half-cycle welds of same polarity – positive or negative • Antipolar welding alternates positive and negative polarity welds Application Note 700114 provides additional information for this option 146 EN1000/EN1001 770015 Revision C Error Codes Error Codes are displayed on Control Panel with E.r. in SCHEDULE display and Code number in DATA display. ERROR CODE 01 02 03 04 05 06 07 08 09 10 11 12 13 14 (flashing) REASON/CAUSE TLS open or overheated FS1 & FS7 both closed FS1 & FS11 both closed Weld initiated in PROGRAM mode FS1,FS3,FS7,FS11 closed to GND Back-step or Retraction closed FS1 initiated while other sequence active FS3 initiated while other sequence active FS7 initiated while other sequence active FS11 initiated while other sequence active Control Board or Relay problem Control Board Hardware error Full conduction detected EEPROM error – memory corrupt 15 17 18 19 20 22 23 24 26 27 28 32 (flashing) 37 (EN1001 only) Pressure Switch open too long Nominal AVC reading too low Nominal AVC reading too high AVC reading too low AVC reading too high +18 VDC out of range Maximum firing angle exceeded Minimum firing angle exceeded SCR Contactor short detected Retraction valve not on Process Output 10 error Invalid data in EEPROM Calibration data out of range 147 REMEDY Wait for TLS to cool or check for open circuit Two Stage Operation not allowed with FS7 Two Stage Operation not allowed with FS11 Return control to OPERATE mode Initiations must be open at power on or after Emergency Stop Open TS1-TLS1/AUX1 Open TS1-FS1 Open TS1-FS3 Open TS1-FS7 Open TS1-FS11 Replace Control Board Replace Control Board Change to higher welding transformer tap Clear all Schedules & Extended Functions / Re-route wiring in cabinet / Replace Control Board if necessary Close Pressure Switch / Check wiring for open Reprogram nominal setting / Check C.C. value Reprogram nominal setting / Check C.C. value AVC could not compensate / Change tap or Percent AVC could not compensate / Change tap or Percent Line voltage too high / Wrong voltage jumper settings Full conduction reached / Set Automatic Power Factor Full conduction reached / Set Automatic Power Factor Check Contactor for short / Check Firing Board Turn on retraction valve via TS1-TLS1/AUX1 Attempting to weld in No Weld with P.O.=10 Clear Schedule with corrupted data or clear Extended Functions Change to Auto-Range mode / Run in Preset-Range without correct RMS current values / Return Control Board to factory for re-calibration EN1000/EN1001 770015 Revision C Troubleshooting Section 11.0 of Instruction Manual 700120 includes helpful Troubleshooting Chart and Guide 148 EN1000/EN1001 770015 Revision C Weld Control with Options 149 EN1000/EN1001 770015 Revision C QUESTIONS ? ENTRON Controls, LLC. 1402 S. Batesville Road Greer, SC 29650 (864) 416-0190 FAX (864) 416-0195 www.entroncontrols.com [email protected] 150 EN1000/EN1001 770015 Revision C THANK YOU ! ENTRON Controls, LLC. 1402 S. Batesville Road Greer, SC 29650 (864) 416-0190 FAX (864) 416-0195 www.entroncontrols.com [email protected] 151 EN1000/EN1001 770015 Revision C
