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iPAK2 Technical Manual

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

For firmware version 2.01

Summary of Contents for iPAK2

Page 1: ...iPAK2 Technical Manual Welding control for MFDC spot projection roll spot seam and multi welding applications For firmware version 2 01...

Page 2: ...s and trade dress may not be used in connection with any product or service that is not BF ENTRON s in any manner that is likely to cause confusion among customers or in any manner that disparages or...

Page 3: ...r 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 iPAK2 Wate...

Page 4: ...rete I O 21 Section 5 MODBUS I O 24 Section 6 Weld control 30 Section 7 Electrode management 38 Section 8 Status information 46 Section 9 History log 49 Section 10 Multiwelding 50 Section 11 Seam weld...

Page 5: ...hernet port supports simultaneous programming and control via a single physical cable Short circuit proof outputs and a guided contact pilot relay provides enhanced safety Connection to the power syst...

Page 6: ...Pre heat Main heat Post heat 5 Slope Constant current Cascade Mux 5 8 Multi air valve 4 5 8 Aux valves 7 Force profile 5 Electrodes 8 Real time clock Data log spot welds 6000 Expansion Analog control...

Page 7: ...n heat Cool2 Downslope Pulses Post heat 1 Hold Off WAV selection 1 Motor control Aux valve control Retract Hi lift Electrode selection 1 Force profile 1 Current monitor Force monitor Spot weld Roll sp...

Page 8: ...Pendant iPAK2 series controls work with the same WSP3 pendant that is used with EN7000 WS2003 and iPAK v1 Access to all parameters is provided plus diagnostic indication 3 MODBUS A PLC or HMI MODBUS...

Page 9: ...Section 1 Introduction 9 Communications Ethernet RS485 RS232...

Page 10: ...ion 1 Introduction 10 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 fir...

Page 11: ...Section 1 Introduction 11 Multi welder Up to 8 transformers and cylinders cascade or independent firing...

Page 12: ...Section 1 Introduction 12 Seam welder with one transformer Seam welder with a multi tap transformer...

Page 13: ...nverters have maximum primary current ratings as follows 150 A 360 A 600 A 1000 A 1500 A LMI For higher currents multiple LMI modules can be connected together The standard iPAK family operates with a...

Page 14: ...is used to connect a WSP3 programming pendant or a PC A ribbon cable assembly is available for converting to the standard 9 way D sub style of connector Connector P6 is used internally to connect to...

Page 15: ...Terminals L1 L2 L3 PE A suitable MF welding transformer rectifier should be connected to the inverter at terminals H1 and H2 The transformer must also be connected to the protective earth PE Addition...

Page 16: ...Section 2 Getting started 16 User s connections discrete...

Page 17: ...be required depending on the application Make sure there is sufficient air pressure and cooling water where necessary Section 13 Programming switch on then use the Initialise all data function to clea...

Page 18: ...nd Main mode P W A welding operation should be possible at this stage Begin by using the gun short circuit The iPAK2 should report the measured current on the diagnostic display Section 7 Electrode ma...

Page 19: ...ts for the signal before it proceeds If the Start signal is removed while waiting the sequence is aborted Retract RT1 This input is used to control the Retract function Reset fault FR1 This input rese...

Page 20: ...s output indicates that the stepper has reached its limit Pre warn This output indicates that the stepper is close to its limit AV1 Additional outputs that can be used during the weld sequence AV2 AV3...

Page 21: ...ts are accessible via connectors P1 P2 P3 P4 and P5 The connectors are two part terminals for use with wires up to 1 mm2 If the iPAK2 is supplied fitted into a case some connections will have been pre...

Page 22: ...et counter tip dress ack 14 5 Retract RT1 15 6 Reset fault FR1 16 4 2nd stage PS1 17 15 P64 BP64 Edit enable Pin I O bit 1 15 AV1 SV1 2 14 AV2 SV2 3 13 AV3 SV3 4 1 HAV RV1 5 Do not connect 6 5 Counter...

Page 23: ...d COM0 7 Data receive COM1 8 Data send COM1 9 Data receive COM2 10 Data send COM2 11 Data receive COM3 12 Data send COM3 1 Analog input 2 2 Analog input 2 3 Toroid input 4 Toroid input 5 Ground 1 Anal...

Page 24: ...S function 16 Read the outputs using MODBUS function 3 MODBUS access types Write inputs Type Value Description Function code UINT 16 Write multiple registers Read offset UINT 0 Read length UINT 0 Writ...

Page 25: ...r Bit 8 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...

Page 26: ...per Bit 8 IX3 0 BOOL QX1 0 P1 Bit 9 IX3 1 BOOL discrete input P1 P2 Bit 10 IX3 2 BOOL discrete input P2 P4 Bit 11 IX3 3 BOOL discrete input P4 P8 Bit 12 IX3 4 BOOL discrete input P8 P16 Bit 13 IX3 5 B...

Page 27: ...Bit 0 IX18 0 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...

Page 28: ...2 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 En...

Page 29: ...s fail Bit 0 IX30 0 BOOL Bit 112 Short circuit Bit 1 IX30 1 BOOL Bit 113 Fan failure Bit 2 IX30 2 BOOL Bit 114 Inverter not ready Bit 3 IX30 3 BOOL Bit 115 LMI config error Bit 4 IX30 4 BOOL Bit 116 L...

Page 30: ...control iPAK2 controls the weld sequence by using the I O in conjunction with the welding parameters The parameters are stored in programs so that different materials and machine sequences can be use...

Page 31: ...rce applied Downslope ms 0 1999 Welding current is decreased during this time Post heat3 ms 0 1999 The post heat welding current is applied Hold ms 0 1999 Electrode force continues after the welding c...

Page 32: ...0 1999 Welding current is decreased during this time Post heat2 ms 0 1999 The post heat welding current is applied Cool2 ms 0 1999 The material is allowed to cool with electrode force applied Hold ms...

Page 33: ...current can be tested between limits High limit 0 99 Current high limit Low limit 0 99 Current low limit 1 Pre heat program option must be enabled to use this feature 2 Post heat program option must b...

Page 34: ...al Post monitor2 yes no The current can be tested between limits High limit 0 99 Current high limit Low limit 0 99 Current low limit 1 Pre heat program option must be enabled to use this feature 2 Pos...

Page 35: ...sed from the start the Hold interval Off1 2 kN lbf variable Force used from the start the Off interval Wait for force3 yes no Wait until the applied force has been reached Test force yes no Test the a...

Page 36: ...e selected 1 Extended feature Valves not being used for the WAV or motor function may be used as AUX valves WAV motor settings always override any corresponding AUX settings The weld programs contain...

Page 37: ...ugget growth and reduce electrode wear The Start signal must be maintained for the full duration of the sequence if pulsations are set to 10 or more otherwise the sequence will terminate after 10 puls...

Page 38: ...epper provides a means of gradually increasing the current to compensate for electrode wear The counter counts the number of welds that the electrode has done and allows the electrode to be dressed a...

Page 39: ...0 The increase in heat during the step Current 0 0 50 0 The increase in current during the step Preset 1 5 Apply predefined values to the stepper curve Enable stepper yes no Enables or disables the st...

Page 40: ...ption Enable counter yes no 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...

Page 41: ...ata The displayed 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...

Page 42: ...ay be difficult to arrange toroids for multiple secondary 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 circums...

Page 43: ...ers 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 require...

Page 44: ...2 mV 0 10000 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 Ana...

Page 45: ...ectrode 0 7 The electrode number Transformer 0 7 The transformer that the electrode is connected to The diagram shows how the electrodes can be assigned to transformers Electrodes 0 and 1 are assigned...

Page 46: ...inhibited The selected weld program is inhibited 20 Output fault One or more outputs have failed 21 Reserved 22 Too many links Too many weld programs are linked together 23 Bad link A link has been ma...

Page 47: ...77 Reserved 78 Reserved 79 Reserved 80 Reserved 81 Tip dress 0 Dress the electrodes and then reset counter 0 82 Tip dress 1 Dress the electrodes and then reset counter 1 83 Tip dress 2 Dress the elec...

Page 48: ...transformer 115 Fan fail Check inverter fans 116 Inverter not ready Check control connections to inverter 117 LMI config error Check connections on LMI modules 118 LMI error Check indicator panel on...

Page 49: ...e The time and date when the entry was recorded Program 0 255 The weld program used Pre current kA 0 500 The current recorded during the Pre heat interval Main current kA 0 500 The current recorded du...

Page 50: ...e assigned to the welding transformers The electrode number is determined by the weld program Parameter Units Range Description Electrode 0 7 The electrode number The weld programs can be linked toget...

Page 51: ...T3 There are two methods available for multiwelding Multi gun operation allows each welding program to be triggered independently but allows for selection of a transformer and electrode Multi gun casc...

Page 52: ...tarted independently but different electrodes and transformers can be selected The WAV output can be a separate output for each program Start input EOS output WAV output Program select Current transfo...

Page 53: ...gun cascade operation the program select inputs select the first program in the cascade If a fault occurs during a cascade sequence Stop on fault1 Description Off Cascade will continue Fault output wi...

Page 54: ...de a flexible sequence that works in conjunction with the inputs and outputs to produce several different types of seam weld e g continuous seam seam pulsation seam modulation seam pre heat roll spot...

Page 55: ...he welding current has finished Current control Main mode P W CCu CCC Operating mode of the Main heat interval Main heat The heat used during the Main heat interval Main current kA The current used du...

Page 56: ...plied Hold ms Electrode force continues after the welding current has finished Current control Main mode P W CCu CCC Operating mode of the Main heat interval Main heat The heat used during the Main he...

Page 57: ...interval Main heat The heat used during the Main heat interval Main current kA The current used during the Main heat interval Main monitor1 yes no The current can be tested between limits Post mode P...

Page 58: ...the Pre heat interval Pre heat The heat used during the Pre heat interval Pre current kA The current used during the Pre heat interval Pre monitor1 yes no The current can be tested between limits Mai...

Page 59: ...Hold ms Electrode force continues after the welding current has finished Current control Pre mode P W CCu CCC Operating mode of the Pre heat interval Pre heat The heat used during the Pre heat interv...

Page 60: ...rol Main mode P W CCu CCC Operating mode of the Main heat interval Main heat The heat used during the Main heat interval Main current kA The current used during the Main heat interval Main monitor1 ye...

Page 61: ...ut is not used The motor output is not used1 Start input 2nd stage input Motor output Sequence begins Squeeze Before Squeeze The 2nd stage input is checked before the Squeeze interval The motor output...

Page 62: ...ted until a fault reset is given iPAK v1 mode yes no Changes the sense of the READY output to NOT READY AV4 5 and 6 are used for MUX selection Program select External The Program Select inputs select...

Page 63: ...CCu 0 to 100 heat CCC 0 to 100 current 3 Duty cycle limiter Duty is calculated over a 2 second averaging time The inverter rating applies at up to 20 duty At higher duties the maximum output current...

Page 64: ...ll 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 select bit 64 is no longer ava...

Page 65: ...AK2 System requirements NetFlash is a Microsoft Windows compatible PC program It requires the latest Java Runtime Environment which is available from https java com download The minimum screen resolut...

Page 66: ...If no network is available the PC can be connected directly to the iPAK2 Set the IP address in the iPAK2 Section 15 Appendix Set the IP address in the PC contact your system administrator For example...

Page 67: ...he network or from a file Network configuration Locates welding controls on the network Flash programming tool Allows the firmware in the iPAK2 to be updated Restart weld control Restarts the iPAK2 fo...

Page 68: ...assigned descriptive names and locations This function allows the names and locations to be edited Add a welding control to the network Remove a welding control from the network Scan for welding cont...

Page 69: ...ol for editing If Set as target IP address is selected the IP address will be shown as the target IP address Alternatively the target address can be set by using the Edit button To add a descriptive n...

Page 70: ...reen is shown This screen contains the parameters that control the weld sequence for the selected weld program NetFlash uses tabs to navigate the parameter categories Select the appropriate tab to edi...

Page 71: ...ged 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 to all para...

Page 72: ...l scroll if required Access the selected function Alter the selected parameter Press both keys together to set the parameter to 0 or to its minimum value Diagnostic screen Status Ready Measured Pre cu...

Page 73: ...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 i o status El...

Page 74: ...the settings in the iPAK2 from a backup stored in the WSP3 pendant Note that this operation will overwrite all data which was previously stored in the iPAK2 After the restore operation the backup rem...

Page 75: ...rted Write the data using MODBUS function 16 Read the data using MODBUS function 3 MODBUS access types Write data Type Value Description Function code UINT 16 Write multiple registers Read offset UINT...

Page 76: ...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 77: ...ld program 10 IW10 WORD 0 1999 Reserved Weld program 11 IW11 WORD Main current Weld program 12 IW12 DWORD 0 500000 Cool2 time Weld program 14 IW14 WORD 0 1999 Pulsations Weld program 15 IW15 WORD 1 99...

Page 78: ...st current Weld program 56 IW56 DWORD 0 500000 Reserved Weld program 58 IW58 WORD Reserved Weld program 59 IW59 WORD Reserved Weld program 60 IW60 WORD Attributes Weld program 61 IW61 WORD Inhibited B...

Page 79: ...IW8 WORD 0 32767 Reserved 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 IW...

Page 80: ...uration 9 IW9 WORD 0 external 1 internal Internal prog Configuration 10 IW10 WORD 0 255 I O source Configuration 11 IW11 WORD 0 discrete 1 MODBUS COM0 2 MODBUS COM1 3 MODBUS COM2 4 RS232 COM3 Regulati...

Page 81: ...gement ensure the Calibration parameters are set 01 Testing the weld current The current for each weld can be tested against upper and lower limits 1 In the weld program enable the Monitor option for...

Page 82: ...Force used from the start the Upslope interval Main heat kN lbf variable Force used from the start of the Main heat interval Cool2 kN lbf variable Force used from the start of the Cool2 interval Downs...

Page 83: ...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 High Lift Air Valve switches on and the electrodes open f...

Page 84: ...the electrodes go to the fully open position Welding will not 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...

Page 85: ...put is determined by the weld program 1 In the weld program use the Valve 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 wi...

Page 86: ...ls 86 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...

Page 87: ...ther 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 prog...

Page 88: ...ansformers 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...

Page 89: ...eld 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 ar...

Page 90: ...e air solenoid ADVANCE to the AV1 SV1 output or whichever output you have programmed to provide the WAV function 2 Connect the hydraulic solenoid INTENSIFY to the AV2 SV2 output or whichever AUX outpu...

Page 91: ...e 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 discrete I O is de...

Page 92: ...memories and then activated when iPAK2 starts In this way it is possible to retain different firmwares and activate them without having to reprogram iPAK2 When new features become available NetFlash i...

Page 93: ...ts the selected memory becomes active Setting the IP address iPAK2 uses a device server for Ethernet communications on COM0 and COM1 The device server is an xPort AR manufactured by Lantronix www lant...

Page 94: ...Section 15 Appendix 94 Select the iPAK2 xPort AR device then select Assign IP Select Assign a specific IP address and then select Next...

Page 95: ...pendix 95 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 96: ...starts the weld sequence See also Start signal kA Kilo amp 1000 amps kVA Unit of power 1000 volt amps mA Milliamp 1 1000 amp mV Millivolt 1 1000 volt Off time In a Repeated weld sequence this is the t...

Page 97: ...Tip dressing Filing or machining 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 tor...

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