Entron iPAK2 Technical Manual

iPAK2 Technical Manual

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

For firmware version 2.01

iPAK2 Technical Manual 2

iPAK2 Technical Manual

Copyright © 2019 BF ENTRON Ltd. and/or its affiliates. All rights reserved.

 The information in this manual is subject to change.
 BF ENTRON assumes no responsibility for any errors that may appear in this manual.
 BF ENTRON assumes no responsibility for any injury, loss or damage caused by improper installation,

use or application of the iPAK2 welding control

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

authority from BF ENTRON

 BF ENTRON's trademarks 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 discredits BF ENTRON. All other trademarks not owned by BF ENTRON are
the property of their respective owners, who may or may not be affiliated with, connected to, or
sponsored by BF ENTRON.

BF ENTRON Ltd.
Building 80 Bay 1

First Avenue

The Pensnett Estate

Kingswinford

West Midlands DY6 7FQ

Phone [phone] • Fax [phone]

www.entroncontrols.com

Issue Date Comment

2.00 27-02-19 Initial release

2.00.01 13-06-19 Minor errata corrected

2.00.02 19-06-19 Corrected weld program time range.

2.01 8-08-19 Added Presqueeze to all modes

England

iPAK2 Technical Manual 3

IMPORTANT SAFETY INSTRUCTIONS

READ ALL INSTRUCTIONS BEFORE USING THE iPAK2

WARNING

DO NOT DISASSEMBLE, REPAIR, OR MODIFY THE iPAK2. These actions can cause electric shock and fire.

 Use only as described in this manual. Use only BF 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 BF 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 iPAK2. 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 iPAK2 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.

iPAK2 Technical Manual 4

Contents

Section 1

Introduction…………………………………………………………………………………………...…5

Section 2

Getting started………...……………………………………………………………..………………13

Section 3

Inputs and outputs…………………….…....……………………………………………………19

Section 4

Discrete 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 welding………………..…….……………………………………………………...…………..54

Section 12

Configuration…………………..…….……………………………………………….….……………62

Section 13

Programming…………………..…….………………………………………………….……….……65

Section 14

Tutorials…………………..…….…………………………………………………………….…………...82

Section 15

Appendix…………………..…….……………………………………………………………….…….…92

Section 16

Terminology……………..…….…………………………………………………………………….…96

Section 1 Introduction 5

Introduction

The iPAK2 controller is suitable for MFDC spot, projection, roll-spot, seam and multi-welding welding
applications.

The controller supports:

 pre-heat, main heat and post-heat intervals
 force profiles
 multi-gun, multi-air valve applications
 multiple electrodes

The iPAK2 has multiple communication and control options and can be configured by a number of
programming options. The Ethernet 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 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 (Section 12 Configuration). The iPAK2 must be restarted after changing this setting.

Section 1 Introduction 6

Features

NetFlash programming
WSP3 programming
Ethernet 1
RS232
RS485
MODBUS TCP/IP
MODBUS RTU









Analogue inputs 2 2
Analogue outputs 2 1
Discrete inputs 16
Discrete outputs 3 16
Weld programmes 256
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 mode 5

1

Two ports

2

0 to 10 V

3

24 V dc, short-circuit proof, monitored

4

Guided contact safety relay, monitored

5

Extended feature




The extended features can be enabled for greater flexibility or more demanding applications.

Section 1 Introduction 7

Weld parameters

Prequeeze
Squeeze
Pre-heat
Cool1
Upslope
Main 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-spot weld 1
Seam weld 1

1

Extended feature

























Part number

Model Part number
iPAK2 01-70-27

Section 1 Introduction 8

Programming options

1.NetFlash

This PC-compatible program displays and allows editing of all
welding parameters and status information.

In addition to programming, NetFlash provides backup/restore
functions for control data, live data logging to a file and a utility for
updating the firmware in the iPAK2.

2. WSP3 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 master can be used to program, control
and monitor an iPAK2. All parameters are directly mapped to
MODBUS registers for easy access. Both MODBUS-TCP/IP
(Ethernet) and MODBUS-RTU (RS485) protocols are supported.

4. Ethernet/IP

An optional adapter card can be fitted to the expansion port,
providing full data access via the EtherNet/IP protocol.

Section 1 Introduction 9

Communications

Ethernet

RS485 RS232

Section 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 firing.

Section 1 Introduction 11

Multi-welder. Up to 8 transformers and cylinders, cascade or independent firing.

Section 1 Introduction 12

Seam welder with one transformer

Seam welder with a multi-tap transformer

Section 2 Getting started 13

Getting started

iPAK2 mounts directly onto an iPAK inverter. The inverters 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 supply voltage in the range 380-480V AC but lower and higher voltage inverters are
available.

Section 2 Getting started 14

Control connectors

Connectors P1, P2, P3, P4 and P5 are two-part terminals, for use with wires up to 1mm2.

The RS232 port 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 the inverter power pack, and is not used for users
connections.

Connector P7 is used for MUX driver cards on systems with more than one transformer.

Section 2 Getting started 15

Power connectors

A 3-phase supply via a suitable protective device (such as a circuit breaker) should be connected to the
inverter as shown (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).

Additional earthing and/or a protective device is required for the secondary circuit depending on the
application.

These tasks must only be carried out by qualified personnel.

Section 2 Getting started 16

User’s connections (discrete)

Section 2 Getting started 17

Initialisation

 Make the basic connections as shown below. Additional connections may 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 clear the

iPAK2’s memory.

 Section 12 Configuration: set the Configuration parameters appropriately for the application.

Section 2 Getting started 18

 Section 13 Programming: edit program 0 to set up a basic weld sequence e.g. Squeeze =

200, Main heat = 100, Hold = 200, Pulses=1, and 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 management: perform the current and CCC calibration procedures.
 Make any other adjustments which may be required and set up other programmes for welding.

Section 3 Inputs and outputs 19

Inputs and outputs

iPAK2 uses a number of inputs and outputs to control and monitor the weld sequence.

Inputs

Input AWS

Start FS1 When this input is activated a weld sequence begins. If the input is removed

Weld on NW1 This input enables the weld current. If this input is inactive a weld sequence will

Stop ES1 Sequencing is inhibited or aborted if this input is not active.
Thermal TT1 This input is usually connected to a normally closed thermal contact attached to

2nd stage PS1 If enabled, iPAK2 checks that the 2nd Stage signal is present before

Retract RT1 This input is used to control the Retract function.
Reset fault FR1 This input resets the Fault output and clears the status messages. Only

Reset
counter/tip
dress
acknowledge
Reset

2

stepper
P1 BP1 Program select inputs. Weld program selection is made by applying the binary
P2 BP2
P4 BP4
P8 BP8
P16 BP16
P32 BP32
P64 BP64
Toroid Input for the toroid. Resistance must be in the range 10 to 300 Ohms.
Analog 0 to 10 V analog input. Can be used to monitor a proportional air regulator valve

designation

Used to reset the counter(s) or acknowledge a tip dress request.

1

SR1 Used to reset the stepper(s).

Description

during the Squeeze interval the sequence is aborted. If the input is maintained
through the Squeeze interval but switched off subsequently, the sequence
terminates normally.

not produce any current.

the weld transformer. Sequencing is inhibited if this input is not active.

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 it proceeds. If the Start signal is removed while waiting, the
sequence is aborted.

momentary application is required (minimum time 40ms).

code for the required program. Programs 0 to 127 can be selected (programs
128 to 255 can still be selected internally or via the fieldbus).

If the ‘key-switch’ security option is selected, then input P64 (on the discrete
interface only) is not available. In this case, programs 0 to 63 can be selected
(programs 64 to 255 can still be selected internally or via the fieldbus).

output or other sensor for force control and monitoring.
input in ANALOG mode.

Also used as the control

Section 3 Inputs and outputs 20

Outputs

Output AWS

Description

designation
EOS EH1 This output switches on to indicate the end of the weld sequence.
HAV RV1 Used in conjunction with the Retract input to control the welding head.
Fault FT1 This output indicates a fault condition.
Ready3 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

This output indicates that the counter has reached its limit or that a tip dressing

operation is required.
Stepper This 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
AV4
AV5
AV6
AV7
AV8
Analog 0 to 10 V analog output. Can be used to drive a proportional air regulator valve

for force control

1

Momentary operation will reset all expired counters. If maintained for more than 5 seconds all counters will be

reset, regardless of status.

2

Momentary operation will reset all expired steppers. If maintained for more than 5 seconds all steppers will be

reset, regardless of status.

3

If iPAK (v1) mode is selected (Section 12 Configuration)

 the sense of the READY output is reversed and it signifies NOT READY
 outputs AV4, 5, and 6 are used for MUX selection and are not available

Section 4 Discrete I/O 21

Discrete I/O

The inputs and outputs are accessible via connectors P1, P2, P3, P4 and P5. The connectors are two­part terminals for use with wires up to 1 mm

If the iPAK2 is supplied fitted into a case some connections will have been pre-wired by BF ENTRON.
See the case wiring diagram for details.

2

Section 4 Discrete I/O 22

Outputs are rated 500 mA @24 V dc
AWS designations in parenthesis

1

inputs must be linked if not required

Pin I/O bit

1. 24 V (internal)

2. 24 V for I/O

3. 2 Stop (ES1)

4. 3 Transformer thermal (TT1)

5. 1 Weld on (NW1)

1

1

6. 0 V

Pin I/O bit

1. 24 V (24 VDC)

2. 0 Start (FS1)

3.

4.

5.

6. 9 P1 (BP1)

7. 10 P2 (BP2)

8. 11 P4 (BP4)

9. 12 P8 (BP8)

10. 13 P16 (BP16)

11. 14 P32 (BP32)

12. 8 Reset stepper (SR1)

13. 7 Reset counter/tip dress ack

14. 5 Retract (RT1)

15. 6 Reset fault (FR1)

nd

16. 4 2

stage (PS1)

17. 15 P64 (BP64)/Edit enable

WSP3 Power

1

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

7. 6 Stepper

8. 7 Pre-warn

9. 12 AV4 (SV4)

10. 11 AV5 (SV5)

11. 10 AV6 (SV6)

12. 9 AV7 (SV7)

13. 8 AV8 (SV8)

14. 0 EOS (EH1)

15. 2 Fault (FT1)

16. 3 Ready

17. 4 Contactor (MC1)

18. 0 V (SVC)

Section 4 Discrete I/O 23

MUX

1. Analog input #1 (0 to 10 V)

2. 0 V

3. Analog output #1 (0 to 10 V)

4. Ground

1. Analog input #2

2. Analog input #2

3. Toroid input

4. Toroid input

5. Ground

MODBUS-RTU

NetFlash
MODBUS-TCP/IP

1. Heartbeat

2. Ready

3. Sequence initiated

4. Weld current

5. Data receive COM0

6. Data send 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

Expansion

Section 5 MODBUS I/O 24

MODBUS I/O

iPAK2 can be operated via MODBUS instead of using the discrete inputs and outputs.

Both MODBUS TCP/IP (Ethernet) and MODBUS RTU (RS485) protocols are supported.

Write the inputs using MODBUS 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
Write offset UINT 16#8000 (= 32768)
Write length UINT 2

Read outputs
Type Value Description
Function code UINT 3 Read holding registers
Read offset UINT 16#9000 (= 36864)
Read length UINT 24
Write offset UINT 0
Write length UINT 0

Section 5 MODBUS I/O 25

MODBUS mapping (inputs to iPAK2)

Variable Channel Address Type Description
Write inputs %QW0 WORD ARRAY [0..1] Write multiple registers
Write inputs [0] %QW0 WORD WRITE 16#8000 (= 32768)
Start Bit 0 %QX0.0 BOOL
Weld on Bit 1 %QX0.1 BOOL
Stop Bit 2 %QX0.2 BOOL
Transformer thermal Bit 3 %QX0.3 BOOL
2nd stage Bit 4 %QX0.4 BOOL
Retract Bit 5 %QX0.5 BOOL
Reset fault Bit 6 %QX0.6 BOOL
Reset counter Bit 7 %QX0.7 BOOL
Reset stepper 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 %QX1.7 BOOL
Write inputs [1] %QW2 WORD WRITE 16#8001 (= 32769)
P1 Bit 0 %QX2.0 BOOL
P2 Bit 1 %QX2.1 BOOL
P4 Bit 2 %QX2.2 BOOL
P8 Bit 3 %QX2.3 BOOL
P16 Bit 4 %QX2.4 BOOL
P32 Bit 5 %QX2.5 BOOL
P64 Bit 6 %QX2.6 BOOL
P128 Bit 7 %QX2.7 BOOL
Reserved Bit 8 %QX3.0 BOOL
Reserved Bit 9 %QX3.1 BOOL
Reserved Bit 10 %QX3.2 BOOL
Reserved Bit 11 %QX3.3 BOOL
Reserved Bit 12 %QX3.4 BOOL
Reserved Bit 13 %QX3.5 BOOL
Reserved Bit 14 %QX3.6 BOOL
Reserved Bit 15 %QX3.7 BOOL

Section 5 MODBUS I/O 26

MODBUS mapping (outputs from iPAK2)

Variable Channel Address Type Description
Read outputs %IW0 WORD ARRAY [0..23] Read holding registers
Read outputs [0] %IW0 WORD READ 16#9000 (= 36864)
EOS Bit 0 %IX0.0 BOOL
HAV Bit 1 %IX0.1 BOOL
Fault Bit 2 %IX0.2 BOOL
Ready Bit 3 %IX0.3 BOOL
Contactor Bit 4 %IX0.4 BOOL
Counter Bit 5 %IX0.5 BOOL
Stepper Bit 6 %IX0.6 BOOL
Pre-warn Bit 7 %IX0.7 BOOL
AV8 Bit 8 %IX1.0 BOOL
AV7 Bit 9 %IX1.1 BOOL
AV6 Bit 10 %IX1.2 BOOL
AV5 Bit 11 %IX1.3 BOOL
AV4 Bit 12 %IX1.4 BOOL
AV3 Bit 13 %IX1.5 BOOL
AV2 Bit 14 %IX1.6 BOOL
AV1 Bit 15 %IX1.7 BOOL
Read outputs [1] %IW2 WORD READ 16#9001 (= 36865)
Start Bit 0 %IX2.0 BOOL
Weld on Bit 1 %IX2.1 BOOL
Stop Bit 2 %IX2.2 BOOL
Transformer thermal Bit 3 %IX2.3 BOOL
2nd stage Bit 4 %IX2.4 BOOL
Retract Bit 5 %IX2.5 BOOL
Reset fault Bit 6 %IX2.6 BOOL
Reset counter Bit 7 %IX2.7 BOOL
Reset stepper Bit 8 %IX3.0 BOOL
P1 Bit 9 %IX3.1 BOOL
P2 Bit 10 %IX3.2 BOOL
P4 Bit 11 %IX3.3 BOOL
P8 Bit 12 %IX3.4 BOOL
P16 Bit 13 %IX3.5 BOOL
P32 Bit 14 %IX3.6 BOOL
P64 Bit 15 %IX3.7 BOOL
Read outputs [2] %IW4 WORD READ 16#9002 (= 36866)
Start Bit 0 %IX4.0 BOOL
Weld on Bit 1 %IX4.1 BOOL
Stop Bit 2 %IX4.2 BOOL
Thermal Bit 3 %IX4.3 BOOL
2nd stage Bit 4 %IX4.4 BOOL
Retract Bit 5 %IX4.5 BOOL
Reset fault Bit 6 %IX4.6 BOOL
Reset counter Bit 7 %IX4.7 BOOL
Reset stepper Bit 8 %IX5.0 BOOL
P1 Bit 9 %IX5.1 BOOL
P2 Bit 10 %IX5.2 BOOL
P4 Bit 11 %IX5.3 BOOL
P8 Bit 12 %IX5.4 BOOL
P16 Bit 13 %IX5.5 BOOL
P32 Bit 14 %IX5.6 BOOL
P64 Bit 15 %IX5.7 BOOL

≘ %QX0.0
≘ %QX0.1
≘ %QX0.2
≘ %QX0.3
≘ %QX0.4
≘ %QX0.5
≘ %QX0.6
≘ %QX0.7
≘ %QX1.0
≘ discrete input P1
≘ discrete input P2
≘ discrete input P4
≘ discrete input P8
≘ discrete input P16
≘ discrete input P32
≘ discrete input P64

≘ discrete input Start
≘ discrete input Weld on
≘ discrete input Stop
≘ discrete input Thermal
≘ discrete input 2
≘ discrete input Retract
≘ discrete input Reset fault
≘ discrete input Reset counter
≘ discrete input Reset stepper
≘ discrete input P1
≘ discrete input P2
≘ discrete input P4
≘ discrete input P8
≘ discrete input P16
≘ discrete input P32
≘ discrete input P64

nd

stage

Section 5 MODBUS I/O 27

Variable Channel Address Type Description
Analog input (mV) Read outputs [3] %IW6 WORD READ 16#9003 (= 36867)
Analog output (mV) Read outputs [4] %IW8 WORD READ 16#9004 (= 36868)
% pulse width Read outputs [5] %IW10 WORD READ 16#9005 (= 36869)
Reserved Read outputs [6] %IW12 WORD READ 16#9006 (= 36870)
Reserved Read outputs [7] %IW14 WORD READ 16#9007 (= 36871)
Status register 0 Read outputs [8] %IW16 WORD READ 16#9008 (= 36872)
Stop Bit 0 %IX16.0 BOOL Bit 0
Reserved Bit 1 %IX16.1 BOOL
Retract not ready Bit 2 %IX16.2 BOOL Bit 2
Inverter hot Bit 3 %IX16.3 BOOL Bit 3
Transformer hot Bit 4 %IX16.4 BOOL Bit 4
Pilot fault Bit 5 %IX16.5 BOOL Bit 5
Restart required Bit 6 %IX16.6 BOOL Bit 6
Headlock Bit 7 %IX16.7 BOOL Bit 7
Reserved Bit 8 %IX17.0 BOOL
Reserved Bit 9 %IX17.1 BOOL
Reserved Bit 10 %IX17.2 BOOL
Reserved Bit 11 %IX17.3 BOOL
Reserved Bit 12 %IX17.4 BOOL
Reserved Bit 13 %IX17.5 BOOL
Reserved Bit 14 %IX17.6 BOOL
Test mode Bit 15 %IX17.7 BOOL Bit 15
Status register 1 Read outputs [9] %IW18 WORD READ 16#9009 (= 36873)
Start on 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 Bit 21
Bad link Bit 6 %IX18.6 BOOL Bit 22
Maximum current Bit 7 %IX18.7 BOOL Bit 23
Toroid over range Bit 8 %IX19.0 BOOL Bit 24
CT over range Bit 9 %IX19.1 BOOL Bit 25
Maximum pulse width Bit 10 %IX19.2 BOOL Bit 26
Calibration error Bit 11 %IX19.3 BOOL Bit 27
Reserved Bit 12 %IX19.4 BOOL
Reserved Bit 13 %IX19.5 BOOL
Reserved Bit 14 %IX19.6 BOOL
Reserved Bit 15 %IX19.7 BOOL
Status register 2 Read outputs [10] %IW20 WORD READ 16#900A (= 36874)
Low force Bit 0 %IX20.0 BOOL Bit 32
High force Bit 1 %IX20.1 BOOL Bit 33
Low pre-current Bit 2 %IX20.2 BOOL Bit 34
High pre-current Bit 3 %IX20.3 BOOL Bit 35
Low main current Bit 4 %IX20.4 BOOL Bit 36
High main current Bit 5 %IX20.5 BOOL Bit 37
Low post-current Bit 6 %IX20.6 BOOL Bit 38
High post-current Bit 7 %IX20.7 BOOL Bit 39
No 2nd stage Bit 8 %IX21.0 BOOL Bit 40
No force Bit 9 %IX21.1 BOOL Bit 41
Reserved Bit 10 %IX21.2 BOOL
Reserved Bit 11 %IX21.3 BOOL
Reserved Bit 12 %IX21.4 BOOL
Reserved Bit 13 %IX21.5 BOOL
Reserved Bit 14 %IX21.6 BOOL
Reserved Bit 15 %IX21.7 BOOL

Section 5 MODBUS I/O 28

Variable Channel Address Type Description
Status register 3 Read outputs [11] %IW22 WORD READ 16#900B (= 36875)
End of count 0 Bit 0 %IX22.0 BOOL Bit 48
End of count 1 Bit 1 %IX22.1 BOOL Bit 49
End of count 2 Bit 2 %IX22.2 BOOL Bit 50
End of count 3 Bit 3 %IX22.3 BOOL Bit 51
End of count 4 Bit 4 %IX22.4 BOOL Bit 52
End of count 5 Bit 5 %IX22.5 BOOL Bit 53
End of count 6 Bit 6 %IX22.6 BOOL Bit 54
End of count 7 Bit 7 %IX22.7 BOOL Bit 55
Reserved Bit 8 %IX23.0 BOOL
Reserved Bit 9 %IX23.1 BOOL
Reserved Bit 10 %IX23.2 BOOL
Reserved Bit 11 %IX23.3 BOOL
Reserved Bit 12 %IX23.4 BOOL
Reserved Bit 13 %IX23.5 BOOL
Reserved Bit 14 %IX23.6 BOOL
Reserved Bit 15 %IX23.7 BOOL
Status register 4 Read outputs [12] %IW24 WORD READ 16#900C (= 36876)
End of electrode 0 Bit 0 %IX24.0 BOOL Bit 64
End of electrode 1 Bit 1 %IX24.1 BOOL Bit 65
End of electrode 2 Bit 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
End of electrode 7 Bit 7 %IX24.7 BOOL Bit 71
Reserved Bit 8 %IX25.0 BOOL
Reserved Bit 9 %IX25.1 BOOL
Reserved Bit 10 %IX25.2 BOOL
Reserved Bit 11 %IX25.3 BOOL
Reserved Bit 12 %IX25.4 BOOL
Reserved Bit 13 %IX25.5 BOOL
Reserved Bit 14 %IX25.6 BOOL
Reserved Bit 15 %IX25.7 BOOL
Status register 5 Read outputs [13] %IW26 WORD READ 16#900D (= 36877)
Tip dress 0 Bit 0 %IX26.0 BOOL Bit 80
Tip dress 1 Bit 1 %IX26.1 BOOL Bit 81
Tip dress 2 Bit 2 %IX26.2 BOOL Bit 82
Tip dress 3 Bit 3 %IX26.3 BOOL Bit 83
Tip dress 4 Bit 4 %IX26.4 BOOL Bit 84
Tip dress 5 Bit 5 %IX26.5 BOOL Bit 85
Tip dress 6 Bit 6 %IX26.6 BOOL Bit 86
Tip dress 7 Bit 7 %IX26.7 BOOL Bit 87
Reserved Bit 8 %IX27.0 BOOL
Reserved Bit 9 %IX27.1 BOOL
Reserved Bit 10 %IX27.2 BOOL
Reserved Bit 11 %IX27.3 BOOL
Reserved Bit 12 %IX27.4 BOOL
Reserved Bit 13 %IX27.5 BOOL
Reserved Bit 14 %IX27.6 BOOL
Reserved Bit 15 %IX27.7 BOOL

Section 5 MODBUS I/O 29

Variable Channel Address Type Description
Status register 6 Read outputs [14] %IW28 WORD READ 16#900E (= 36878)
Prewarn 0 Bit 0 %IX28.0 BOOL Bit 96
Prewarn 1 Bit 1 %IX28.1 BOOL Bit 97
Prewarn 2 Bit 2 %IX28.2 BOOL Bit 98
Prewarn 3 Bit 3 %IX28.3 BOOL Bit 99
Prewarn 4 Bit 4 %IX28.4 BOOL Bit 100
Prewarn 5 Bit 5 %IX28.5 BOOL Bit 101
Prewarn 6 Bit 6 %IX28.6 BOOL Bit 102
Prewarn 7 Bit 7 %IX28.7 BOOL Bit 103
Reserved Bit 8 %IX29.0 BOOL
Reserved Bit 9 %IX29.1 BOOL
Reserved Bit 10 %IX29.2 BOOL
Reserved Bit 11 %IX29.3 BOOL
Reserved Bit 12 %IX29.4 BOOL
Reserved Bit 13 %IX29.5 BOOL
Reserved Bit 14 %IX29.6 BOOL
Reserved Bit 15 %IX29.7 BOOL
Status register 7 Read outputs [15] %IW30 WORD READ 16#900F (= 36879)
Bus 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
LMI error Bit 5 %IX30.5 BOOL Bit 117
Duty cycle limit Bit 6 %IX30.6 BOOL Bit 118
Reserved Bit 7 %IX30.7 BOOL
Reserved Bit 8 %IX31.0 BOOL
Reserved Bit 9 %IX31.1 BOOL
Reserved Bit 10 %IX31.2 BOOL
Reserved Bit 11 %IX31.3 BOOL
Reserved Bit 12 %IX31.4 BOOL
Reserved Bit 13 %IX31.5 BOOL
Reserved Bit 14 %IX31.6 BOOL
Reserved Bit 15 %IX31.7 BOOL
Pre-heat current (A) Read outputs [16] %IW32 DWORD READ 16#9010 (= 36880)
Main current (A) Read outputs [18] %IW36 DWORD READ 16#9012 (= 36882)
Post-heat current (A) Read outputs [20] %IW40 DWORD READ 16#9014 (= 36884)
Program number Read outputs [22] %IW44 WORD READ 16#9016 (= 36886)
Force1 Read outputs [23] %IW46 WORD READ 16#9017 (= 36887)

1

value is multiplied by the scale factor (898.88 for kN or 4 for lbf

Section 6 Weld control 30

Weld 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 used. There are 256 weld
programs.