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iPAK2

User Guide

Welding control for MFDC spot, projection, roll-spot, seam and multi-welding

applications.

For firmware version 2.04

Summary of Contents for 01-70-27

Page 1: ...iPAK2 User Guide Welding control for MFDC spot projection roll spot seam and multi welding applications For firmware version 2 04...

Page 2: ...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 n...

Page 3: ...ication 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 iPAK2 Water ingr...

Page 4: ...12 2 Weld Control 15 2 1 Sequence timing 15 2 2 Program options 16 2 3 Current control 17 2 3 1 PW mode 17 2 3 2 CCu mode 17 2 3 3 CCC mode 17 2 4 Timing diagrams 18 2 4 1 Spot weld 18 2 4 2 Spot pul...

Page 5: ...asurement by built in CT 34 4 3 3 Current measurement by external toroid spot weld only 35 4 4 CCC calibration 36 4 5 Force calibration 37 5 Input Output I O 38 5 1 Inputs 38 5 2 Outputs 39 5 3 Softst...

Page 6: ...4 Cyclic I O class 1 connection 58 7 5 Parameter programming 59 7 6 Interfacing with a PLC 59 8 Configuration 60 9 Duty cycle limiter 61 10 Status messages 62 11 History log 63 12 Programming 64 12 1...

Page 7: ...tion monitor C Monitor 70 13 3 Using the Valves to control a multi head machine 71 13 4 Controlling a multi welder 74 13 5 Resetting Faults 76 13 5 1 WSP3 76 13 5 2 NetFlash 76 13 5 3 Discrete input 7...

Page 8: ...ncludes integrated EtherNet IP For iPAK2 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 Connect...

Page 9: ...Multi air valve 5 6 8 Aux valves 7 Force profile 5 Electrodes 8 Real time clock Data log spot welds 6000 Expansion slot Analog control mode 6 1 Two simultaneous connections 2 Standard on v2 model oth...

Page 10: ...heat 1 Hold Off WAV selection 1 Aux valve control Retract Hi lift Electrode selection 1 Force profile 1 SCR selection 1 Current monitor Conduction monitor 1 Force monitor Spot weld Roll spot weld 1 Se...

Page 11: ...h the same WSP3 pendant that is used with EN7000 iPAK and WS2003 Access to all parameters is provided plus diagnostic indication 1 4 3 EtherNet IP On v2 models EtherNet IP is integrated as standard On...

Page 12: ...iPAK2 User Guide 11 1 5 Communications...

Page 13: ...K2 User Guide 12 1 6 Applications Standard machines portable manual guns robot guns multi welders and seam welders Standard machine Multi head machine Up to eight cylinders Cascade or independent firi...

Page 14: ...iPAK2 User Guide 13 Multi welder Up to 8 transformers and cylinders Cascade or independent firing...

Page 15: ...iPAK2 User Guide 14 Seam welder with one transformer Seam welder with a multi tap transformer...

Page 16: ...s time Main heat ms 0 1999 The main welding current is applied Cool22 ms 0 1999 The material is allowed to cool with electrode force applied Downslope ms 0 1999 Welding current is decreased during thi...

Page 17: ...ff The measured conduction will be checked against the C Monitor shunt limit C Monitor wear 2 on off The measured conduction will be checked against the C Monitor wear limit Retry 2 On off Weld schedu...

Page 18: ...rent2 kA 0 500 The current used during the Post heat interval in CCC mode Set point for monitoring Test current on off Each current can be tested between limits High limit 0 99 Current high limit Low...

Page 19: ...P Current Presqueeze Squeeze Main heat Hold Cool 1 Pre heat Upslope Downslope START I P Post heat 2 4 2 Spot pulsation Pre heat 0 Cool1 0 Post heat 0 Pulsations 3 Force profile off EOS O P WAV O P For...

Page 20: ...2 4 4 Seam MOTOR O P WAV O P Force O P Current Presqueeze Squeeze Main heat Hold Cool 1 Pre heat Upslope Downslope START I P Post heat Main heat Main heat Main heat Cool 2 Cool 2 Cool 2 The position...

Page 21: ...eat 0 Pulsations 1 Force profile off WAV O P Force O P Current Presqueeze Squeeze Hold START I P Main heat Off Hold Off Squeeze Hold Squeeze Main heat Main heat MOTOR O P To use Roll Spot set Seam wel...

Page 22: ...ff The input is not used The MOTOR output will not be driven Second Stage Before Squeeze The input is checked before the squeeze time runs MOTOR O P WAV O P Force O P Current Presqueeze Squeeze Hold S...

Page 23: ...ched off the Retract Air Valve switches off and the electrodes close to the mid position Welding can proceed in this case When the Retract Input is switched on the Retract Air Valve switches on and th...

Page 24: ...the electrodes go to the fully open position Welding cannot proceed in this case Maintained When the Retract Input is switched on the High Lift Air Valve switches on and the electrodes close to the mi...

Page 25: ...d1 kN lbf variable Force used from the start the Hold interval Wait for force2 on off Wait until the applied force has been reached Test force on off Test the applied force at the end of the Main inte...

Page 26: ...lectrode AV1 AV8 AV1 AV8 Any combination of AV1 to AV8 may be selected Valves not being used for the WAV or MOTOR function may be used as AUX valves WAV MOTOR settings always override any correspondin...

Page 27: ...se program configuration parameter This can be set by programming either manually or via a communications interface 2 8 2 External program selection If the Program select configuration parameter is se...

Page 28: ...e custom current profiles Note Pre heat and post heat are not available Force feedback is not available The input signal will control a different parameter depending on the mode set in the selected we...

Page 29: ...a cascade Up to eight transformers can be directly connected Up to 8 electrodes can be assigned to the welding transformers The electrode number is assigned in the weld program Weld program parameter...

Page 30: ...be assigned to transformers SCRs Electrodes 0 and 1 are assigned to transformer SCR 0 T0 Electrodes 2 and 3 are assigned to transformer SCR 1 T1 Electrodes 4 5 and 6 are assigned to transformer SCR 2...

Page 31: ...tarted independently but different electrodes and transformers can be selected The WAV signal can use a different output for each program Start input EOS output WAV output Program select Current trans...

Page 32: ...he cascade The Link program parameter specifies the next program in the cascade The cascade ends when a program runs with its Link option set to Off If a fault occurs during a cascade sequence Configu...

Page 33: ...tepper counter and calibration information 4 1 Steppers A stepper is programmed by means of a curve which will provide values of heat and current increments related to the number of spots done The cur...

Page 34: ...nable counter on off Enables or disables the counter Count welds 0 9999 The number of welds that have been done since the last reset End count welds 0 99999 The maximum number of welds that can be don...

Page 35: ...played secondary current will be the measured primary current multiplied by this value This method does not allow for losses in the transformer but will provide reasonable accuracy 2 Points 1 2 This i...

Page 36: ...circuits The toroids need to be switched in and out of circuit at the appropriate moment in the sequence or errors will occur In these circumstances use the CT measurement method The CT method has the...

Page 37: ...in CCC calibration Heat Current H2 H1 I1 I2 The iPAK2 will use these values to determine the relationship between Heat and Current CCC mode can now be selected in the welding schedules and required cu...

Page 38: ...0 Analog output point 2 OUT Point 2 kN lbf Measured output force point 2 IN Point 1 mV 0 10000 Analog input point 1 IN Point 1 kN lbf Measured input force point 1 IN Point 2 mV 0 10000 Analog input po...

Page 39: ...tage signal is present before proceeding to weld The checking is programmable to take place either before or after the Squeeze interval If the signal is not present iPAK2 waits for the signal before i...

Page 40: ...1 This output is active if iPAK2 is ready to weld The output switches off under some fault conditions Contactor MC1 This output can be used to control an isolation contactor Counter tip dress request...

Page 41: ...ling is set in Force calibration Analog Out Configuration parameter set to Current Outputs a signal representing the measured current Scaling must be set in the Waveform 10V configuration parameter 5...

Page 42: ...rent sourcing Connect load between output and 0V Output P3 pin AV1 1 AV2 2 AV3 3 HAV 4 Counter tip dress request 6 Stepper 7 Pre warn 8 AV4 9 AV5 10 AV6 11 AV7 12 AV8 13 EOS 14 Fault 15 Ready 16 Conta...

Page 43: ...eartbeat LED 1 This LED should always be flashing at 1Hz The duty indicates Long ON short OFF The control is in BIOS only mode Use NetFlash to install an application Short ON long OFF The control is r...

Page 44: ...E COMn where n desired port see table below Protocol Cable connected to Port MODBUS TCP IP RJ45 on iPAK2 TS COM1 RJ45 on EtherNet IP adapter card COM5 RJ45 on iPAK2v2 TS COM5 MODBUS RTU DSUB9 RS485 CO...

Page 45: ...QX1 0 BOOL Reserved Bit 9 QX1 1 BOOL Reserved Bit 10 QX1 2 BOOL Reserved Bit 11 QX1 3 BOOL Reserved Bit 12 QX1 4 BOOL Reserved Bit 13 QX1 5 BOOL Reserved Bit 14 QX1 6 BOOL Reserved Bit 15 QX1 7 BOOL W...

Page 46: ...Reset fault Bit 6 IX2 6 BOOL QX0 6 Reset counter Bit 7 IX2 7 BOOL QX0 7 Reset stepper Bit 8 IX3 0 BOOL QX1 0 Reserved Bit 9 IX3 1 BOOL Reserved Bit 10 IX3 2 BOOL Reserved Bit 11 IX3 3 BOOL Reserved B...

Page 47: ...BOOL Bit 16 Weld off Bit 1 IX18 1 BOOL Bit 17 Program inhibited Bit 2 IX18 2 BOOL Bit 18 Output fault Bit 3 IX18 3 BOOL Bit 19 Reserved Bit 4 IX18 4 BOOL Too many links Bit 5 IX18 5 BOOL Bit 21 Bad li...

Page 48: ...IX24 2 BOOL Bit 66 End of electrode 3 Bit 3 IX24 3 BOOL Bit 67 End of electrode 4 Bit 4 IX24 4 BOOL Bit 68 End of electrode 5 Bit 5 IX24 5 BOOL Bit 69 End of electrode 6 Bit 6 IX24 6 BOOL Bit 70 End...

Page 49: ...30 0 BOOL Inverter short circuit Bit 1 IX30 1 BOOL Inverter fan failure Bit 2 IX30 2 BOOL Inverter not ready Bit 3 IX30 3 BOOL LMI config error Bit 4 IX30 4 BOOL LMI error Bit 5 IX30 5 BOOL Duty cycle...

Page 50: ...16 4080 16512 WORD ARRAY 0 63 Electrode 3 16 40C0 16576 WORD ARRAY 0 63 Electrode 4 16 4100 16640 WORD ARRAY 0 63 Electrode 5 16 4140 16704 WORD ARRAY 0 63 Electrode 6 16 4180 16768 WORD ARRAY 0 63 El...

Page 51: ...f 1 on Test force Bit 12 IX1 4 BOOL 0 off 1 on Test pre current Bit 13 IX1 5 BOOL 0 off 1 on Test main current Bit 14 IX1 6 BOOL 0 off 1 on Test post current Bit 15 IX1 7 BOOL 0 off 1 on Presqueeze ti...

Page 52: ...eld program 31 IW31 WORD Post heat valves1 Weld program 32 IW32 WORD Hold valves1 Weld program 33 IW33 WORD Off valves1 Weld program 34 IW34 WORD 1 Weld program nn IXnn 0 0 BOOL AV1 state 1 ON Weld pr...

Page 53: ...program Weld program 51 IW51 WORD 0 255 Reserved Weld program 52 IW52 WORD Reserved Weld program 53 IW53 WORD Reserved Weld program 54 IW54 WORD Reserved Weld program 55 IW55 WORD Reserved Weld progra...

Page 54: ...Bit 4 IX0 4 BOOL 0 off 1 on Transformer Electrode 1 IW1 WORD 0 7 Counter Electrode 2 IW2 WORD 0 9999 Endcount Electrode 3 IW3 WORD 0 9999 Dressings done Electrode 4 IW4 WORD 0 9999 Max dressings Elect...

Page 55: ...erved Calibration 9 IW9 WORD Toroid sensitivity Calibration 10 IW10 WORD 1 60000 mV kA Convert CT Calibration 11 IW11 WORD 0 use 2 points 1 use turns ratio CT X1 Calibration 12 IW12 DWORD 0 32000 CT Y...

Page 56: ...imperial Electrodes Configuration 6 IW6 WORD 0 single 1 multi Fault Configuration 7 IW7 WORD Stop Bit 0 IX7 0 BOOL 1 stop on fault EOS Bit 1 IX7 1 BOOL 1 EOS on fault Headlock Bit 2 IX7 2 BOOL 1 headl...

Page 57: ...1 Configuration 27 IW27 WORD 0 255 IP address1 Configuration 28 IW28 WORD 0 255 IP address1 Configuration 29 IW29 WORD 0 255 IP address lsb 1 Configuration 30 IW30 WORD 0 255 Sub net mask msb 1 Config...

Page 58: ...licit UDP 44818 Explicit UDP IO 2222 Implicit Cyclic I O 7 3 Status LEDs MS NS On power up the LEDs perform the following sequence as defined by the EtherNet IP specification LE1 MS LE2 NS Duration s...

Page 59: ...ter access is always available even if I O Source is set to something other than COM6 The controlling device usually a plc must then be set up to initiate the connection The following screen shot show...

Page 60: ...uld be interpreted as 16 bit words in little endian format lsb sent first The definition of these words can be found in the Modbus section of this manual For example to modify a weld parameter in prog...

Page 61: ...ry The 2nd stage input is checked at the start of every spot within a sequence Applies to spot repeat cascade and roll spot modes but not seam Retract Simple Selects the Retract function See Welding c...

Page 62: ...n by the curve below The iPAK2 protects against weld sequences that would exceed the allowable duty cycle In this event the inverter will Stop at the end of a spot weld Stop immediately in a seam weld...

Page 63: ...t Reduce heat current Calibration error Check parameters in calibration program Low force Check the analog input and output circuits and or adjust force parameters High force Check the analog input an...

Page 64: ...ep Prewarn 7 Stepper 7 has completed its 9th step Inverter DC BUS error Check inverter Inverter short circuit Check inverter Inverter fan failure Check inverter Inverter not ready Wait for inverter to...

Page 65: ...ch only the key holders will be able to make edits All parameters remain viewable read only When configured this feature applies to the WSP3 Note that if this feature is used then the P64 program sele...

Page 66: ...y are changed immediately in the iPAK2 The WSP3 is a hand held programming pendant with a 20x4 character display and a sealed keypad The WSP3 can be used to access diagnostic information in addition t...

Page 67: ...nction Alter the selected parameter Press both keys together to set the parameter to 0 or to its minimum value 12 2 2 Diagnostic or Status screen Status message Ready Measured Pre current 0 A prog 7 P...

Page 68: ...ess and hold then press main menu Use program program menu Edit program Edit time Edit electrode Edit current History log Edit force Discrete I O status Edit valves Bus I O status Edit options Analog...

Page 69: ...tialise data The Initialise function sets all of the parameters in the iPAK2 to predefined values The Initialise function will overwrite all previously stored data in the iPAK2 After an initialise ope...

Page 70: ...of the programmable AUX valves feature 1 Connect the air solenoid ADVANCE to the AV1 SV1 output or whichever output you have programmed to provide the WAV function 2 Connect the hydraulic solenoid INT...

Page 71: ...Monitor The control measures the percentage conduction of the Main heat interval The user may set low shunt and high wear limits thus setting an acceptance window These limits are absolute values the...

Page 72: ...alve parameters to select an output that will be used as the WAV 2 The WAV will become active when the Start input is active and will remain active until the end of the weld sequence unless programmed...

Page 73: ...72 The diagram shows the operation in multi gun mode Start input EOS output AV1 output AV2 output AV3 output AV4 output Program 0 1 2 3 select Current Program 0 Current Program 1 Current Program 2 Cu...

Page 74: ...er in multi gun cascade mode The program select inputs select the first program in the cascade 0 in this example Start input EOS output AV1 output AV2 output AV3 output AV4 output Program First progra...

Page 75: ...nsformers for each welding head The welding heads can be controlled as described in the previous tutorial 1 Choose the transformers that will be assigned to the electrodes The procedure is described i...

Page 76: ...d programs 4 and 5 are assigned to Electrode 2 5 2 6 3 Weld programs 6 and 7 are assigned to Electrode 3 7 3 8 4 Weld programs 8 and 9 are assigned to Electrode 4 9 4 10 5 Weld programs 10 and 11 are...

Page 77: ...3 5 3 Discrete input Input Pin number Description Reset fault P2 15 This input resets the Fault output and clears the status messages Only momentary application is required minimum time 40ms The discr...

Page 78: ...r for Ethernet communications on COM0 and COM1 The device server is an xPort AR device manufactured by Lantronix To set the IP address of the main board port on iPAK2 use Lantronix DeviceInstaller sof...

Page 79: ...iPAK2 User Guide 78 Select the iPAK2 xPort AR device then select Assign IP Select Assign a specific IP address and then select Next...

Page 80: ...Guide 79 Enter the IP address subnet mask and gateway then select Next Select Assign to complete the assignment Device Installer will show the progress of the operation Select Finish to return to the...

Page 81: ...to update the firmware Initialise NetFlash and select the target iPAK2 as described in the Tutorial section setting the IP address Select the Flash Programming tool The following screen is shown Sele...

Page 82: ...Milliamp 1 1000 amp mV Millivolt 1 1000 volt Off time In a Repeated weld sequence this is the time between sequences Expressed in mains cycles PHA See Phase angle control Pulse width PW control Open...

Page 83: ...worn electrodes to restore their original shape and dimensions Toroid A device used for sensing current in a cable The current carrying cable must pass through the toroid Upslope A linear increase in...

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