700202: RDH Options

700202: RDH Options
INSTRUCTION MANUAL
700202J
RDH OPTIONS
FOR MICROPROCESSOR BASED
EN1000/EN1001 SERIES WELD CONTROLS
MANUAL INCLUDES:
RDH – Remote Data Harness Addition to Weld Control
RDE – Remote Data Entry (8.5 x 8.5) – OBSOLETE
RDEjr. – Remote Data Entry Junior (5.5 x 5.5)
MM2/MM8 – Memory Modules
RDE Cable Assemblies
NOTICE
This Manual supersedes 700132G, 700177A, 700201A, 700202A
ENTRON Controls, LLC.
1402 S. Batesville Road
Greer, South Carolina 29650
(864) 416-0190
FAX: (864) 416-0195
www.entroncontrols.com
ENTRON Controls, LLC. • 700202J • Page 1
THIS PAGE
INTENTIONALLY
BLANK
Page 2 • 700202J • ENTRON Controls, LLC.
ENTRON Controls, LLC.
MICROPROCESSOR BASED WELDING CONTROLS
INSTALLATION AND OPERATION MANUAL FOR:
Model Series RDH Options

CAUTION

READ THIS MANUAL COMPLETELY BEFORE ATTEMPTING
TO INSTALL OR OPERATE THIS CONTROL
ENTRON Controls, LLC., reserves the right to alter the contents of this
manual without previous notice.
ENTRON Controls, LLC.
Greer, South Carolina 29650
ENTRON Controls, LLC. • 700202J • Page 3
TABLE OF CONTENTS
1.0 GENERAL DESCRIPTION ................................................................................. 5
1.1
1.2
1.3
1.4
2.0
3.0
4.0
5.0
6.0
7.0
RDH (REMOTE DATA HARNESS) ................................................................................... 5
RDE & RDEjr. (REMOTE DATA ENTRY) .......................................................................... 5
MM2/MM8 MEMORY MODULES ..................................................................................... 5
CABLE ASSEMBLIES ....................................................................................................... 5
RDH HARNESS ................................................................................................. 6
2.1 RDH OPTION FIELD RETROFIT KIT ............................................................................... 6
2.2 ORDERING INFORMATION ............................................................................................. 7
2.3 WIRING DIAGRAMS ........................................................................................................ 8
RDE (REMOTE DATA ENTRY) – OBSOLETE ................................................................. 9
3.1 OPERATION ................................................................................................................... 10
3.2 ORDERING INFORMATION ........................................................................................... 10
RDEjr. (REMOTE DATA ENTRY JUNIOR) ....................................................... 11
4.1 OPERATION ................................................................................................................... 12
4.2 ORDERING INFORMATION ........................................................................................... 12
MM2/MM8 MEMORY MODULES..................................................................... 13
5.1 DOCUMENTATION REFERENCES ............................................................................... 13
5.2 REQUIRED EQUIPMENT AND SOFTWARE ................................................................. 13
5.3 COPY ALL DATA FROM CONTROL TO MM2/MM8 ....................................................... 14
5.4 DOWNLOAD ALL DATA FROM MM2/MM8 TO CONTROL ............................................ 14
5.5 ERROR CODES ............................................................................................................. 16
5.6 ORDERING INFORMATION ........................................................................................... 16
RDE AND RDEjr. CABLE ASSEMBLIES ......................................................... 17
6.1 RDE-RDE CABLE ASSEMBLY ....................................................................................... 17
6.2 RDEjr. CABLE ASSEMBLY – FIELD ASSEMBLY OF 9 PIN
D-SUBMINIATURE CABLE EXTENSION ....................................................................... 18
6.3 ORDERING INFORMATION ........................................................................................... 19
WARRANTY AND SERVICE ............................................................................ 20
FIGURES
FIGURE 1-1.
FIGURE 2-1.
FIGURE 2-2.
FIGURE 3-1.
FIGURE 3-2.
FIGURE 4-1.
FIGURE 4-2.
FIGURE 5-1.
FIGURE 5-2.
FIGURE 5-3.
FIGURE 5-4.
FIGURE 6-1.
FIGURE 6-2.
FIGURE 6-3.
FIGURE 6-4.
BASIC CONNECTIONS OVERVIEW ......................................................................... 5
RDH HARNESS ......................................................................................................... 6
RDE MOUNTING DETAILS ........................................................................................ 7
RDE ............................................................................................................................ 9
RDE CONNECTIONS .............................................................................................. 10
RDEjr. ....................................................................................................................... 11
RDEjr. CONNECTIONS ........................................................................................... 12
MM2 AND MM8 ........................................................................................................ 13
CONNECTION OF MM2-RDE OR MM8-RDE TO THE CONTROL ......................... 14
CONNECTION OF MM2 TO THE CONTROL .......................................................... 15
CONNECTION OF MM8 TO THE CONTROL .......................................................... 15
RDE-RDE HARNESS WIRING ................................................................................ 17
RDE-RDE HARNESS LABELING ............................................................................ 17
RDEjr. CABLE ASSEMBLY EXTENSION ................................................................. 19
RIBBON CABLE DETAIL .......................................................................................... 18
TABLES
TABLE 2-1.
TABLE 6-1.
RDH COMPONENTS ................................................................................................. 7
RDEjr. CABLE ASSEMBLY PARTS LIST ................................................................. 19
Page 4 • 700202J • ENTRON Controls, LLC.
1.0 GENERAL DESCRIPTION
TYPICAL SINGLE CONTACTOR CONNECTIONS
Figure 1-1. Basic Connections Overview
1.1 RDH (REMOTE DATA HARNESS)
A RDH (Remote Data Harness) is an open accessory port into the control from the outside that
can expand the use of an existing ENTRON Control. Once the RDH option is installed in the
weld control, several other options can then be connected to this external connector.
1.2 RDE & RDEjr. (REMOTE DATA ENTRY)
The ENTRON Remote Data Entry (RDE/RDEjr.) option provides a means of programming a
weld control from a location separate from the control. A machine operator’s position, for
example, may require frequent adjustment of a weld schedule. The RDE/RDEjr. may be located
near the operator when the weld control cabinet is mounted on an inaccessible side of the
welder (see Figure 1-1). See Sections 3.0 and 4.0 for detailed explanation.
1.3 MM2/MM8 MEMORY MODULES
The MM2 Memory Module is designed as a backup device for EN1000/EN1001 Single Function
Series Controls. The MM8 Memory Module is designed as a backup device for any EN1000/
EN1001 Cascade Control. See Figure 1-1 and Section 5.0 for detailed explanation.
1.4 CABLE ASSEMBLIES
RDE options come with cable and connectors. Users must construct their own assembly (see
Section 6.0). RDEjr. options come with six-foot attached pre-assembled cable assembly (see
Section 6.2).
RDE and RDEjr. cable assemblies should be kept as short as possible. Some applications may
require more than six feet between the weld control and the RDEjr. When distances greater than
six feet are required, ENTRON recommends the use of the RT4 – RS485 interface which allows
distances of up to several miles between the data entry device (RT4) and the weld control (see
Instruction Manual 700171).
ENTRON Controls, LLC. • 700202J • Page 5
2.0 RDH HARNESS
A RDH (Remote Data Harness) option is an open accessory port into the control from the
outside that can expand the use of an existing ENTRON Control. The RDH is nothing more
than a harness that extends the communication bus to the outside of the control. This interface
is not industrially hardened enough to travel long distances outside the control but works well
with typical six-foot lengths. See Section 6.2 if longer lengths are needed.
ENTRON
SINGLE CONTACTOR
CONTROL CABINET
ENTRON
CASCADE
CONTROL CABINET
! TO OPTIONS
!
TO OPTIONS
Figure 2-1. RDH Harness
2.1 RDH OPTION FIELD RETROFIT KIT
A RDH may be used to add the RDE or RDEjr. option or MM2/MM8 to an existing control in
a “B”, “C”, “S”, “E”, “T/D” or “LS/LF” Cabinet. A RDE or RDEjr. can be added to virtually any
EN1000 or EN1001 Series Control that has no pre-existing options. Mounting positions for 9
Pin D-Subminiature connector are available on “B”, “C”, “S”, “E”, “T/D” and “LS/LF” Cabinets.
If the customer has a J4-MM2 or J4-MM8 module, it will need to be unplugged so the J4 end of
the J4-RDE cable may be attached to the control. In cabinets built before the mid 1990s and on
NEMA 12 style cabinets “H”, “G”, and “U”, 9 Pin D-Subminiature connector mounting positions
were not provided on all cabinet styles and the customer will need to modify the cabinet to
mount the D-Subminiature end of the J4-RDE cable. Greenlee provides a punch (Greenlee Part
No. 229; see Figure 2-2) that may be used to punch a mounting for this connector. For customers
with controls with options plugged into the J4 connector on PCB1 or controls not in the EN1000,
EN1001, EN1003, or EN1004 families, please contact factory for availability of RDE input
options for your application.
Page 6 • 700202J • ENTRON Controls, LLC.
2.1 RDH OPTION FIELD RETROFIT KIT (cont.)
Table 2-1. RDH Components
RDH Field Retrofit Kit - 600718
Qty.
Description
1
Assem, Harness, J4-RDE, 44O
1
Label, RDE
Part No.
322369-007
460295
In standard controls provided by ENTRON, the J4-RDE Harness in “E” and “S” Cabinets is 44
inches long (P/N 322369-007); the J4-RDE Harness in “C/D/T/LS/LF” Cabinets is 17-1/2 inches
long (P/N 322369-006). The 44O Harness included in this kit is universal for all cabinet types
and can be bundled and tied back.
Figure 2-2. RDE Mounting Details
NOTICE
DO NOT connect RS232 or other serial devices to the RDE port.
2.2 ORDERING INFORMATION
Weld controls can be ordered with RDH options or they may be field installed. When required
at time of order, add the RDH designation to Model Number after the Series type; for example,
EN1000/RDH.
ENTRON Controls, LLC. • 700202J • Page 7
2.3 WIRING DIAGRAMS
421274
EN1000-Series/RDH with RDE Option for use with EN1000 &
EN1001 Single Contactor Controls and EN1000 & EN1001 Cascade/
Multi-Valve Controls
421180-005
EN1000-Series/RDH, “S” Cabinet
421210-015
EN1000-Series/RDH, “D/T/LS/LF” Cabinet
421210-028
EN1000-FPX(SCR)/RDH/485, 11x11 Flat Plate
421210-034
EN1000-Series/RDH/SP, “D/T/LS/LF” Cabinet, SP=24VDC Power
Supply
421212-004
EN1000-Series/RDH, “E” Cabinet
421268-003
EN1001-Series/RDH, “E” Cabinet
421269-002
EN1001-Series/RDH, “D/T/LS/LF” Cabinet
421269-024
EN1001/S49/SP-Series/RDH, “D/T/LS/LF” Cabinet, SP=DC Valve
Outputs & 24VDC Power Supply
421269-030
EN1001/S49/SP-3200/RDH, “LS/LF” Cabinet, SP=Customer Supplied
Circuit Breaker and Contactor Mounting
421377-008
EN1001(TGA)-1200/GF/RDH, “D/T” Cabinet with “S” Connector &
24VAC Valve Transformer
421387-006
EN1000(TGA)-1200/GF/RDH, “D/T” Cabinet with “S” Connector
421414
EN(2)1000-1200/RDH, “LF” Cabinet
421438-018
EN1001-FP(SCR)/RDH, 9x24 Flat Plate, Cascade/Multi-Valve Control,
230/380/460/575V
Page 8 • 700202J • ENTRON Controls, LLC.
3.0 RDE (REMOTE DATA ENTRY) – OBSOLETE - See RDEjr. Section 4.0
The ENTRON Remote Data Entry (RDE) option provides a means of programming a weld
control from a location separate from the control. A machine operator’s position, for example,
may require frequent adjustment of a weld schedule. The RDE may be located near the operator
when the weld control cabinet is mounted on an inaccessible side of the welder. The RDE is
powered by the control to which it is connected and needs no additional power; it can be moved
wherever it is needed.
The standard RDE option includes a remote panel measuring 8-3/4" x 8-3/4" x 3" (Figure 3-1)
with a carrying handle (which can be moved to any side). It is constructed of 14 Ga. steel and is
equipped with a standard (silk screen printed) ENTRON Dial Plate with push button switches.
The unit comes with two cage clamp (non-solder) style 9 pin male D-Subminiature connectors
and 25 feet of cable for connecting RDE to the parent weld control.
9 PIN
CONNECTOR

Figure 3-1. RDE
Any weld control intended for use with the RDE must contain a RDH (see Section 2.0). This
harness is internal to the weld control cabinet and connects the RDE to the control. The location
of the plug-in interface connection will differ depending on which model is ordered.
Standard length cable supplied with control is 25 feet and is assembled in the field.
Special consideration must be given when routing the RDE cable to the remote location. Be
sure some physical distance exists between high voltage wires and the RDE cable to eliminate
the introduction of electrical noise and insure proper data transmission between the control and
RDE Display Panel. It is recommended to insulate the mounting of this cabinet from the machine
to prevent circulating currents.
NOTICE
No differential voltages can exist between the device the RDE is mounted to and the weld
control cabinet.
ENTRON Controls, LLC. • 700202J • Page 9
EN1000 SERIES
CONTROL
Figure 3-2. RDE Connections
3.1 OPERATION
Operation of the RDE is simple as it is a complete reflection of the parent control. The same
buttons and displays are provided on the RDE unit. As of October 1, 2003, the software on
Cascade Series Controls has been revised so multiple welds and valves can be programmed by
use of the data LEDs (see Instruction Manual 700194).
The weld control can be programmed for either location. A PROGRAM LOCKOUT key switch
can be used at either location with the RDE. Special consideration must be given when routing
the RDE cable to the remote location. Be sure some physical distance exists between high
voltage wires and the RDE cable to eliminate the introduction of electrical noise and insure
proper data transmission between the control and RDE Display Panel. Connection and
disconnection to and from weld control should be done with power off.
3.2 ORDERING INFORMATION
The RDE can be ordered for any EN1000 Single Contactor and Cascade Control with or without
Constant Current. Check with factory for availability of RDE and RDH options on special
controls and controls with multiple options.
To order the RDE option, ask for:
RDE
(RDE is a Model Number in itself and is not
part of the weld control Model Number.)
NOTICE
For a control to be able to use the RDE option, it must have the RDH option.
Page 10 • 700202J • ENTRON Controls, LLC.
4.0 RDEjr. (REMOTE DATA ENTRY JUNIOR)
The ENTRON Remote Data Entry Junior (RDEjr.) option provides a means of programming a
weld control from a location separate from the control. A machine operator’s position, for
example, may require frequent adjustment of a weld schedule. The RDEjr. may be located near
the operator when the weld control cabinet is mounted on an inaccessible side of the welder.
The RDEjr. is powered by the control to which it is connected and needs no additional power; it
can be moved wherever it is needed.
This unit is enclosed in a 5-3/16 x 5-3/8 plastic case (Figure 4-1). It has a membrane keypad that
exactly models the parent weld control’s Dial Plate. The RDEjr. has a fixed length, non- removable
six-foot long pendant cord. See Section 6.2 for information to build a 9 Pin D-Subminiature
cable extension for the RDEjr. A PROGRAM LOCKOUT key switch is not available on RDEjr.
units. The PIN LOCKOUT mode can still be used (see EXTENDED FUNCTIONS section in
Instruction Manual 700120).
Figure 4-1. RDEjr.
Any weld control intended for use with the RDEjr. must contain a RDH (see Section 2.0). This
harness is internal to the weld control cabinet and connects the RDEjr. to the control. The
location of the plug-in interface connection will differ depending on which model is ordered.
Standard length cable supplied with control is six feet and is permanently installed. Other lengths
can be supplied, see Section 6.2.
Special consideration must be given when routing the RDEjr. cable to the remote location. Be
sure some physical distance exists between high voltage wires and the RDEjr. cable to eliminate
the introduction of electrical noise and insure proper data transmission between the control and
RDEjr. Display Panel. It is recommended to insulate the mounting of this cabinet from the
machine.
NOTICE
No differential voltages can exist between the device the RDEjr. is mounted to and the weld
control cabinet.
ENTRON Controls, LLC. • 700202J • Page 11
EN1000 SERIES
CONTROL

NO CONNECTOR WIRE PERMANENTLY ATTACHED
Figure 4-2. RDEjr. Connections
4.1 OPERATION
Operation of the RDEjr. is simple as it is a complete reflection of the parent control. As of
October 1, 2003, the software on Cascade Series Controls has been revised so multiple welds
and valves can be programmed by use of the data LEDs as the RDEjr. has no Valve or Contactor
specific displays (see Instruction Manual 700194).
The weld control can be programmed for either location. A PROGRAM LOCKOUT key switch
can only be used at the weld control location with the RDEjr. The PIN LOCKOUT mode can be
used with the RDEjr. (see EXTENDED FUNCTIONS section in Instruction Manual 700120).
Special consideration must be given when routing the RDEjr. cable to the remote location. Be
sure some physical distance exists between high voltage wires and the RDEjr. cable to eliminate
the introduction of electrical noise and insure proper data transmission between the control and
RDEjr. Display Panel. The six-foot cable length of the RDEjr. is the only approved and supplied
length of cable for that unit and is permanently attached to the unit. Longer lengths may be
constructed using low capacitance cable similar to those used in RS485 networks (ENTRON
P/N 900258). See Section 6.2 for RDE-RDE Cable Assembly. Connection and disconnection to
and from weld control should be done with power off.
4.2 ORDERING INFORMATION
The RDEjr. can be ordered for any EN1000 Single Contactor and Cascade Controls with or
without Constant Current. Check with factory for availability of RDEjr. and RDH options on
special controls and controls with multiple options.
To order the RDEjr. option, ask for:
RDEjr.
(RDEjr. is a Model Number in itself and is not
part of the weld control Model Number.)
NOTICE
For a control to be able to use the RDEjr. option, it must have the RDH option.
Page 12 • 700202J • ENTRON Controls, LLC.
5.0 MM2/MM8 MEMORY MODULES
The MM2 Memory Module is designed as
a backup device for any EN1000/EN1001
Series Control with PROM firmware
version 619016-001R or later.
The MM8 Memory Module is designed as
a backup device for any EN1000 Cascade
Control with Program Board 410321 and
PROM firmware version 619011-002A or
later or EN1001 Cascade Control with
Program Board 410363 and PROM
firmware version 619044-001B or later.
Figure 5-1. MM2 and MM8
Other ENTRON Series Controls are able to incorporate the MM2 or MM8 as backup devices.
Contact factory for specific control availability.
In either MM2 or MM8, there are two versions of this device:
MM2-RDE/MM8-RDE for controls with RDE option and MM2/MM8 for all other controls.
The only difference between these two versions is the connection to the control. The MM2RDE/MM8-RDE is designed to plug into an external 9 pin D-Subminiature connector. The
MM2 is designed to plug directly into the internal J4 connector on the Control Board or, in the
case of the MM8, to plug into the J4-B Connector on the WELD/VALVE LED Indicator Board.
5.1 DOCUMENTATION REFERENCES
MM2:
MM8:
Instruction Manual 700120
Instruction Manual 700194
EN1000/EN1001 Controls
EN1000/EN1001 Cascade Controls
5.2 REQUIRED EQUIPMENT AND SOFTWARE
MM2:
1. Any EN1001 Series Control with Control Board 600572-002 Revision V or an
older version of the board with PROM firmware version 619016-001R or later
or EN1000 Series Control with Control Board 600541 Revision WW or later.
2. MM2-RDE – Memory Module with 9 pin D-Subminiature connector, P/N 600662
(RDE option);
- or MM2 – Memory Module with 16 pin connector, P/N 600663 (J4 option).
MM8:
1. Any EN1000 Cascade Control with Program Board 410321 and PROM firmware
version 619011-002A or later or EN1001 Cascade Control with Program Board
410363 and PROM firmware version 619044-001B or later.
2. MM8-RDE – Memory Module with 9 pin D-Subminiature connector, P/N
600662-001 (RDE option);
- or MM8 – Memory Module with 16 pin connector, P/N 600663-001 (J4 option).
ENTRON Controls, LLC. • 700202J • Page 13
5.3 COPY ALL DATA FROM CONTROL TO MM2/MM8
Before copying all data from the control to the MM2/MM8, turn ALL power to control off.
Connect MM2/MM8 to the control, as shown in Figures 5-2, 5-3, and 5-4. With the control in
10 and press the
PROGRAM mode, use EXTENDED FUNCTION parameter C.A.
C.A., enter C.A.
C.A.=10
ENTER push button. In the latest software revision, after releasing ENTER, flashing S.t.o.r
S.t.o.r..
and t.o.E.E. will be on the DATA display. If ENTER is pressed again, all SCHEDULE data and
EXTENDED FUNCTIONS data will be stored in the Memory Module. Otherwise, if any other
push button is pressed, copying will be cancelled.
NOTICE
Previous contents of the MM2/MM8 device will be overwritten and unretrievable.
5.4 DOWNLOAD ALL DATA FROM MM2/MM8 TO CONTROL
Before downloading all data from the MM2/MM8 to the control, turn ALL power to control off.
Connect MM2/MM8 to the control, as shown in Figures 5-2, 5-3, and 5-4. With the control in
PROGRAM mode, use EXTENDED FUNCTION parameter C.A.
C.A., enter C.A.
C.A.=111 and press the
ENTER push button. In the latest software revision, after releasing ENTER, r.E.L.d. will be on
the DATA display. If the ENTER push button is pressed again, all SCHEDULE data and
EXTENDED FUNCTIONS data in the control will be overwritten with new downloaded data
from MM2/MM8. Otherwise, if any other push button is pressed, downloading will be cancelled.
Record date, Machine Identification information, etc., on the side of the Marker Tag opposite
the ENTRON Label.
Figure 5-2. Connection of MM2-RDE or MM8-RDE to the control
Page 14 • 700202J • ENTRON Controls, LLC.
5.4 DOWNLOAD ALL DATA FROM MM2/MM8 TO CONTROL (cont.)
Figure 5-3. Connection of MM2 to the control
Figure 5-4. Connection of MM8 to the control
The 16 pin socket is provided on the Marker Tag to protect the pins of the MM2/MM8 device
when it is not plugged into the Control Board.
NOTICE
Pin 1 of the MM2/MM8 MUST be plugged in to pin 1 of the J4 socket while power to the
control is off, or damage to the control and the MM2/MM8 will result.
ENTRON Controls, LLC. • 700202J • Page 15
5.5 ERROR CODES
33 – No Memory Module
ERROR CODE E.r
E.r..=33
This ERROR will be displayed if the MM2/MM8 is not connected to the control, or if the
MM2/MM8 does not exist, or if MM2/MM8 is not plugged in properly.
34 – Download CHECKSUM ERROR
ERROR CODE E.r
E.r..=34
This ERROR will be displayed if a CHECKSUM ERROR exists during download of data
from the MM2/MM8 to the control.
35 – Copy CHECKSUM ERROR
ERROR CODE E.r
E.r..=35
This ERROR will be displayed if a CHECKSUM ERROR exists during copy of data from
the control to the MM2/MM8.
NOTICE
If errors occur, retry. If errors persist, Memory Module may be defective.
5.6 ORDERING INFORMATION
The MM2 and MM8 can be ordered for any EN1000/EN1001 Single Contactor and Cascade
Control with or without Constant Current. Check with factory for availability of MM2/MM8
and RDH options on special controls and controls with multiple options.
To order the MM2 option, ask for:
MM2
(MM2 is a Model Number in itself and is not
part of the weld control Model Number.)
To order the MM8 option, ask for:
MM8
(MM8 is a Model Number in itself and is not
part of the weld control Model Number.)
NOTICE
For a control to be able to use the MM2/MM8 option, it must have the RDH option.
Page 16 • 700202J • ENTRON Controls, LLC.
6.0 RDE AND RDEjr. CABLE ASSEMBLIES
6.1 RDE-RDE CABLE ASSEMBLY
Provided cable assemblies will need to be constructed onsite after routing through conduits,
holes, troughs, etc. All cables should be separated as much as possible from other high voltage
wires connecting to solenoid valves, welding transformers, and the AC line. Pre-fabricated
RDE-RDE cable assemblies are not available. RDE options are provided with cables and
connectors as standard.
To create an RDE-RDE Harness, the following parts are required:
2
331136
Connector, 9 pin, Screw Terminal, “D” Style, Plug
25' 900258
Cable, 4 Conductor, 24 Ga. Stranded w/shield
2
460136
Label, RDE
Additional Connectors, Cable and Labels are available at additional cost.
Assembly Instructions:
1. Cut cable to length or route from source to destination. DO NOT route cable with or
place cable in same conduit with wires carrying 120 VAC or higher.
2. Strip outer insulation and foil shield at each end 1-1/2" and wire both ends as shown in
Figure 6-1.
3. Inspect connections before proceeding to next step. Note that one wrong connection
will stop ALL communication.
4. Assemble cover to plug assembly at both ends by snapping cover in place and using the
provided screw to secure the assembly.
5. Complete assembly by installing the provided labels on all connectors as shown in
Figure 6-2.
Figure 6-2. RDE-RDE
Harness labeling
Figure 6-1. RDE-RDE Harness wiring
ENTRON Controls, LLC. • 700202J • Page 17
6.2 RDEjr. CABLE ASSEMBLY – FIELD ASSEMBLY OF 9 PIN
D-SUBMINIATURE CABLE EXTENSION
The RDEjr. has been designed with a permanently attached six-foot long 9 pin D-Subminiature
male pendant. Some applications may require more than six feet between the RDEjr. and the
weld control. ENTRON has not tested lengths over six feet. When distances greater than six
feet are required, ENTRON recommends the use of the RT4 – RS485 interface which allows
distances of up to several miles between the data entry device (RT4) and the weld control (see
Instruction Manual 700171).
In cases where the customer wants to extend the six- foot pendant on the RDEjr., ENTRON
supplies the components and instructions below. ENTRON does not support the use of cords
beyond six feet in length. Please make note of the following information:
1. +5V is sent through this cable and is NOT fused. This same +5V is used by all other
components on the Control Board. Adding length may cause excessive voltage drop to
the RDEjr.
2. A 2 wire serial interface is used to send data to and from the RDEjr. Extended cable
length adds capacitance to these leads and will effect rise times and eventually cause
malfunction.
3. The serial interface used is not industrially hardened and will not tolerate radiated noise
and current loops introduced by cable extensions and improper routing and wiring.
Assembly Instructions (see Figure 6-3):
1. Run the retaining nut of the Connector Backshell (Part of Item ) on to the Cable (Item
). Strip the insulation on the Cable back approximately 2" on one end and unravel the
shield braid into two halves, folding each half back against the Cable insulation.
2. Remove unused wires from the flat cable back to the insulation (see Figure 6-4). Locate
the undivided portion closest to the end and assemble the Female Connector (Item ) to
the ribbon as shown, approximately 1" from the end of the insulation.
3. Insulate the inside of the Backshell (Item ) so the ends of the ribbon cable cannot
make contact with the metal shell.
4. Install the Jackscrews (Item ) with their associated hardware as the two halves of the
Backshell (Item ) are assembled so the ends lie over the folded back shield braid.
5. On the opposite end, run the retaining nut of the Connector Backshell (Part of Item )
on to the Cable. Strip the Cable insulation back approximately 2" and unravel the shield
braid into two halves, folding each half back against the Cable insulation.
6. Remove unused wires from the flat cable back to the insulation (see Figure 6-4). Locate
the undivided portion closest to the end and assemble the Male Connector (Item ) to
the remaining ribbon as shown, approximately 1" from the end of the insulation.
7. Insulate the inside of the Backshell (Item ) so the ends of the ribbon cable cannot
make contact with the metal shell.
8. Install the Thumbscrews (Item ) with their associated hardware as the two halves of
the Backshell (Item ) are assembled so the ends lie over the folded back shield braid.
Page 18 • 700202J • ENTRON Controls, LLC.
6.2 RDEjr. CABLE ASSEMBLY (cont.)
Table 6-1. RDEjr. Cable Assembly Parts List
PARTS LIST
QTY. ITEM DESCRIPTION
1
1
CABLE, .05 ROUND, SHIELDED, FLAT RIBBON
2
2
CONNECTOR, BACKSHELL FOR 9 PIN D-SUB
1
3
CONNECTOR, 9 PIN, METALLIC, D-SUB, IDC, FEMALE
1
4
CONNECTOR, 9 PIN METALLIC D-SUB, IDC, MALE
1
5
JACKSCREW, D-SUB BACKSHELL
1
6
THUMBSCREW, D-SUB BACKSHELL
as
7
LABEL, 1/2 X 1” WIDE OR INSULATION
needed
PART NO.
900297
331152
331127
331153
331124
331154
900296
Figure 6-3. RDEjr. Cable Assembly Extension
NOTICE
The trimmed ends of Item  cannot come in
contact with Backshell (Item ). Apply Insulation
(Item ) as needed on the inside (wire side) of
Backshell to act as insulation.
Figure 6-4. Ribbon Cable detail
6.3 ORDERING INFORMATION
Contact factory directly in regards to ordering. Order parts in Table 6-1 as spare parts.
ENTRON Controls, LLC. • 700202J • Page 19
7.0 ENTRON LIMITED WARRANTY AND FACTORY SERVICE
ENTRON Controls, LLC., warrants that all ENTRON control panels, EXCEPT Mid-frequency
Inverter controls, silicon controlled rectifiers (SCRs), insulated gate bipolar transistors (IGBTs),
SCR and IGBT assemblies, circuit breakers, and electro-mechanical contactors, are free of
manufacturing defects for a period of TWO YEARS from the date of original purchase and, in
the event of a manufacturing defect, ENTRON will repair or replace, at its discretion, the defective
part without any cost for parts or labor.
All silicon controlled rectifiers, SCR and IGBT assemblies, circuit breakers, and electromechanical contactors in ENTRON control panels are covered by a limited warranty from
the original manufacturer. If these parts fail because of a manufacturing defect, they will not
be repaired or replaced by ENTRON, but will be returned by ENTRON to the original
manufacturer in accordance with said manufacturer’s warranty.
ENTRON Controls, LLC., warrants that all Mid-frequency Inverter controls are free of
manufacturing defects for a period of ONE YEAR from the date of original purchase and, in
the event of a manufacturing defect, ENTRON will repair or replace, at its discretion, the defective
part without any cost for parts or labor.
To obtain repairs or replacement parts under this warranty, the defective part must be returned,
prepaid, to ENTRON Controls, LLC., 1402 S. Batesville Road, Greer, SC 29650. Please send
your repair to the attention of “Service” with a description of the problem you are experiencing,
contact person, and phone number.
EXCLUSIONS: This warranty does not cover damage by accident or misuse, unauthorized
repair or modification to any control assembly by the customer.
IMPORTANT NOTE: The warranty period is considered from the date of shipment and
is tracked by a serial number code.
USE OF OUT OF WARRANTY REPAIR SERVICE:
To obtain service for any printed circuit board assembly or welding control after the warranty
period, send assembly or control, prepaid, to ENTRON Controls, LLC., and ENTRON will
repair printed circuit board assembly or control and return it to you without further warranty.
Additional service charges will be invoiced at time of shipment.
Your ENTRON Controls, LLC., Original Equipment
Manufacturers (OEMs), Dealers and Distributors are your
first response contact to secure technical assistance on
control or welding problems. Should they be unable to
assist you, please contact your ENTRON sales
representative or the factory directly. Contact the factory
at 864-416-0190.
Page 20 • 700202J • ENTRON Controls, LLC.
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