Entron EN7000v2 Manuale utente

User Manual

EN7000v2

Firmware Version

2.27

July 23

Document No. 700257

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Product Model: EN7000v2

Firmware Version: 2.27

July 23 | Doc No 700257

DISCLAIMER

Information contained in this document is believed to be accurate and reliable. The manufacturer does not provide any

representations or warranties, expressed or implied, as to the accuracy or completeness of such information and shall

have no liability for the consequences of use of such information. The manufacturer reserves the right to make changes

to information published in this document, including without limitation specifications and product descriptions, at any

time and without notice.

BF ENTRON accepts no liability for any injury, loss or damage caused by improper installation, use or application of its

products. The user shall only use the product for purposes that are proper and in accordance with all applicable laws,

rules, and regulations.

means, including photocopying, recording, or other electronic or mechanical methods, without the prior written

permission of the publisher.

TRADEMARKS

BF ENTRON and/or its affiliates’ trademarks may not be used in connection with any product or service that is not BF

ENTRON’s, in any manner this is likely to cause confusion among customers or in any manner that disparages or

discredits BF ENTRON. All other trademarks not owned by BF ENTRON are the property of their respective owners, who

may or may not be affiliated with, connected to, or sponsored by BF ENTRON.

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Product Model: EN7000v2

Firmware Version: 2.27

July 23 | Doc No 700257

Document Revisions

Languages

This document is only published in the English language.

Date

Document

Number

Approved

Document Changes

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Product Model: EN7000v2

Firmware Version: 2.27

July 23 | Doc No 700257

Table of Contents

1BACKGROUND.............................................................................................................................................................9

1.1 Description of the User................................................................................................................................................... 9

1.2 Conventions Used in This Manual .............................................................................................................................. 9

1.3 Explanation of Symbols................................................................................................................................................10

1.4 Important Safety Instructions ...................................................................................................................................11

1.5 Technical Support ..........................................................................................................................................................13

1.5.1 Internet...................................................................................................................................................................................................................... 13

1.5.2 Documentation Request..................................................................................................................................................................................... 13

1.5.3 Service and Technical Support........................................................................................................................................................................ 13

2INTRODUCTION....................................................................................................................................................... 14

2.1 Weld Control ....................................................................................................................................................................14

2.2 Features .............................................................................................................................................................................14

2.3 Product Hardware Specifications.............................................................................................................................15

2.3.1 Power Specifications ........................................................................................................................................................................................... 15

2.3.2 Function and Monitoring Specifications..................................................................................................................................................... 15

2.3.3 EN7000v2 Weld Timer Specifications......................................................................................................................................................... 16

2.3.4 Environmental Specifications.......................................................................................................................................................................... 16

2.4 Main Component Overview ........................................................................................................................................17

2.5 Wiring Diagrams.............................................................................................................................................................18

2.5.1 Customer Connections Diagram (3U3633) ............................................................................................................................................... 20

2.6 Standard Machine ..........................................................................................................................................................21

2.7 Multi-Welding Machine................................................................................................................................................21

2.8 Modes of Current Control ............................................................................................................................................24

2.8.1 Phase Angle Mode “PHA”................................................................................................................................................................................... 25

2.8.2 Constant Current Regulation “CCR”.............................................................................................................................................................. 25

2.9 Installation........................................................................................................................................................................26

2.9.1 Installation Instructions..................................................................................................................................................................................... 26

2.9.2 Configure the Control.......................................................................................................................................................................................... 30

2.9.3 Current Calibration .............................................................................................................................................................................................. 37

2.10 Force Calibration............................................................................................................................................................47

2.10.1 Force Calibration Procedure ...................................................................................................................................................................... 48

2.11 Preventative Maintenance..........................................................................................................................................49

3COMMUNICATIONS SETUP ...................................................................................................................................51

3.1 Overview............................................................................................................................................................................51

3.2 Set the IP Address of the Control..............................................................................................................................53

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July 23 | Doc No 700257

3.3 Ethernet Communications ..........................................................................................................................................56

3.3.1 Connect via NetFlash™Programming Software...................................................................................................................................... 56

3.3.2 Configure for EtherNet/IP (EIP) .................................................................................................................................................................... 58

3.3.3 Configure for MODBUS-TCP/IP ...................................................................................................................................................................... 59

3.4 MODBUS-RTU...................................................................................................................................................................60

3.5 WSP3 Pendant .................................................................................................................................................................62

4ENTRON PROGRAMMING TOOLS........................................................................................................................63

4.1 NetFlash™..........................................................................................................................................................................63

4.1.1 System requirements .......................................................................................................................................................................................... 63

4.1.2 Installing NetFlash™............................................................................................................................................................................................ 64

4.1.3 Removing NetFlash™........................................................................................................................................................................................... 64

4.1.4 Running NetFlash™.............................................................................................................................................................................................. 64

4.1.5 Main window components ............................................................................................................................................................................... 64

4.1.6 The target IP address .......................................................................................................................................................................................... 66

4.1.7 Restart control ....................................................................................................................................................................................................... 67

4.1.8 Control type............................................................................................................................................................................................................. 67

4.1.9 Networks window ................................................................................................................................................................................................ 68

4.1.10 Edit Control Parameters............................................................................................................................................................................... 70

4.1.11 Editing Parameters ......................................................................................................................................................................................... 72

4.1.12 Log Tab................................................................................................................................................................................................................. 73

4.1.13 Flash Programming Tool.............................................................................................................................................................................. 74

4.1.14 Setup NetFlash™Users/Security .............................................................................................................................................................. 76

4.2 WSP3...................................................................................................................................................................................78

4.2.1 Keypad ....................................................................................................................................................................................................................... 78

4.2.2 Diagnostic Screen.................................................................................................................................................................................................. 79

4.2.3 Menus......................................................................................................................................................................................................................... 80

4.3 Built-in Touch screen....................................................................................................................................................81

4.3.1 Touch screen........................................................................................................................................................................................................... 81

4.3.2 Status screen ........................................................................................................................................................................................................... 81

4.3.3 Main menu ............................................................................................................................................................................................................... 83

5PROGRAMMING WELD PROGRAMS ................................................................................................................... 86

5.1 Overview............................................................................................................................................................................86

5.2 What is a weld program?.............................................................................................................................................86

5.3 Parameters .......................................................................................................................................................................87

5.4 Weld Program Types.....................................................................................................................................................93

5.5 Programming a Spot Weld with the WSP3......................................................................................................... 100

5.6 Programming a Spot Weld with NetFlash........................................................................................................... 106

5.7 Programming a Spot Weld with Touchscreen .................................................................................................. 110

5.8 Program Selection....................................................................................................................................................... 116

5.8.1 Internal Program Selection.............................................................................................................................................................................117

5.8.2 External Program Selection............................................................................................................................................................................117

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July 23 | Doc No 700257

5.8.3 Program Selection for Spot Welding ..........................................................................................................................................................117

5.8.4 Program Selection for Seam Welding ........................................................................................................................................................117

6FAULTS & TROUBLESHOOTING ........................................................................................................................118

6.1 Fault and Status Messages........................................................................................................................................ 118

6.2 LED Indicators on Timer........................................................................................................................................... 124

6.2.1 Heartbeat LED ....................................................................................................................................................................................................124

6.2.2 Ready LED.............................................................................................................................................................................................................125

6.2.3 Sequence LED .....................................................................................................................................................................................................125

6.2.4 Weld LED ...............................................................................................................................................................................................................125

6.2.5 Data Send/Receive LEDs ..............................................................................................................................................................................125

6.2.6 Network Status / Module Status LEDs..................................................................................................................................................125

6.3 How to Reset Faults .................................................................................................................................................... 126

6.3.1 WSP3 Pendant....................................................................................................................................................................................................126

6.3.2 NetFlash™Software.........................................................................................................................................................................................126

6.3.3 Discrete Input.....................................................................................................................................................................................................127

6.3.4 Fieldbus Input ....................................................................................................................................................................................................127

7INPUTS & OUTPUTS .............................................................................................................................................128

7.1 Inputs............................................................................................................................................................................... 128

7.2 Outputs............................................................................................................................................................................ 130

7.3 Discrete Connections ................................................................................................................................................. 131

7.3.1 Inputs .......................................................................................................................................................................................................................131

7.3.2 Outputs ....................................................................................................................................................................................................................131

7.3.3 Analog Signals (0 to 10V) ................................................................................................................................................................................131

7.3.4 Discrete Connections Schematic ..................................................................................................................................................................132

7.3.5 Softstart...................................................................................................................................................................................................................133

8Modbus RTU...........................................................................................................................................................134

8.1 Modbus overview ........................................................................................................................................................ 134

8.2 Using discrete outputs AV1 to AV8 in Fieldbus mode.................................................................................... 134

8.3 Using Modbus-RTU on RS485 via COM2..................................................................................................................... 134

8.3.1 Configuring the RS485 port............................................................................................................................................................................135

8.4 Using Mobus RTU with EN7000.............................................................................................................................. 137

9READ & WRITE DATA WITH EXTERNAL DEVICES .......................................................................................138

9.1 Overview......................................................................................................................................................................... 138

9.2 MODBUS.......................................................................................................................................................................... 138

9.2.1 Function Codes.....................................................................................................................................................................................................138

9.2.2 Inputs .......................................................................................................................................................................................................................138

9.2.3 Outputs ....................................................................................................................................................................................................................140

9.2.4 Programming Parameters...............................................................................................................................................................................145

9.3 Ethernet/IP (EIP) ........................................................................................................................................................ 157

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July 23 | Doc No 700257

9.3.1 Implicit Messaging..............................................................................................................................................................................................157

9.3.2 Explicit Messaging ..............................................................................................................................................................................................158

10 ADVANCED FEATURES.....................................................................................................................................160

10.1 History Log..................................................................................................................................................................... 160

10.1.1 Currents .............................................................................................................................................................................................................160

10.1.2 Force....................................................................................................................................................................................................................160

10.1.3 Viewing the Log..............................................................................................................................................................................................161

10.1.4 Exporting History Log .................................................................................................................................................................................162

10.1.5 Resetting History Log ..................................................................................................................................................................................162

10.2 Security Settings .......................................................................................................................................................... 163

10.2.1 PIN Codes ..........................................................................................................................................................................................................164

10.2.2 Edit Switch........................................................................................................................................................................................................164

10.2.3 NetFlash™User Security.............................................................................................................................................................................165

10.3 Updating the Firmware............................................................................................................................................. 166

10.4 Backup & Restoring.................................................................................................................................................... 168

10.4.1 WSP3 Pendant.................................................................................................................................................................................................168

10.4.2 NetFlash.............................................................................................................................................................................................................173

10.5 Electrode Management.............................................................................................................................................. 174

10.5.1 Steppers.............................................................................................................................................................................................................174

10.5.2 Counters.............................................................................................................................................................................................................177

10.5.3 Calibration ........................................................................................................................................................................................................179

10.6 Seam Welding ............................................................................................................................................................... 180

10.6.1 Programming a Seam Weld with NetFlash ........................................................................................................................................180

10.7 Multi-weld Operations............................................................................................................................................... 185

10.7.1 Electrode & Transformer Assignment .................................................................................................................................................185

10.7.2 Linking Programs ..........................................................................................................................................................................................188

10.7.3 Multi-Electrode Operation.........................................................................................................................................................................188

10.7.4 Cascade Operation ........................................................................................................................................................................................192

10.8 Analog Control Mode.................................................................................................................................................. 194

10.9 Valve Control................................................................................................................................................................. 195

10.10 Valve Delays.............................................................................................................................................................. 196

10.10.1 Programming Valve Delay Parameters using NetFlash................................................................................................................197

10.10.2 Programming Valve Delay Parameters using WSP3......................................................................................................................200

10.11 Current Limits.......................................................................................................................................................... 202

11 TUTORIALS .........................................................................................................................................................204

11.1 Controlling an Air over Oil System........................................................................................................................ 204

11.2 Using Valves to Control a Multi-Head Machine................................................................................................. 206

11.2.1 Configure Control for Extended Mode .................................................................................................................................................207

11.2.2 Configure the Control for Multi-Electrodes .......................................................................................................................................207

11.2.3 Program the WAV Output for Each Weld Program in the Cascade Sequence ....................................................................208

11.2.4 Link Programs Together (Cascade).......................................................................................................................................................211

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July 23 | Doc No 700257

11.3 Controlling a Multi-Welder/Cascade.................................................................................................................... 213

11.3.1 Configure Control for Extended Mode .................................................................................................................................................213

11.3.2 Assign Electrode to a Transformer........................................................................................................................................................215

11.3.3 Programming a Multi-Welder/Cascade Sequence..........................................................................................................................215

11.4 Configuring & Calibrating EN7000v2 with the WSP3 Pendant................................................................... 218

11.4.1 Configure the Weld Control ......................................................................................................................................................................219

11.4.2 Reset & Turn Off Electrode Stepper ......................................................................................................................................................221

11.4.3 Calibrate Current (Toroid / Rogowski coil) ......................................................................................................................................222

11.4.4 CCR –Constant Current Regulation.......................................................................................................................................................225

12 TERMINOLOGY ..................................................................................................................................................227

13 ADDITIONAL WIRING DIAGRAMS ................................................................................................................229

13.1 Customer Connections Diagram (3U3633)........................................................................................................ 229

13.2 3U3740............................................................................................................................................................................ 230

13.3 3U3731............................................................................................................................................................................ 233

13.4 3U3743............................................................................................................................................................................ 237

13.5 3U3726............................................................................................................................................................................ 241

13.6 421547 ............................................................................................................................................................................ 244

13.7 421548 ............................................................................................................................................................................ 245

BACKGROUND

Description of the User

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Product Model: EN7000v2

Firmware Version: 2.27

July 23 | Doc No 700257

1BACKGROUND

1.1 Description of the User

This manual has been written to inform qualified custom equipment manufacturers, integrators, control engineers, weld

engineers, and/or maintenance technicians how to safely install, setup, operate, and maintain the weld control.

Qualified Personnel Only

The information contained in this manual is intended for Qualified Personnel, as defined

by the National Electrical Code (NEC). Always follow Electrical Safety in the Workplace

per NFPA 70E or equivalent standard in your location.

This manual has been written for the EN7000v2 AC weld control product line with an EN7000v2 weld timer. The manual

applies to the V2.27 version of firmware on the EN7000V2 timer.

This document should be carefully read before installing and operating the weld control. Failure to follow the

instructions defined in this manual could create a safety hazard or impact the warranty on the product.

1.2 Conventions Used in This Manual

The following style conventions are used in this document:

Bold Italics type font is used for emphasis

•Bulleted lists generic lists and do not define a sequence or procedures

1) Numerical lists define a sequence or procedures

Courier text is used for system output, such as an error message or script

URLs, complete paths, filenames, prompts, and syntax

BACKGROUND

Explanation of Symbols

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Product Model: EN7000v2

Firmware Version: 2.27

July 23 | Doc No 700257

1.3 Explanation of Symbols

This section defines the symbols used throughout this document.

DANGER!

Danger indicates a hazard with a high level of risk which, if not avoided, will result in

immediate, serious personal injury or loss of life. Examples are: exposed high voltage;

exposed fan blades.

WARNING!

The Warning symbol indicates a hazard with a potential hazard which could result in

personal injury or loss of life. Examples are: not using proper personal protect; removal

of guards.

CAUTION!

The Caution symbol indicates a hazard which could result in non-life threating personal

injury or damage to equipment. CAUTION may also be used to alert against unsafe

practices.

PACEMAKER

Individuals with cardiac devices should maintain a safe distance due to strong magnetic

fields arising from resistance welding. The function of cardiac pacemakers and

defibrillators may be disturbed, which may cause death or considerable health

damages! These persons should avoid the welding system unless authorized by a

licensed physician.

NOTICE

The Notice symbol is used for making recommendations on use or supplementary

information. Non-compliance with these recommendations may result in damage to the

control, welding machine or workpiece and voiding of the warranty.

HELPFUL TIP

The Helpful Hint symbol is used to provide additional information on a topic that may be

helpful to the user.

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