Entron EN7000 User manual

EN7000

User Guide

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

applications.

For firmware versions 1.18 and 2.18

EN7000 User Guide

Document change record

 The information in this manual is subject to change.

 ENTRON assumes no responsibility for any errors that may appear in this manual.

 ENTRON assumes no responsibility for any injury, loss or damage caused by improper

installation, use or application of the EN7000 welding control

 The reproduction, transmission or use of this document or contents is not permitted without

express authority from ENTRON

 ENTRON's trademarks and trade dress may not be used in connection with any product or service

that is not ENTRON's, in any manner that is likely to cause confusion among customers or in any

manner that disparages or discredits ENTRON. All other trademarks not owned by ENTRON are

the property of their respective owners, who may or may not be affiliated with, connected to, or

sponsored by ENTRON.

Issue Date Comment

1.00 27/02/17 Added parameter descriptions and % conduction parameter.

1.02 23/05/17 Increased weld programs from 128 to 256. New options for SCR select and CT

calibration. New options for valves. New tutorial (resetting faults). Issue number

corresponds to EN7000 firmware.

1.04 26/09/17 Updated issue number.

1.05 30/11/17 Added seam welding features.

1.07 09/04/18 Models 5 and 6 discontinued. Seam welding features added to Models 3 and 4.

1.08 12/09/18 Added note to reset stepper/counter inputs. Updated status codes.

1.09 15/01/19 Revised description of force control.

1.10 12/02/19 Data log contains 6000 records

1.11 27/02/19 Models 1 and 2 discontinued. Model 3 is referred to as EN7000 and model 4 as

EN7000-TS. EN7000 and EN7000-TS can emulate the functionality of Models 1 and 2.

1.12 30/7/19 Toroid test added. Corrections to Modbus I/O and Status codes.

1.13 29/8/19 Added Presqueeze to all modes and Air/Oil tutorial. Added C-Monitor.

1.14 16/12/19 New format. Includes EN7000v2. Added Analog control. New seam sequence.

1.15 11/03/20 Added Toroid factor parameter. Added Retry feature.

1.16 20/7/20 Added 0V setting to CCR calibration for analog mode

1.18 14/9/20 Changed description of 2

-stage Once/Every configuration parameter

EN7000 User Guide

IMPORTANT SAFETY INSTRUCTIONS

READ ALL INSTRUCTIONS BEFORE USING THE EN7000

WARNING

DO NOT DISASSEMBLE, REPAIR, OR MODIFY THE EN7000. These actions can cause electric shock and fire.

 Use only as described in this manual. Use only ENTRON recommended accessories and

replacement parts.

 Stop operation if any problems occur. If the equipment is not working as it should, has been

dropped, damaged, left outdoors, or been in contact with water, contact ENTRON.

 Only apply the specified power. Application of a voltage or current beyond the specified range

can cause electric shock or fire.

 Do not use damaged plugs or connecting cables.

 Keep water and water containers away from the EN7000. Water ingress can cause a short circuit,

electric shock, or fire.

 Do not insert objects into openings. Do not use with any opening blocked; keep free of dust and

debris.

 Do not install the EN7000 in any of the following environments

o damp environments where humidity is 90% or higher.

o dusty environments.

o environments where chemicals are handled.

o environments near a high-frequency noise source.

o hot or cold environments where temperatures are above 40°C or below 0°C, or

environments where water will condense.

EN7000 User Guide

Table of Contents

Section Page

1. Introduction.................................................................................................................... 7

1.1. Part numbers........................................................................................................... 7

1.2. Features................................................................................................................... 8

1.3. Weld schedule parameters................................................................................... 9

1.4. Programming options .......................................................................................... 10

1.4.1. NetFlash.......................................................................................................... 10

1.4.2. WSP3 Pendant ............................................................................................... 10

1.4.3. Built-in touch screen ..................................................................................... 10

1.4.4. EtherNet/IP ..................................................................................................... 10

1.4.5. Modbus .......................................................................................................... 10

1.5. Communications.................................................................................................. 11

1.6. Applications .......................................................................................................... 12

2. Weld Control ................................................................................................................ 15

2.1. Sequence timing .................................................................................................. 15

2.2. Program options ................................................................................................... 16

2.3. Current control ..................................................................................................... 17

2.4. Timing diagrams ................................................................................................... 18

2.4.1. Spot weld ....................................................................................................... 18

2.4.2. Spot pulsation................................................................................................ 18

2.4.3. Spot repeat.................................................................................................... 19

2.4.4. Seam .............................................................................................................. 19

2.4.5. Roll-spot.......................................................................................................... 20

2.4.6. Second stage ................................................................................................ 21

2.4.7. Retract............................................................................................................ 22

2.5. Force control......................................................................................................... 24

2.6. Valve control ........................................................................................................ 25

2.7. Multi-Electrode operation ................................................................................... 26

2.8. Program selection ................................................................................................ 26

2.8.1. Internal program selection........................................................................... 26

2.8.2. External program selection .......................................................................... 26

2.8.3. Program selection for Spot welding............................................................ 26

2.8.4. Program selecting for seam welding.......................................................... 26

EN7000 User Guide

2.9. Analog control...................................................................................................... 27

3. Multi-weld operation................................................................................................... 28

3.1. Multi-Electrode operation ................................................................................... 30

3.2. Cascade operation ............................................................................................. 31

4. Electrode management............................................................................................. 32

4.1. Steppers................................................................................................................. 32

4.2. Counters ................................................................................................................ 33

4.3. Current calibration ............................................................................................... 34

4.4. Force calibration .................................................................................................. 35

5. Input/Output (I/O)....................................................................................................... 36

5.1. Inputs ..................................................................................................................... 36

5.2. Outputs.................................................................................................................. 37

5.3. Softstart.................................................................................................................. 37

5.4. Analog signals....................................................................................................... 38

5.4.1. CT .................................................................................................................... 38

5.4.2. Toroid.............................................................................................................. 38

5.4.3. Analog input.................................................................................................. 38

5.4.4. Analog output ............................................................................................... 38

5.5. Discrete interface................................................................................................. 39

5.5.1. Inputs .............................................................................................................. 39

5.5.2. Outputs........................................................................................................... 39

5.6. LED indicators ....................................................................................................... 40

5.6.1. Heartbeat LED (1).......................................................................................... 40

5.6.2. Synchronized LED (2) .................................................................................... 40

5.6.3. Sequence LED (3).......................................................................................... 40

5.6.4. Weld LED (4)................................................................................................... 40

5.6.5. Data Send/Receive LEDs (5…12) ................................................................ 40

5.6.6. NS/MS LEDs..................................................................................................... 40

6. Modbus......................................................................................................................... 41

6.1. Access types......................................................................................................... 41

6.2. Inputs to EN7000 ................................................................................................... 42

6.3. Outputs from EN7000 ........................................................................................... 43

6.4. Parameter mapping ............................................................................................ 47

6.4.1. Weld program parameters .......................................................................... 48

EN7000 User Guide

6.4.2. Electrode parameters .................................................................................. 51

6.4.3. Calibration parameters ................................................................................ 52

6.4.4. Configuration parameters ........................................................................... 53

7. EtherNet/IP ................................................................................................................... 55

7.1. Functionality.......................................................................................................... 55

7.2. Ports ....................................................................................................................... 55

7.3. Status LEDs (MS & NS)........................................................................................... 55

7.4. Cyclic I/O (class 1 connection) .......................................................................... 56

7.5. Parameter programming .................................................................................... 57

7.6. Interfacing with a PLC ......................................................................................... 57

8. Configuration............................................................................................................... 58

9. Status messages .......................................................................................................... 59

10. History log.................................................................................................................. 61

11. Programming............................................................................................................ 62

11.1. Security .............................................................................................................. 62

11.1.1. PIN codes....................................................................................................... 62

11.1.2. Edit switch ...................................................................................................... 62

11.2. Programming with WSP3 pendant.................................................................. 63

11.2.1. Keypad........................................................................................................... 64

11.2.2. Diagnostic or Status screen.......................................................................... 64

11.2.3. Menus ............................................................................................................. 65

11.2.4. Backup/Restore............................................................................................. 66

11.2.5. Initialise data.................................................................................................. 66

11.3. Programming with NetFlash............................................................................. 66

11.4. Programming with the Touch-screen ............................................................. 67

11.5. Programming with MODBUS ............................................................................ 67

11.6. Programming with EtherNet/IP........................................................................ 67

12. Dimensions and Mounting ...................................................................................... 68

12.1. Gear plate mounting ....................................................................................... 68

12.1.1. EN7000............................................................................................................ 68

12.1.2. EN7000v2........................................................................................................ 68

12.2. Front panel mounting....................................................................................... 69

12.2.1. EN7000-TS ....................................................................................................... 69

12.2.2. EN7000v2-TS ................................................................................................... 69

EN7000 User Guide

13. Tutorials...................................................................................................................... 70

13.1. Setting up a constant current weld................................................................ 70

13.2. Testing the weld current................................................................................... 71

13.2.1. Current monitor ............................................................................................. 71

13.2.2. Conduction monitor (C-Monitor) ................................................................ 71

13.3. Using the Valves to control a multi-head machine ...................................... 72

13.4. Controlling a multi-welder ............................................................................... 75

13.5. Controlling an Air over oil system.................................................................... 77

13.6. Setting the power factor.................................................................................. 78

13.7. Resetting Faults ................................................................................................. 79

13.7.1. Touch-screen ................................................................................................. 79

13.7.2. WSP3 ............................................................................................................... 79

13.7.3. NetFlash.......................................................................................................... 79

13.7.4. Discrete input................................................................................................. 79

13.7.5. Bus input ......................................................................................................... 79

13.8. Setting the IP address....................................................................................... 80

13.8.1. EN7000v2 and EN7000v2-TS.......................................................................... 80

13.8.2. EN7000 and EN7000-TS.................................................................................. 80

13.9. Updating the firmware..................................................................................... 83

14. Terminology .............................................................................................................. 84

EN7000 User Guide

1. Introduction

The EN7000 is a Single-phase AC and 3-phase DC constant current and proportional force

controller for 50/60 Hz spot, projection and seam welding applications.

The controller is available in two formats:

 EN7000: welding control with pre-heat, main heat and post-heat intervals, force

profile, multi-gun, multi-air valve, multi electrode manager and expansion port.

Gear-plate (flat plate) mounted.

 EN7000-TS: as EN7000, plus built-in touch screen display.

Front panel mounted.

EN7000 EN7000-TS

Multiple communication and control options are supported by a number of programming

methods. The Ethernet port supports simultaneous programming and control connection via a

single physical cable. EN7000v2 and EN7000v2-TS include integrated EtherNet/IP. For EN7000 and

EN7000-TS, EtherNet/IP can be provided via an optional plug-in adapter board.

Short-circuit proof outputs and a guided-contact pilot relay provides enhanced safety.

Connection to the power system is via a single ribbon cable. Analog inputs and outputs can be

used to drive a proportional air regulator valve for force control.

Operation in Standard mode provides a basic set of features for simple applications. Extended

mode adds advanced features for more demanding applications. Choose between Standard

or Extended features (See Configuration section). EN7000 must be restarted after changing this

setting.

1.1. Part numbers

Model Part number

EN7000 01-07-03

EN7000-TS 01-07-04

EN7000v2 01-27-03

EN7000v2-TS 01-27-04

EN7000 User Guide

1.2. Features

Model

EN7000 EN7000-TS

NetFlash

programming



WSP3 programming 



Built-in programmer



Panel mounting 

Gear-plate mounting 

Ethernet



EtherNet/IP



RS232 



RS485 



MODBUS TCP/IP 



MODBUS RTU 



Analogue inputs

1 1

Analogue outputs

1 1

Discrete inputs 16 16

Discrete outputs

16 16

Weld programmes 256 256

Pre-heat 



Main heat 



Post-heat



Slope 



Constant current 



Power factor adjust 



Cascade/Mux

8 8

Multi air valve

6, 7

8 8

Aux valves 7 7

Force profile



Electrodes/SCRs

8 8

Real-time clock 



Data log (spot welds) 6000 6000

Expansion slot 



Analog control



Colour touch-screen display

Two simultaneous connections

Standard on v2 models, otherwise requires plug-in adapter board.

0 to 10 V

24 V dc, short-circuit proof, monitored

Extended feature

Guided contact safety relay, monitored

The symbol is used throughout this manual to indicate

that the feature is available when the configuration parameter

Features is set to extended.

Extended

EN7000 User Guide

1.3. Weld schedule parameters

EN7000/EN7000-TS

Presqueeze 

Squeeze 

Pre-heat 

Cool1 

Upslope 

Main heat 

Cool2 

Downslope 

Pulses 

Post-heat



Hold 

Off 

WAV selection



Aux valve control 

Retract/Hi-lift 

Electrode selection



Force profile



SCR selection



Current monitor 

Retry



Conduction monitor



Force monitor 

Spot weld 

Roll-spot weld



Seam weld



Extended feature

The extended features option can be enabled for greater flexibility or

more demanding applications.

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