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

 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 +44 (0)1384 455401 • Fax +44 (0)1384 455551

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

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.

Section 6 Weld control 31

Spot sequence timing

The weld programs contain the following timing parameters.

Parameter Units Range Description Presqueeze ms 0 - 1999 The time for the electrodes to close onto the work piece. Squeeze ms 0 - 1999 The time between the initial application of the electrode force and

Pre-heat1 ms 0 - 1999 The pre-heat welding current is applied Cool11 ms 0 - 1999 The material is allowed to cool with electrode force applied Upslope ms 0 - 1999 Welding current is increased during this 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 this time Post-heat3 ms 0 - 1999 The post-heat welding current is applied Hold ms 0 - 1999 Electrode force continues after the welding current has finished Off4 ms 0 - 1999 Electrode force is released until the next sequence begins

1

Pre-heat program option must be enabled to use this feature

2

Pulsations program option must be greater than 1 to use this feature

3

Post-heat program option must be enabled to use this extended feature

the first application of welding current

The diagram shows how the parameters control the sequence. The Presqueeze and Cool2 intervals are not shown.

Start input

EOS output

WAV output

Force

Current

Interval

Squeeze

Pre-heat

Cool1

Upslope

Main heat

Downslope

Post heat

Hold

Off

Upslope can be used on hard, irregular shaped, oxidized and aluminium materials Downslope can be used to reduce marking and embrittlement

Section 6 Weld control 32

p

t

p

t p

p

t

p

t

p

t

Seam sequence timing (extended feature)

The weld programs contain the following timing parameters. All parameters can be adjusted during the sequence.

Parameter Units Range Description Presqueeze ms 0 - 1999 The time for the electrodes to close onto the work piece. Squeeze ms 0 - 1999 The time between the initial application of the electrode force and

Pre-heat1 ms 0 - 1999 The pre-heat welding current is applied Cool11 ms 0 - 1999 The material is allowed to cool with electrode force applied Upslope ms 0 - 1999 Welding current is increased during this time Main heat ms 0 - 1999 The main welding current is applied Downslope ms 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 0 - 1999 Electrode force continues after the welding current has finished

1

Pre-heat program option must be enabled to use this feature

2

Post-heat program option must be enabled to use this feature

The diagram shows how the parameters control the sequence. (Presqueeze not shown)

the first application of welding current

Start input1

EOS output

WAV output

Motor output2

Force

Current

e

slo

Interval

1

The intervals from Upslope to Cool2 repeat until the Start input is removed.

2

The operation of the motor output is determined by the 2nd stage test (Section 12 Configuration).

Squeeze

Pre-heat

Main hea

Cool1

U

Downslo

Post-hea

e

slo

Main hea

Cool2

U

Downslo

Post-heat

e

slo

Main hea

Cool2

U

Downslo

Post-hea

Cool2

Hold

Section 6 Weld control 33

–

t

–

Spot current control

The weld programs contain the following current control parameters.

Parameter Units Range Description Pre-mode1 P/W – CCu – CCC Operating mode of the Pre-heat interval Pre-heat1 % 0.0 – 99.9 The % heat used during the Pre-heat interval Pre-current1 kA 0 – 500 The current used during the Pre-heat interval Pre-monitor1 yes/no The current can be tested between limits Main mode P/W – CCu – CCC Operating mode of the Main heat interval Main heat % 0.0 –99.9 The % heat used during the Main heat interval Main current kA 0 – 500 The current used during the Main heat interval Main monitor yes/no The current can be tested between limits Post mode2 P/W Post hea

2

% 0.0 Post current2 kA 0 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

Post-heat program option must be enabled to use this extended feature

CCu –CCC Operating mode of the Post-heat interval

99.9 The % heat used during the Post-heat interval

500 The current used during the Post-heat interval

P/W (constant Pulse Width) mode. The current and heat parameters are independently adjustable. The inverter pulse-width is fixed. The current parameter is used for monitoring only.

CCu (Constant Current uncalibrated) mode.

The current and heat parameters are independently

adjustable. The inverter uses a variable pulse-width to determine and regulate the actual current. The current parameter is used for monitoring only.

CCC (Constant Current Calibrated) mode.

The current parameter is adjustable but the heat is

automatically determined by the iPAK2 from the calibration data.

The diagram shows how the parameters control the welding current. The Cool2 interval is not shown.

Start input

EOS output

WAV output

Force

Main heat/current

Pre-heat/current

Post-heat/current

Current

Interval

Squeeze

Pre-heat

Cool1

Upslope

Main heat

Downslope

Post-heat

Hold

Off

Section 6 Weld control 34

–

Seam current control (extended feature)

The weld programs contain the following current control parameters.

Parameter Units Range Description Pre-mode1 P/W – CCu – CCC Operating mode of the Pre-heat interval Pre-heat1 % 0.0 – 99.9 The % heat used during the Pre-heat interval Pre-current1 kA 0 – 500 The current used during the Pre-heat interval Pre-monitor1 yes/no The current can be tested between limits Main mode P/W – CCu – CCC Operating mode of the Main heat interval Main heat % 0.0 –99.9 The % heat used during the Main heat interval Main current kA 0 – 500 The current used during the Main heat interval Main monitor yes/no The current can be tested between limits Post mode2 P/W Post heat2 % 0.0 Post current2 kA 0 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

Post-heat program option must be enabled to use this feature

CCu –CCC Operating mode of the Post-heat interval

99.9 The % heat used during the Post-heat interval

500 The current used during the Post-heat interval

P/W (constant Pulse Width) mode. The current and heat parameters are independently adjustable. The inverter pulse-width is fixed. The current parameter is used for monitoring only.

CCu (Constant Current uncalibrated) mode.

The current and heat parameters are independently

adjustable. The inverter uses a variable pulse-width to determine and regulate the actual current. The current parameter is used for monitoring only.

CCC (Constant Current Calibrated) mode.

The current parameter is adjustable but the heat is

automatically determined by the iPAK2 from the calibration data.

The diagram shows how the parameters control the welding current.

Start input

EOS output

WAV output

Force

Main heat/current

Pre-heat/current

Post-heat/current

Current

Interval

Squeeze

Pre-heat

Cool1

Upslope

Main heat

Downslope

Post-heat

Cool2

Hold

Section 6 Weld control 35

Force control

The weld programs contain the following force control parameters.

Parameter Units Range Description Squeeze1 kN/lbf variable Force used from the start of the Squeeze interval Pre-heat1 kN/lbf variable Force used from the start the Pre-heat interval Cool11 kN/lbf variable Force used from the start the Cool1 interval Upslope1 kN/lbf variable 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 Downslope1 kN/lbf variable Force used from the start of the Downslope interval Post-heat1 kN/lbf variable Force used from the start the Post-heat interval Hold1 kN/lbf variable Force used from the start the Hold interval

1,2

Off

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 applied force at the end of the Main interval High limit % 0 - 99 Force high limit Low limit % 0 - 99 Force low limit

1

Force profile program option must be enabled to use this extended feature. If the force profile option is

disabled the Main heat force is used for the duration of the weld.

2

Repeat mode program option must be enabled to use this feature.

3

Occurs at the same time as 2nd stage. If Wait for force is required without 2nd stage, select 2nd stage

Before or After Squeeze (Section 12 Configuration) and permanently assert the 2

nd

stage input.

The diagram shows how iPAK2 can control the welding force. The Cool2 interval is not shown.

Start input

EOS output

WAV output

Force

Current

Interval

Squeeze

Pre-heat

Cool1

Upslope

Main heat

Downslope

Post-heat

Hold

Off

Section 6 Weld control 36

Valves

iPAK2 controls have eight digital outputs or valves (AV1 – AV8) that can be operated independently during a weld sequence. The valves are categorised as WAV, motor

 A WAV valve turns on at start of sequence and turns off at the end of the Hold interval.  The operation of a motor valve is determined by the 2  An AUX valve may be programmed to come on during any interval of the weld sequence,

including the Off time in repeat mode.

Mode Configuration WAV function Motor function Description

Single electrode AV1 n/a

spot

Multi-electrode1 AV1 – AV8 n/a

Single electrode AV1 AV2

seam1

Multi-electrode1 AV1 – AV8 AV1 – AV8

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 the following valve control parameters.

Parameter Units Range Description WAV AV1 –AV8 WAV output Motor1 AV1 – AV8 Motor output Squeeze AV1 – AV8 on/off Valve states during the Squeeze interval Pre-heat AV1 – AV8 on/off Valve states during the Pre-heat interval Cool1 AV1 – AV8 on/off Valve states during the Cool1 interval Upslope AV1 – AV8 on/off Valve states during the Upslope interval Main heat AV1 – AV8 on/off Valve states during the Main heat interval Cool2 AV1 – AV8 on/off Valve states during the Cool2 interval Downslope AV1 – AV8 on/off Valve states during the Downslope interval Post-heat AV1 – AV8 on/off Valve states during the Post-heat interval Hold AV1 – AV8 on/off Valve states during the Hold interval Off2 AV1 – AV8 on/off Valve states during the Off interval

1

Seam mode only.

2

Repeat mode program option must be enabled to use this feature.

1

or AUX valves.

nd

stage test (Section 12 Configuration).

AV1 is automatically selected Any combination of AV1 to AV8 may be selected AV1 and AV2 are automatically selected Any combination of AV1 to AV8 may be selected

Section 6 Weld control 37

Options

Each weld program has a number of optional features.

Parameter Range Description Pre-heat yes/no Enables or disables the Pre-heat parameters Post-heat yes/no Enables or disables the Post-heat parameters Pulsations 1 - 99 The number of times the Main heat – Cool2 interval is repeated Link yes/no The next welding program will be started automatically if the input signals

Repeat yes/no The welding program will be repeated if the input signals are maintained Force profile yes/no Use multiple force values during the weld Inhibit yes/no An inhibited program will not run

1

If an inhibited program is not linked then attempting to run it will produce the error message. If the program is linked, then the program will be skipped and the next linked program will run. This feature may be used to temporarily disable a program in a cascade.

Pulsations can be used to temper the material, control nugget 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 pulses.

are maintained

1

Program selection

The program that will be used for welding can be selected in one of two ways

 Section 12 Configuration: by using the Program Select inputs (external)  Section 13 Programming: by using the Use Program parameter (internal)

If the external method is used, inputs P1 – P64 correspond to the binary value of the program that will be used. If the internal method is used, the Use Program parameter determines the weld program that will be used. The program number can be changed during the weld sequence.

Multi-electrode operation (extended feature)

Each welding program can be assigned an electrode.

Parameter Units Range Description Electrode 0 - 7 The electrode number

When a program is used, iPAK2 will automatically trigger the correct transformer by referencing the electrode/transformer assignment as described below. In addition, the electrode number is also used to access the appropriate stepper, counter and calibration information

Section 7 Electrode management 38

Electrode management

Electrode management is provided via a combination of stepper and counter functions.

The stepper 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 number of times before it is replaced. The extended features provide eight steppers and counters that can be assigned to up to eight transformers.

Section 7 Electrode management 39

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 curve is defined by a set of 10 points.

Current or Heat

dH9/dI

dH4/dI

dH3/dI

dH2/dI

9

4

3

2

dH1/dI

1

dH0/dI

0

Spots

Step 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9

Parameter Units Range Description Step 0 - 9 The step number Spots welds 0 - 9999 The number of welds in the step +Heat % 0.0 - 50.0 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 stepper Stop at end yes/no The iPAK2 can inhibit welding at the end of the last step Spots done welds 0 - 99999 The number of welds that have been done since the last reset

P/W and CCu modes will make use of both the +Heat and +Current parameters. CCC mode uses only the +Current parameters.

The Stepper output is active at the end of the last step. The Prewarn output is active during the last step.

To get started enter the values for Step 9 then select a Preset to load the intermediate values

Section 7 Electrode management 40

Counters

A counter is programmed by entering values related to the electrode maintenance and lifetime.

Parameter Units Range Description 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 be done Stop at end yes/no The iPAK2 can inhibit welding until the counter is reset Enable tip dress yes/no Enables or disables the tip dressing feature Dressings done 0 - 9999 The number of times the electrodes have been dressed Max dressings 0 - 9999 The maximum number of times the electrodes can be dressed Reset to welds 0 - 9999 The weld count following a tip dress operation

If tip dressing is enabled the iPAK2 will activate the Tip Dress Request output when the Count value is reached.

Current or Heat

@reset,stepper=n

Tip-dress Tip-dress Tip-dress Tip-dress Replace electrodes

max. dressings=4

n

Count up to

Dressings done

012340

Reset counter input

Tip-dress (Counter) output Pre-warn output

End of stepper output

Reset stepper input

Count up to-n

Count up to-n Count up to-n

Spots

Count up to-n

See note 1

Section 7 Electrode management 41

Current calibration

Current is measured by one of two methods:

1. Primary current is measured by the iPAK2 built-in CT.

2. Secondary current can be measured via an externally connected Toroid (spot weld modes

only).

The method is selected by the Configuration parameter Measure (Section 12 Configuration).

Maximum Primary Current

The inverter chassis has a maximum output current specification dependant on the inverter size. The iPAK2 detects this value on power-up and sets it as an absolute maximum. The output current can be set below this maximum value. It is important to do this before attempting any of the following calibration procedures (Section 12 Configuration).

Current measurement by built-in CT

In order to display secondary current, there are two methods provided for conversion:

1. Turns ratio: The turns ratio may be obtained from the welding transformer data. 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 1&2: This is the more accurate method and also calibrates the iPAK2 to match an

external current meter. Two test welds establish the relationship between primary current (as measured by the CT) and secondary current measured using the external meter as follows:

 Initially, select the turns-ratio method and set the turn ratio to 1:1 so that the iPAK2

measures and displays primary current.

 Produce a short circuit weld at a low heat in CCu mode and note the primary current (Ip1)

from the iPAK2 and the corresponding secondary current (Is1) using an external weld current meter.

 Repeat the short circuit weld at a higher heat and note again the primary current (Ip2) and

secondary current (Is2).

 Now select the Points 1&2 method and enter the four measurements (Ip1, Is1 and Ip2,

Is2).

The iPAK2 uses the characteristic to calculate the secondary current from the measured primary current.

I

s

I

s2

I

s1

I

p1

I

p2

p

Section 7 Electrode management 42

Current measurement by external toroid (spot weld only)

A toroid (Rogowski coil) is connected around the welding transformer secondary. Most such coils have a nominal output of 150 mV/kA. The iPAK2 provides a sensitivity parameter which may be adjusted to provide for absolute matching with an external current meter.

At the nominal 150 mV/kA, iPAK2 will handle signals corresponding to about 50 kA. If the current is expected to exceed 50 kA then it is necessary to use an attenuator device such as a TAM/1 between the toroid and iPAK2. The attenuator will have options for x1, x2, x3, x4 etc. The factor selected should be entered into the iPAK2 so that it is able to calculate the actual current from the (attenuated) measured current.

In multi-electrode or multi-transformer (cascade) systems it may 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 circumstances use the CT measurement method. The CT method has the advantage of not requiring an external toroid.

Parameter Units Range Description Max. primary current A 0 - max Limits maximum output Conversion method points/ratio Method used to convert primary current to secondary current Turns ratio 1 - 999 The turns ratio of the welding transformer Point 1 (primary) kA 0 - 32.0 The measured value of primary current at a low heat (Ip1) Point 1 (secondary) kA 0 - 500.0 The measured value of secondary current at a low heat (Is1) Point 2 (primary) kA 0 - 32.0 The measured value of primary current at a high heat (Ip2) Point 2 (secondary) kA 0 - 500.0 The measured value of secondary current at a high heat (Is2) Toroid mV/kA 100 - 60000 The sensitivity of the toroid Toroid factor 1 - 10 The ratio of the external attenuator (1 if no attenuator fitted)

Section 7 Electrode management 43

CCC calibration

The current must be calibrated before carrying out the following procedure.

When operating in CCu mode the inverter uses the Heat parameter to determine the output current. In order to be able to control the output current directly in amps it is necessary to establish the relationship between Heat and Current as follows:

 Produce a short circuit weld at a low heat in CCu mode and note the heat setting (H1) from the

iPAK2 and the corresponding measured current (I1).

 Repeat the short circuit weld at a higher heat and note Heat (H2) and Current (I2).  Enter these values as the ‘Points 1&2’ parameters in CCC calibration.

Current

I

2

I

1

H

1

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 current programmed directly in amps. The Heat parameter is no longer required.

This calibration also assists the iPAK to produce a rapid rise-time to the desired current without causing any significant transient conditions.

Parameter Units Range Description Point 1 (heat) % 0 – 99.9 The set value of low heat (H1) Point 1 (current) kA 0 - 500.0 The measured value of current at a low heat (I1) Point 2 (heat) % 0 – 99.9 The set value of high heat (H2) Point 2 (current) kA 0 - 500.0 The measured value of current at a high heat (I2)

In multi-electrode systems there are separate calibration files for each gun. Each electrode must be calibrated before being used.

H

Heat

2



Section 7 Electrode management 44

Force calibration

The analog input and analog output can be used for force control in terms of kN or lbf when they have been calibrated.

Parameter Units Range Description OUT Point 1 mV 0 - 10000 Analog output (point 1) OUT Point 1 kN/lbf Measured output force (point 1) OUT Point 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 Analog input (point 2) IN Point 2 kN/lbf Measured input force (point 2)

The relationship between the analog input and output and the electrode force can be determined by measuring the values at two points. The values define a linear relationship between mV and kN/lbf.

The force can be calibrated for each electrode.

Section 7 Electrode management 45

Multi-electrode operation (extended feature)

Multi-electrode operation allows each welding program to be triggered independently and also allows the assignment of an electrode to a transformer.

Parameter Units Range Description Electrode 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 to transformer 0

Electrodes 2 and 3 are assigned to transformer 1

Electrodes 4 and 5 are assigned to transformer 2

Electrodes 6 and 7 are assigned to transformer 3

The electrodes are assigned to weld programs in the same way.

T0

T1

T2

T3

E0

E1

E2

E3

E4

E5

E6

E7

Section 8 Status 46

Status information

iPAK2 reports a number of conditions to assist with diagnostics, quality control and maintenance. Each condition corresponds to a code which is accessible via MODBUS.

Co

Condition Action de 0 Normal 1 Stop Check the Stop input 2 Sync. error Check 27 V ac sync signal and/or the Frequency parameter in Configuration 3 Retract not ready Operate the Retract input 4 Inverter hot Check inverter cooling 5 Transformer hot Check weld transformer cooling 6 Pilot fault Safety relay fault. Do not use the iPAK2 and return it for service. 7 Restart required Restart the iPAK2 8 Headlocked The welding head is locked because of a fault condition 9 Toroid short circuit Connection to Toroid (secondary feedback coil) is short-circuit 10 Toroid open circuit Connection to Toroid (secondary feedback coil) is open-circuit 11 Reserved 12 Reserved 13 Reserved 14 Reserved 15 Reserved 16 Test mode For service use only 17 Start on The Start input is on following a weld sequence or stop/power-up condition 18 Weld off Check the Weld On input 19 Program 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 made to a weld program that cannot be used 24 Max. current Check secondary circuit. Reduce heat/current. 25 Toroid overrange Reduce current or use an external signal attenuator 26 CT overrange Check calibration parameters 27 Max. pulse width Check secondary circuit. Reduce heat/current. 28 Calibration error Check parameters in calibration program 29 Reserved 30 Reserved 31 Reserved 32 Reserved 33 Low force Check the analog input and output circuits and/or adjust force parameters 34 High force Check the analog input and output circuits and/or adjust force parameters 35 Low pre-current Check toroid feedback and/or adjust Pre-heat parameters 36 High pre-current Check toroid feedback and/or adjust Pre-heat parameters 37 Low main current Check toroid feedback and/or adjust Main heat parameters 38 High main current Check toroid feedback and/or adjust Main heat parameters 39 Low post-current Check toroid feedback and/or adjust Post-heat parameters 40 High post-current Check toroid feedback and/or adjust Post-heat parameters 41 No 2nd stage Check the 2ndStage input

Section 8 Status 47

42 No force Check analog input circuit 43 Reserved 44 Reserved 45 Reserved 46 Reserved 47 Reserved 48 Reserved 49 End of count 0 Reset counter 0 50 End of count 1 Reset counter 1 51 End of count 2 Reset counter 2 52 End of count 3 Reset counter 3 53 End of count 4 Reset counter 4 54 End of count 5 Reset counter 5 55 End of count 6 Reset counter 6 56 End of count 7 Reset counter 8 57 Reserved 58 Reserved 59 Reserved 60 Reserved 61 Reserved 62 Reserved 63 Reserved 64 Reserved 65 End of electrode 0 Reset stepper 0 66 End of electrode 1 Reset stepper 1 67 End of electrode 2 Reset stepper 2 68 End of electrode 3 Reset stepper 3 69 End of electrode 4 Reset stepper 4 70 End of electrode 5 Reset stepper 5 71 End of electrode 6 Reset stepper 6 72 End of electrode 7 Reset stepper 7 73 Reserved 74 Reserved 75 Reserved 76 Reserved 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 electrodes and then reset counter 2 84 Tip dress 3 Dress the electrodes and then reset counter 3 85 Tip dress 4 Dress the electrodes and then reset counter 4 86 Tip dress 5 Dress the electrodes and then reset counter 5 87 Tip dress 6 Dress the electrodes and then reset counter 6 88 Tip dress 7 Dress the electrodes and then reset counter 7 89 Reserved 90 Reserved 91 Reserved 92 Reserved 93 Reserved 94 Reserved 95 Reserved 96 Reserved 97 Prewarn 0 Stepper 0 has completed its 9th step 98 Prewarn 1 Stepper 1 has completed its 9th step 99 Prewarn 2 Stepper 2 has completed its 9th step 100 Prewarn 3 Stepper 3 has completed its 9th step 101 Prewarn 4 Stepper 4 has completed its 9th step 102 Prewarn 5 Stepper 5 has completed its 9th step 103 Prewarn 6 Stepper 6 has completed its 9th step 104 Prewarn 7 Stepper 7 has completed its 9th step 105 Reserved

Section 8 Status 48

106 Reserved 107 Reserved 108 Reserved 109 Reserved 110 Reserved 111 Reserved 112 Reserved 113 DC bus failure Check mains supply to inverter 114 Short circuit Check cables from inverter to welding transformer. Check 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 LMI modules 119 Duty cycle limit The allowable duty cycle is being exceeded. Reduce time, current or rate of operation. 120 Reserved 121 Reserved 122 Reserved 123 Reserved 124 Reserved 125 Reserved 126 Reserved 127 Reserved 128 Reserved

Section 9 History log 49

–

History log

iPAK2 stores the results of the last 6000 spot welds in a history log. Each record contains the following information:

Parameter Units Range Description Time and date 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 Post-current kA 0 Force kN/lbf Variable The force recorded during the weld

500 The current recorded during the Main heat interval 500 The current recorded during the Post-heat interval

The log can be viewed or reset as required.

Section 10 Multiwelding 50

Multiwelding (extended feature)

iPAK2 allows up to four transformers to be directly connected or up to eight when used with a decoder.

Up to 8 electrodes can be 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 together.

The electrode is assigned to a transformer:

Parameter Units Range Description Electrode 0 - 7 The electrode number Transformer 0 - 7 The transformer that the electrode is connected to

Section 10 Multiwelding 51

The diagram shows how the electrodes can be assigned to transformers

T0

Electrodes 0 and 1 are assigned to transformer 0

T1

Electrodes 2 and 3 are assigned to transformer 1

T2

Electrodes 4, 5 and 6 are assigned to transformer 2

T3

Electrode 7 is assigned to transformer 3

E0

E1

E2

E3

E4 E6

E5

E7

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 cascade operation allows up to sixteen welding programs to be linked together and triggered

from a single start command. The programs then ripple through with minimal time between them, selecting transformers and electrodes on the fly. The linked programs are known as a cascade.

Section 10 Multiwelding 52

Multi-gun operation

Each welding program is started independently but different electrodes and transformers can be selected.

Start input

EOS output

WAV output

Program select

Current (transformer 0)

Current (transformer 1)

Current (transformer 2)

Current (transformer 3)

The WAV output can be a separate output for each program

Section 10 Multiwelding 53

Multi-gun cascade operation

Different electrodes and transformers can still be selected but the welding programs are linked together and started by a single Start command. Cancelling the Start command at any time will abort the cascade sequence

Start input

EOS output

WAV output

Program select

Current (transformer 0)

Current (transformer 1)

Current (transformer 2)

Current (transformer 3)

First

program #

In multi-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 will remain on only until next weld. On Cascade will pause. Cascade will continue when the fault is reset.

1

Section 12 Configuration

Section 12 Configuration 54

Seam welding (extended feature)

iPAK2 can be used for seam welding applications. The seam program parameters provide 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

The parameters are described in Section 6 Weld control and can be adjusted during the weld. Intervals that are not required may be set to 0.

Section 12 Configuration 55

Continuous seam

A continuous seam weld maintains a set current for the duration of the weld. The following example shows how this type of sequence may be implemented.

Parameter Setting Description

Sequence timing

Presqueeze ms The time for the electrodes to close onto the work piece. Squeeze ms The time between the initial application of the electrode force

Main heat ms The main welding current is applied Hold ms Electrode force continues after the welding current has

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 during the Main heat interval Main monitor1 yes/no The current can be tested between limits Low limit1 % Current low limit High limit1 % Current high limit

Options

Pre-heat no Disable the Pre-heat parameters Post-heat no Disable the Post-heat parameters

1

optional

Start input1

EOS output

WAV output

Motor output2

Force

Current

and the first application of welding current

finished

Interval

1

The Main heat interval is repeated until the Start input is removed.

2

The operation of the motor output is determined by the 2nd stage test (Section 12 Configuration).

Squeeze

Man

heat

Hold

Section 12 Configuration 56

q

Seam pulsation

Seam pulsation can be used in applications where a continuous weld is not required. The Main heat and the Cool2 intervals are repeated for the duration of the weld. The following example shows how this type of sequence may be implemented.

Parameter Setting Description

Sequence timing

Presqueeze ms The time for the electrodes to close onto the work piece. Squeeze ms The time between the initial application of the electrode force

Main heat ms The main welding current is applied Cool2 ms The material is allowed to cool with electrode force applied Hold ms Electrode force continues after the welding current has

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 during the Main heat interval Main monitor1 yes/no The current can be tested between limits Low limit1 % Current low limit High limit1 % Current high limit

Options

Pre-heat no Disable the Pre-heat parameters Post-heat no Disable the Post-heat parameters

1

optional

Start input1

EOS output

WAV output

Motor output2

Force

Current

and the first application of welding current

finished

ueeze

Interval

1

The Main heat – Cool2 intervals are repeated until the Start input is removed.

2

The operation of the motor output is determined by the 2nd stage test (Section 12 Configuration).

S

Main

heat

Cool2

Main

heat

Cool2

Main

heat

Cool2

Main

heat

Cool2

Hold

Section 12 Configuration 57

q

Seam modulation

Seam modulation can be used in applications where a change in current is required. Two Heat intervals are repeated for the duration of the weld. The following example shows how this type of sequence may be implemented.

Parameter Setting Description

Sequence timing

Presqueeze ms The time for the electrodes to close onto the work piece. Squeeze ms The time between the initial application of the electrode force

Main heat ms The main welding current is applied Post-heat ms The post-heat welding current is applied Hold ms Electrode force continues after the welding current has

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 during the Main heat interval Main monitor1 yes/no The current can be tested between limits Post mode P/W – CCu – CCC Operating mode of the Post-heat interval Post heat % The % heat used during the Post-heat interval Post current kA The current used during the Post-heat interval Post monitor1 yes/no The current can be tested between limits Low limit1 % Current low limit High limit1 % Current high limit

Options

Pre-heat no Disable the Pre-Heat parameters Post-heat yes Enable the Post-heat parameters

1

optional

Start input1

EOS output

WAV output

Motor output2

Force

Current

and the first application of welding current

finished

ueeze

Interval

1

The Main heat – Post-heat intervals are repeated until the Start input is removed.

2

The operation of the motor output is determined by the 2nd stage test (Section 12 Configuration).

S

Main

heat

Post-

heat

Main

heat

Post-

heat

Main

heat

Post-

heat

Main

heat

Post-

heat

Hold

Section 12 Configuration 58

q

Seam pre-heat

Pre-heat can be used in applications where the initial current needs to be different to the main current. The following example shows a continuous seam weld with a pre-heat.

Parameter Setting Description

Sequence timing

Presqueeze ms The time for the electrodes to close onto the work piece. Squeeze ms The time between the initial application of the electrode force

Pre-heat ms The pre-heat welding current is applied Main heat ms The main welding current is applied Hold ms Electrode force continues after the welding current has

Current control

Pre-mode P/W – CCu –CCC Operating mode of 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 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 yes/no The current can be tested between limits Low limit1 % Current low limit High limit1 % Current high limit

Options

Pre-heat yes Enable the Pre-heat parameters Post-heat no Disable the Post-heat parameters

1

optional

Start input1

EOS output

WAV output

Motor output2

Force

Current

and the first application of welding current

finished

ueeze

Interval

1

The Main heat interval is repeated until the Start input is removed.

2

The operation of the motor output is determined by the 2nd stage test (Section 12 Configuration).

S

Pre-heat

Main

heat

Hold

Section 12 Configuration 59

q

Seam pre-heat only

Pre-heat can be used in situations when a spot weld is required. The following example shows how to use the pre-heat to produce a spot weld.

Parameter Setting Description

Sequence timing

Presqueeze ms The time for the electrodes to close onto the work piece. Squeeze ms The time between the initial application of the electrode force

Pre-heat ms The pre-heat welding current is applied Main heat 0 The main welding current is not used Hold ms Electrode force continues after the welding current has

Current control

Pre-mode P/W – CCu – CCC Operating mode of 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 Low limit1 % Current low limit High limit1 % Current high limit

Options

Pre-heat yes Enable the Pre-heat parameters Post-heat no Disable the Post-heat parameters

1

optional

Start input1

EOS output

WAV output

Motor output2

Force

Current

and the first application of welding current

finished

ueeze

Interval

1

The Pre-heat interval is interlocked.

2

The operation of the motor output is determined by the 2nd stage test (Section 12 Configuration).

S

Pre-heat

Hold

Section 12 Configuration 60

q

Roll-spot

Roll-spot welds can be used in applications where a motor drive output is required between welds. The following example shows how this type of sequence may be implemented.

Parameter Setting Description

Sequence timing

Roll-spot on Sets roll-spot mode Presqueeze ms The time for the electrodes to close onto the work piece. Squeeze ms The time between the initial application of the electrode force

Main heat ms The main welding current is applied Hold ms Electrode force continues after the welding current has

Off ms The time during which the motor drive operates

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 during the Main heat interval Main monitor1 yes/no The current can be tested between limits Low limit1 % Current low limit High limit1 % Current high limit

Valves

AVn Off time Connect the motor drive to the valve that is activated during

1

optional

Start input1

EOS output

WAV output

AVn output

Motor output2

Force

Current

and the first application of welding current

finished

Off time

ueeze

Interval

1

The weld sequence is repeated until the Start input is removed.

2

The operation of the motor output is determined by the 2nd stage test (Section 12 Configuration).

S

Main

heat

Hold

Off

Squeeze

Main

heat

Hold

Off

Squeeze

Main

heat

Hold

Off

The examples show how the seam weld parameters can be used in any combination to implement several different types of weld sequence.

Section 12 Configuration 61

Configuration

The Configuration parameters affect the operation of the iPAK2.

Parameter Value Description

Features

Weld type

2nd stage

Standard Use standard features Extended Use extended features Spot Use spot welding features Seam Use seam welding features Analog Use analog welding features2 Off The 2

nd

stage input is not used. The motor output is not used1.

Start input

2nd stage input

Motor output

Sequence

begins

Before Squeeze The 2nd stage input is checked before the Squeeze interval. The

motor output is activated when the 2



Squeeze

nd

stage input is confirmed1.

Start input

2nd stage input

Motor output

After Squeeze The 2nd stage input is checked after the Squeeze interval. The

motor output is activated when the 2

Sequence

begins

Squeeze



nd

stage input is confirmed1.

Start input

2nd stage input

Motor output

Sequence

begins



Squeeze

Sequence continues 

Section 12 Configuration 62

2nd stage

Retract

Once The 2

nd

stage input is checked only at the start of a cascade

sequence

Every The 2nd stage input is checked at the start of every program within

a cascade sequence

Simple

Hilift +

Hilift -

Maintained

Measure

Regulation

Primary Measure primary welding current Secondary Measure secondary welding current (requires a toroid connection) Primary Regulate primary current Secondary Regulate secondary current (requires a toroid connection)

Ip limit 0 – inverter specific Sets an upper limit on the inverter output current3

Units

Stop on fault

Metric Measure force in KN Imperial Measure force in lbf yes/no The weld air-valve opens as normal but subsequent welds are

inhibited until a fault reset is given

EOS on fault yes/no The EOS output will be activated

Headlock on fault

iPAK (v1) mode

Program select

yes/no The weld air-valve output is held on and subsequent welds are

inhibited until a fault reset is given

yes/no Changes the sense of the READY output to NOT READY. AV4, 5

and 6 are used for MUX selection. External The Program Select inputs select the weld program Internal The Use Program parameter selects the weld program

Use program 0 - 255 The weld program that will be used if Internal program is selected

Electrodes

Single Use one electrode for the weld programs Multi Use up to 8 electrodes for the weld programs Discrete Use the discrete inputs and outputs COM0 Use MODBUS TCP/IP (Ethernet) on COM0

I/O source

COM1 Use MODBUS TCP/IP (Ethernet) on COM1 COM2 Use MODBUS RTU (RS485) on COM2 COM3 Use RS232 on COM3

Analog output

Force The analog output is used to control force Current The analog output corresponds to the measured weld current

Analog scaling 10V = 0 – 500kA The analog output scaling Contactor 0 – 99 seconds The contactor output is sustained for this time following a weld Toroid test Off / On The connection to an external toroid will be tested. The measured

1

Seam mode only

resistance must lie within the range 10 to 300 Ohms.

Section 12 Configuration 63

2

Analog control

In this mode of operation, the inverter output current can be controlled by applying a 0 to 10 Volt signal to P4 pins 1(+) and 2(-). A Seam sequence is produced, but 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 weld program:

Main mode 0 to 10 V input signal controls

P/W 0 to 100% pulse-width 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 must be de-rated as shown by the curve below:

1.20

1.00

0.80

0.60

De-rating factor

0.40

0.20

0.00

0 102030405060708090100

% Du t y

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

The READY signal will be de-asserted and an error message given. Further initiation is prohibited. Perform a ‘RESET FAULT’ operation to clear.

Section 13 Programming 64

Programming

iPAK2 supports several programming methods:

 NetFlash PC program (Ethernet)  WSP3 pendant (RS232)  MODBUS (Ethernet or RS485)  EtherNet/IP (via optional adapter card) – see separate adapter card manual.

Security

There are two features which can be configured to protect access:

1. Up to five PIN codes can be stored in each control. Users must then enter their code before being granted access permission to edit parameters. All parameters remain viewable (read-only). This feature can be configured to be applied to the WSP3. After initially gaining access, edit permission remains granted for a configurable time-out period.

2. Use of an external switch connected to the P64 input pin. Users are only granted access permission to edit parameters when the switch is activated. By using a key-switch, 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 select bit 64) is no longer available on the discrete signal interface and thus external selection of programs is restricted to the range 0 to 63. This is not normally a problem on manual installations which is typically where security features are required. The full range of programmes (0 to 255) is still available through manual selection or via a network connection.

The above features are configured via the use of NetFlash software. NetFlash itself also has a security feature which can be used to tailor access rights. Users can be allocated usernames, passwords and access levels which restrict users to editing none, some or all parameters, as required. Thus, an administrator can pass copies of NetFlash to various personnel, each having individually permission levels.

Access via network protocols is not restricted as this will generally be via automation systems.

Section 13 Programming 65

NetFlash

NetFlash is a PC-compatible program which provides a graphical user interface to program and monitor one or more iPAK2s. In addition NetFlash provides backup/restore functions for control data, live data logging to a file and a utility for updating the firmware in the iPAK2.

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 resolution is 1280 x 1024.

Installation

NetFlash does not need to be installed. Copy the NetFlash folder and its contents from the supplied media to the PC and run the NetFlash.exe program.

Removal

NetFlash does not need to be uninstalled. To remove NetFlash delete the NetFlash folder and its contents from the PC.

Section 13 Programming 66

Connection

NetFlash uses 10/100 Base-T Ethernet to communicate with the iPAK2.Ensure that the PC has an appropriate Ethernet adapter and that a network connection is in place. Use COM0/1 to connect the iPAK2 to the network

PC + NetFlash

Hub or switch

iPAK2 Ethernet enabled device Ethernet enabled device

If no network is available the PC can be connected directly to the iPAK2:

PC + NetFlash

Set the IP address in the iPAK2 (Section 15 Appendix). Set the IP address in the PC (contact your system administrator). For example:

PC 192.168.0.99 255.255.255.0 Welding control 192.168.0.103 255.255.255.0

Contact the system administrator for further details.

IP address Subnet mask

iPAK2

Section 13 Programming 67

Initialisation

Run the NetFlash.exe program. The home screen is shown:

Displays ENTRON UK contact details

Edit iPAK2 parameters. Allows access to the iPAK2 parameters via the 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 following a change to an application-specific parameter

Security features

Control type

Shows the PC’s IP address

Shows the IP address of the target iPAK2

Shows communication activity on the network

Section 13 Programming 68

Select Network Configuration . The following screen is shown:

Edit timer location. Welding controls that have been detected on the network can be 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 controls on the network

Use the selected welding control as the target welding control when editing

Perform a low-level communications test on the selected welding control

Section 13 Programming 69

Select Scan network for timers. NetFlash will show the compatible welding controls on the network:

Select an IP address and then select OK. NetFlash will ask if the address should be used as the target welding control 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 name and/or location for the welding control, use the Add welding control function. It is not necessary to do this if only one welding control is being used.

When a welding control has been selected as the target the parameters can be changed.

Section 13 Programming 70

Parameters

Caution: when parameters are changed in NetFlash they are changed immediately in the iPAK2.

Select the Edit weld parameters function from the home screen.

Select Load from timer. Data will be loaded from the target welding control:

The Program screen 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 edit the parameters:

Other functions are provided:

Show associated parameters in a different category

Save the parameters in a file

Open or close the metrics window. NetFlash shows the results of the last weld and the status messages

Copy programs

Export the parameters to a CSV file

Section 13 Programming 71

WSP3

Caution: when parameters are changed with the WSP3 they 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 to all parameters.

The WSP3 uses RS232 to communicate with the iPAK2 and should be connected to COM3:

WSP3

Section 13 Programming 72

Keypad

Return to the previous screen or move between menu screens.

Select a different function or parameter. The selected function or parameter will flash and the visible window will 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

Measured Pre-current

Measured Main current

Measured Post-current

If more than one status message is present they are shown sequentially.

Ready

|‐‐0Aprog7 ‐|‐11.7kA5.66kN ‐‐ |  0A ~30.5%

Program used Measured force Measured pulse-width

Section 13 Programming 73

Menus

The functions of the iPAK2 are arranged into a set of menus and screens as follows:

Diagnostic screen

Ready

|‐‐0Aprog7 ‐|‐11.7kA5.66kN ‐‐|0A~30.5%



<<<MAINMENU>>> USEprogram7 01NOV201812.00.00 Editprogram WELDTYPE:SPOT Editelectrode 2ndSTAGE:OFF

Select the first or the last line of the Main Menu…

 << mainmenu>> 

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   Electrode Inverterinformation   Linktoprogram Systeminformation  Copyprogram Editconfiguration <<configuremenu>> Startprogram    Backuptowsp3

Editcounter      Initialisedata Editstepper  Restartsystem Calibratecurrent Calibratecccmode Calibrateforce       Copyelectrode     

Viewlog   Clearlog  

Press and

<<programmenu>>    Editprogram  

<<electrodemenu>> Restorefromwsp3

<<historylog>>      

hold…

Useprogram

…then

press

<<<configure>>>

   

[Configuration parameters]

Section 13 Programming 74

Backup/Restore

The WSP3 allows the data in one iPAK2 to be transferred to another by using the Backup and Restore functions.

 Use the Backup function to make a copy of all the iPAK2’s settings. The copy is held

within the WSP3. The data in the iPAK2 is unchanged. Note that only one backup can be stored in the WSP3 and that this is overwritten each time the backup function is used.

 Use the Restore function to restore all of 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 remains in the WSP3.

Initialise 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 operation, review the configuration and calibration settings and ensure they are appropriate for the application. Also review the welding programs that will be used.

The initialise function can be used when first setting up an iPAK2.

Section 13 Programming 75

MODBUS

A PLC or HMI MODBUS master can be used to program 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.

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 0 Read length UINT 0 Write offset UINT variable Write length UINT 1

Read data Type Value Description Function code UINT 3 Read holding registers Read offset UINT variable Read length UINT 64 Write offset UINT 0 Write length UINT 0

Section 13 Programming 76

MODBUS mapping

Variable Address Type Description Weld programs 256 x 64 WORDS Weld program 0 16#0000 (= 0) WORD ARRAY [0..63] Weld program 1 16#0040 (= 64) WORD ARRAY [0..63] Weld program 2 16#0080 (= 128) WORD ARRAY [0..63] Weld program 3 16#00C0 (= 192) WORD ARRAY [0..63] … … … Weld program 254 16#3F80 (= 16256) WORD ARRAY [0..63] Weld program 255 16#3FC0 (= 16320) WORD ARRAY [0..63]

Electrodes 8 x 64 WORDS Electrode 0 16#4000 (= 16384) WORD ARRAY [0..63] Electrode 1 16#4040 (= 16448) WORD ARRAY [0..63] Electrode 2 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] Electrode 7 16#41C0 (= 16834) WORD ARRAY [0..63]

Calibration 8 x 64 WORDS Calibration 0 16#5000 (= 20480) WORD ARRAY [0..63] Calibration 1 16#5040 (= 20544) WORD ARRAY [0..63] Calibration 2 16#5080 (= 20608) WORD ARRAY [0..63] Calibration 3 16#50C0 (= 20672) WORD ARRAY [0..63] Calibration 4 16#5100 (= 20736) WORD ARRAY [0..63] Calibration 5 16#5140 (= 20800) WORD ARRAY [0..63] Calibration 6 16#5180 (= 20864) WORD ARRAY [0..63] Calibration 7 16#51C0 (= 20928) WORD ARRAY [0..63]

Configuration 1 x 64 WORDS Configuration 16#6000 (= 24576) WORD ARRAY [0..63]

Section 13 Programming 77

Weld program parameters

Variable Channel Address offset Type Description Weld program %IW0 WORD ARRAY [0..63] Attributes Weld program [0] %IW0 WORD Pre heat Bit 0 %IX0.0 BOOL 0 = off, 1 = on Post heat Bit 1 %IX0.1 BOOL 0 = off, 1 = on

Pre-mode

Main mode

Post-mode

Link mode Bit 8 %IX1.0 BOOL 0 = off, 1 = on Repeat mode Bit 9 %IX1.1 BOOL 0 = off, 1 = on Wait force Bit 10 %IX1.2 BOOL 0 = off, 1 = on Force profile Bit 11 %IX1.3 BOOL 0 = off, 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 time Weld program [1] %IW1 WORD 0 – 1999 Squeeze time Weld program [2] %IW2 WORD 0 – 1999 Pre-heat time Weld program [3] %IW3 WORD 0 – 1999 Pre-heat Weld program [4] %IW4 WORD 0 – 1999 Reserved Weld program [5] %IW5 WORD Pre-current Weld program [6] %IW6 DWORD 0 – 500000 Cool1 time Weld program [8] %IW8 WORD 0 – 1999 Main heat time Weld program [9] %IW9 WORD 0 – 1999 Main heat Weld 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 Post-heat time Weld program [16] %IW16 WORD 0 – 1999 Post-heat Weld program [17] %IW17 WORD 0 – 1999 Reserved Weld program [18] %IW18 WORD Post-current Weld program [19] %IW19 DWORD 0 – 500000 Hold time Weld program [21] %IW21 WORD 0 – 1999 Off time Weld program [22] %IW22 WORD 0 – 1999 Upslope time Weld program [23] %IW23 WORD 0 – 1999 Downslope time Weld program [24] %IW24 WORD 0 – 1999 Squeeze valves1 Weld program [25] %IW25 WORD Pre-heat valves1 Weld program [26] %IW26 WORD Cool1 valves1 Weld program [27] %IW27 WORD Upslope valves1 Weld program [28] %IW28 WORD Main heat valves1 Weld program [29] %IW29 WORD Cool2 valves1 Weld program [30] %IW30 WORD Downslope valves1 Weld 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

Bit 2 %IX0.2 BOOL 00 = PHA, 01 = CCu, Bit 3 %IX0.3 BOOL Bit 4 %IX0.4 BOOL 00 = PHA, 01 = CCu, Bit 5 %IX0.5 BOOL Bit 6 %IX0.6 BOOL 00 = PHA, 01 = CCu, Bit 7 %IX0.7 BOOL

Weld program [nn] %IXnn.0.1 BOOL AV2 state 1 = ON Weld program [nn] %IXnn.0.2 BOOL AV3 state 1 = ON Weld program [nn] %IXnn.0.3 BOOL AV4 state 1 = ON Weld program [nn] %IXnn.0.4 BOOL AV5 state 1 = ON Weld program [nn] %IXnn.0.5 BOOL AV6 state 1 = ON Weld program [nn] %IXnn.0.6 BOOL AV7 state 1 = ON Weld program [nn] %IXnn.0.7 BOOL AV8 state 1 = ON

11 = CCC

Section 13 Programming 78

Weld program parameters (continued)

Variable Channel Address offset Type Description Squeeze force Weld program [35] %IW35 WORD 0 – 327672 Pre-heat force Weld program [36] %IW36 WORD 0 – 327672 Cool1 force Weld program [37] %IW37 WORD 0 – 327672 Upslope force Weld program [38] %IW38 WORD 0 – 327672 Main heat force Weld program [39] %IW39 WORD 0 – 327672 Cool2 force Weld program [40] %IW40 WORD 0 – 327672 Downslope force Weld program [41] %IW41 WORD 0 – 327672 Post-heat force Weld program [42] %IW42 WORD 0 – 327672 Hold force Weld program [43] %IW43 WORD 0 – 327672 Off force Weld program [44] %IW44 WORD 0 – 327672 Force low limit Weld program [45] %IW45 WORD 0 – 99 % Force high limit Weld program [46] %IW46 WORD 0 – 99 % Selected WAV Weld program [47] %IW47 WORD 0 – 7 Current low limit Weld program [48] %IW48 WORD 0 – 99 % Current high limit Weld program [49] %IW49 WORD 0 – 99 % Selected electrode Weld program [50] %IW50 WORD 0 – 7 Linked program Weld program [51] %IW51 WORD 0 – 255 Last pre-current Weld program [52] %IW52 DWORD 0 – 500000 Last main current Weld program [54] %IW54 DWORD 0 – 500000 Last post-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 Bit 0 %IX61.0 BOOL 0 = enable, 1 = inhibit Motor valves1 Weld program [62] %IW62 WORD Reserved Weld program [63] %IW63 WORD

2

Divide value by 898.99 for kN. Divide value by 4 for lbf.

Electrode parameters

Variable Channel Address offset Type Description Electrode %IW0 WORD ARRAY [0..63] Attributes Electrode [0] %IW0 WORD Enable counter Bit 0 %IX0.0 BOOL 0 = off, 1 = on Enable tipdress Bit 1 %IX0.1 BOOL 0 = off, 1 = on Enable stepper Bit 2 %IX0.2 BOOL 0 = off, 1 = on Stop at endcount Bit 3 %IX0.3 BOOL 0 = off, 1 = on Stop at endstep 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 Electrode [5] %IW5 WORD 0 – 9999 Stepper spots done Electrode [6] %IW6 DWORD Read only Stepper % done Electrode [8] %IW8 WORD Read only Stepper reset to Electrode [9] %IW9 WORD 0 – 9999 Stepper spots Electrode [10..19] %IW10..19 WORD 0 – 9999 Stepper delta H Electrode [20..29] %IW20..29 WORD 0 – 500 (% x 10) Stepper delta I Electrode [30..39] %IW30..39 WORD 0 – 500 (% x 10) Reserved Electrode[40]-[63]

Section 13 Programming 79

Calibration parameters

Variable Channel Address offset Type Description Calibration %IW0 WORD ARRAY [0..63] Ip max Calibration [0] %IW0 WORD 0 – inverter specific A out X1 Calibration [1] %IW1 WORD 0 – 10000 mV A out Y1 Calibration [2] %IW2 WORD 0 – 32767 A out X2 Calibration [3] %IW3 WORD 0 – 10000 mV A out Y2 Calibration [4] %IW4 WORD 0 – 32767 A in X1 Calibration [5] %IW5 WORD 0 – 10000 mV A in Y1 Calibration [6] %IW6 WORD 0 – 32767 A in X2 Calibration [7] %IW7 WORD 0 – 10000 mV A in Y2 Calibration [8] %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

CT X1 Calibration [12] %IW12 DWORD 0 – 32000 CT Y1 Calibration [14] %IW14 DWORD 0 – 500000 CT X2 Calibration [16] %IW16 DWORD 0 – 32000 CT Y2 Calibration [18] %IW18 DWORD 0 – 500000 CT max Calibration [20] %IW20 DWORD Read only Turns ratio Calibration [22] %IW22 WORD 1 – 999 Reserved Calibration [23] %IW23 WORD CCC X1 Calibration [24] %IW24 WORD 0 – 999 CCC Y1 Calibration [25] %IW25 DWORD 0 – 500000 CCC X2 Calibration [27] %IW27 WORD 0 – 999 CCC Y2 Calibration [28] %IW28 DWORD 0 – 500000 Toroid factor Calibration [30] %IW30 WORD 1 – 10 Reserved Calibration[31]-[63]

1 = use turns ratio

Section 13 Programming 80

Configuration parameters

Variable Channel Address offset Type Description Configuration %IW0 WORD ARRAY [0..63] Weld type Configuration[0] %IW0 WORD 0 = spot

Second stage Configuration[1] %IW1 WORD

Bit 0 Bit 1

Bit 2 %IX1.2 BOOL Reserved Bit 3 %IX1.3 BOOL 0 = check first program

Retract Configuration[2] %IW2 WORD 0 = simple

Measure Configuration[3] %IW3 WORD 0 = primary

Ip limit Configuration[4] %IW4 WORD 0 – inverter specific Units Configuration[5] %IW5 WORD 0 = metric

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 = headlock on fault iPAK (v1) Bit 3 %IX7.3 BOOL 1 = use Not Ready sense Contactor Configuration[8] %IW8 WORD 1 - 99 seconds. 0 = off Program select Configuration[9] %IW9 WORD 0 = external, 1 = internal Internal prog Configuration[10] %IW10 WORD 0 - 255 I/O source Configuration[11] %IW11 WORD 0 = discrete

Regulation Configuration[12] %IW12 WORD 0 = primary

COM2 address Configuration[13] %IW13 WORD 1 - 247 COM2 baud code

Bus monitor Configuration[15] %IW15 WORD 0 = iPAK (v1) inverter

Adapter code Configuration[16] %IW16 WORD Analog output function Analog output scale (10 V =) Security Configuration[20] %IW20 WORD 0 = off

Security timeout Configuration[21] %IW21 WORD 0 – 10 minutes Security PIN0 Configuration[22] %IW22 WORD 1000 - 9999 Security PIN1 Configuration[23] %IW23 WORD 1000 - 9999 Security PIN2 Configuration[24] %IW24 WORD 1000 - 9999 Security PIN3 Configuration[25] %IW25 WORD 1000 - 9999 Security PIN4 Configuration[26] %IW26 WORD 1000 - 9999 Reserved Configuration[27]-[38] Features Configuration[39] %IW39 WORD 0 = standard

Toroid test Configuration[40] %IW40 WORD 0 = Off, 1 = On Reserved Configuration[41]-[63]

Configuration[14] %IW14 WORD 0 = 9600

Configuration[17] %IW17 WORD 0 = force

Configuration[18] %IW18 DWORD 0 – 500 kA

%IX1.0 %IX1.1

BOOL BOOL

1 = seam 2 = analog

00 = none 01 = before Squeeze 10 = after Squeeze

1 = check every program

1 = hilift plus 2 = hilift minus 3 = maintained

1 = secondary

1 = imperial

1 = MODBUS COM0 2 = MODBUS COM1 3 = MODBUS COM2 4 = RS232 COM3

1 = secondary

1 = 19200 2 = 38400 3 = 57600

1 = iPAK2 inverter

1 = waveform

1 = key-switch 2 = PIN on WSP3

1 = extended

Section 14 Tutorials 81

Tutorials

The iPAK2 has a number of features that can improve weld quality, diagnostics and maintenance. Before each tutorial:

 Section 12 Configuration: ensure the Configuration parameters are set appropriately for the

application.

 Section 7 Electrode management: 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 each weld to be tested.

2. Set the Low limit and High limits appropriately. The limits correspond to a percentage of the

required current.

If the weld current falls outside the limits, iPAK2 will signal a weld fault.

Current

High limit

Target

Low limit

Spots

Pass Fault Pass Fault



 



 



Section 14 Tutorials 82

02 Changing the force during a weld

iPAK2 can change the force during a weld when the force profile option is enabled. The force can be changed at the beginning of any interval. The force output corresponds to the analog output on connector X5.

Parameter Units Range Description Squeeze1 kN/lbf variable Force used from the start of the Squeeze interval Pre-heat1 kN/lbf variable Force used from the start the Pre-heat interval Cool11 kN/lbf variable Force used from the start the Cool1 interval Upslope1 kN/lbf variable 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 Downslope1 kN/lbf variable Force used from the start of the Downslope interval Post-heat1 kN/lbf variable Force used from the start the Post-heat interval Hold1 kN/lbf variable Force used from the start the Hold interval

1

If the force profile option is disabled the Main heat force is used for the duration of the weld.

1. In the weld program, enable the force profile option.

2. In the Force parameters, set the values for each interval. The change takes place at the start of

each interval and the force for each interval can be tested against limits.

Section 14 Tutorials 83

03 Using the Retract functions

The Retract function allows the welding head to open in two stages.

 The fully open position allows the work piece to be positioned between the electrodes.  The middle position allows the electrodes to close onto the work piece in order to weld.

iPAK2 has four Retract modes that can be used depending on the application. The mode is selected in the Configuration settings.

Simple

When the Retract Input is switched off, the High Lift 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 fully. Welding will not proceed in this case.

Retract input

HAV output

Start input

WAV output

Hi-lift +

A pulse on the Retract Input causes the High Lift Air Valve to switch on and close the electrodes to the mid position. Welding can proceed in this case.

Whilst the High Lift Air Valve is on, a pulse on the Retract Input causes the valve to switch off and the electrodes go to the fully open position. Welding will not proceed in this case.

Retract input

HAV output

Start input

WAV output

Section 14 Tutorials 84

Hi-lift -

A pulse on the Retract Input causes the High Lift Air Valve to switch off and close the electrodes to the mid position. Welding can proceed in this case.

Whilst the High Lift Air Valve is off, a pulse on the Retract Input causes the valve to switch on and the electrodes go to the fully open position. Welding will not proceed in this case.

Retract input

HAV output

Start input

WAV output

Maintained

When the Retract Input is switched on, the High Lift Air Valve switches on and the electrodes close to the mid position. Welding can proceed in this case.

When the Retract Input is switched off, the High Lift Air Valve switches off and the electrodes open fully. Welding will not proceed in this case.

Retract input

HAV output

Start input

WAV output

Section 14 Tutorials 85

04 Using the valves to control a multi-head machine

iPAK2 can be used with welding machines that have multiple welding heads. By assigning one of the iPAK2s AV outputs, each head can be operated individually.

The weld air valve or WAV output 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 will remain active until the end of the

weld sequence unless programmed otherwise.

For example:

Program WAV Description 0 AV1 Program 0 uses AV1 as the WAV 1 AV2 Program 1 uses AV2 as the WAV 2 AV3 Program 2 uses AV3 as the WAV 3 AV4 Program 3 uses AV4 as the WAV

Section 14 Tutorials 86

The diagram shows the operation in multi-gun mode:

Start input

EOS output

AV1 output

AV2 output

AV3 output

AV4 output

Program select

Current (Program 0)

Current (Program 1)

Current (Program 2)

Current (Program 3)

#0

#1 #2 #3

Section 14 Tutorials 87

The operation is similar when the programs are linked together in multi-gun cascade mode:

Start input

EOS output

AV1 output

AV2 output

AV3 output

AV4 output

Program select

Current ( Program 0)

Current ( Program 1)

Current ( Program 2)

Current ( Program 3)

First

program #

The program select inputs select the first program in the cascade (0 in this example).

Section 14 Tutorials 88

05 Controlling a multiwelder

A multiwelder can use different transformers 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 in Section

10 Multiwelding.

2. Choose the weld programs that will be using the electrodes.

Section 14 Tutorials 89

For example:

Electrode Transformer Description 0 0 1 0 2 0 3 1 4 1 5 2 Electrode 5 is assigned to transformer 2 6 3 7 3

The electrodes can then be assigned to weld programs:

Weld program Electrode Description 0 0 1 0 2 1 3 1 4 2 5 2 6 3 7 3 8 4 9 4 10 5 11 5 12 6 13 6 14 7 15 7

Weld programs 0 and 1 are assigned to Electrode 0

Weld programs 2 and 3 are assigned to Electrode 1

Weld programs 4 and 5 are assigned to Electrode 2

Weld programs 6 and 7 are assigned to Electrode 3

Weld programs 8 and 9 are assigned to Electrode 4

Weld programs 10 and 11 are assigned to Electrode 5

Weld programs 12 and 13 are assigned to Electrode 6

Weld programs 14 and 15 are assigned to Electrode 7

Electrodes 0, 1 and 2 are assigned to transformer 0

Electrodes 3 and 4 are assigned to transformer 1

Electrodes 6 and 7 are assigned to transformer 3

By implication the transformers are used as follows:

Transformer Weld programs Description 0 0, 1, 2, 3, 4, 5 Transformer 0 is used by weld programs 0, 1, 2, 3, 4, and 5 1 6, 7, 8, 9 Transformer 1 is used by weld programs 6, 7, 8 and 9 2 10, 11 Transformer 2 is used by weld programs 10 and 11 3 12, 13, 14,15 Transformer 3 is used by weld programs 12, 13, 14 and 15

Section 14 Tutorials 90

06

Controlling an ‘Air over Oil’ system

An ‘Air over Oil’ system (also referred to as OHMA) uses compressed air to open and close the electrodes plus a hydraulic intensifier to apply the weld force. This type of system can easily be controlled by the iPAK2 by making use 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 (INTENSIFY) to the AV2(SV2) output (or whichever AUX output you wish to use).

3. In your welding schedule(s), set the Presqueeze time to suit the gun closure, and the Squeeze t ime to apply the force pre-weld. Now program the AUX valve chosen in step 2 to come on during all of the intervals which you are using (e.g. Squeeze, Main heat, Hold).

START

ADVANCE

INTENSIFY

CURRENT

Presqueeze Squeeze Mainheat Hold

Section 14 Tutorials 91

07

Resetting faults

Fault conditions and error messages can be reset in several ways.

WSP3

LOWMAINCURRENT

‐‐0aprog0

‐‐10.1ka5.80kn

From the Status screen press

‐‐0a~30.5%

NetFlash

Use to select the Metrics window then select the

reset button

Discrete input

Input Pin number Description Reset fault P2.15 This input resets the Fault output and clears the status

The discrete I/O is described in Section 4 Discrete I/O.

messages. Only momentary application is required (minimum time 40ms).

Bus input

Input Channel Address Description Reset fault Bit 6 %QX0.6 This input resets the Fault output and clears the status

The bus I/O is described in Section 5 MODBUS I/O.

messages. Only momentary application is required (minimum time 40ms).

Section 15 Appendix 92

Appendix

Updating the firmware

The functionality of iPAK2 is determined by firmware stored in reprogrammable memory. iPAK2 has three memories:

Memory Description A Memory A B Memory B BIOS BIOS memory

The firmware can be transferred to one or more of the 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 is used to update the firmware.

 Initialise NetFlash and select the target iPAK2 as described in Section 13 Programming.

 Select the Flash Programming tool . The following screen is shown:

Connect to the iPAK2

Start transfer to the iPAK2

Change the active memory

Select the flash file

Section 15 Appendix 93

 Select the flash file . This will be a file with a .hex extension supplied by ENTRON UK.

 Select connect to the iPAK2 . NetFlash will connect to the target control and report the

current firmware status.

 Select start transfer to the iPAK2 . Select a memory to re-program and NetFlash will

transfer the flash file to the iPAK2.

 If required, select change the active memory . NetFlash will mark the selected memory for

activation. When iPAK2 restarts, 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.lantronix.com

To set the IP address of the iPAK2 use Lantronix’s DeviceInstaller software www.lantronix.com/products/deviceinstaller/

 Download the documentation and Device Installer software. Install the software.  Follow the instructions in the documentation to search for all Lantronix devices on your network. Device

Installer will show the iPAK2 device server in the device list. The example shows an iPAK2/xPort AR with a hardware address of 00-20-4A-D5-FB-7B:

Section 15 Appendix 94

 Select the iPAK2/xPort AR device then select Assign IP:

 Select ‘Assign a specific IP address’ and then select Next:

Section 15 Appendix 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 main screen.

Section 16 Terminology 96

Terminology

Term Description Constant current Closed loop control of weld current resulting in the weld current being regulated to a

CT See Current transformer. Current transformer A coil of wire wound on a circular core. This is used to measure the current in a cable

Cool time The time between weld pulses. Downslope A linear decrease in current from the Main heat value to a final value. Downslope time Time taken for the welding current to decrease from the Main heat value to a final

End of sequence An output that switches on as the electrodes open on completion of a weld. The

EOS See End of sequence. HAV Hi-lift Air Valve. See also Retract. Heat A measure of power put into a phase angle controlled (non- constant current) weld.

Hold The time between the last application of current and the electrodes opening. This

Hold time The time period following the last weld pulse prior to the electrodes opening. This

IP address Internet Protocol address. A unique address used by devices on an Ethernet network. Initiation signal The signal that 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 time between sequences. PHA See Phase angle control. Post-heat The application of current to prevent the weld cooling too quickly. Pre-heat The application of current prior to welding for the purpose of burning through plating

Presqueeze The time interval in a weld sequence for the electrodes to close onto the work piece. Primary current The current in the primary winding of the weld transformer which is the current drawn

Program select A group of inputs representing the binary value of the weld program to be used. Proportional valve A device for regulating air-line pressure. Controlled by 0 to10 V dc signal. Pulsations The number of times the Main heat interval is repeated during the sequence.

Retract The electrodes have two open positions: fully open to move the weld gun to and from

Retract air valve For use on a gun where the electrodes can be opened and closed in two stages. This

2nd stage A signal required to allow the weld sequence to proceed. Secondary current The current in the secondary winding of the weld transformer which is the weld

Squeeze The time interval in a weld sequence for the electrodes to exert full welding force on

programmed value.

passing through the circular core. iPAK2 can use a CT to measure primary current.

value.

output indicates the end of the weld sequence.

The Heat relates directly to the firing angle on the mains voltage waveform. Expressed as a percentage.

interval allows the molten material created by the weld process to solidify.

period allows the molten material to solidify.

or surface contamination.

from the mains whilst welding.

Successive applications of Main heat are separated by Cool2 time.

the work piece, and a working position for welding.

is an electrically operated valve for admitting air to the air cylinder that controls the electrode movement.

current.

Section 16 Terminology 97

the work piece.

Squeeze time The time allowed for the welding electrodes to build up full pressure on the

Start signal The signal that starts the weld sequence. Stepper A program of parameters required for stepping. Stepping A technique of progressively increasing the weld current over the course of a large

Thermostat A switch device that operates at a certain temperature. Tip dress acknowledge An input to acknowledge that the electrodes have been dressed. Tip dress request An output to indicate that the electrodes require dressing. 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

Upslope A linear increase in current from an initial value to the Main heat value. Upslope time Time taken for current to increase from an initial value to the Main heat value. VA Volt amp WAV See Weld air valve. Weld air valve Electrically controlled valve for admitting air to the air cylinder responsible for forcing

Weld current High current passed from one electrode to the other, through the components being

Weld transformer Electrical component for converting mains voltage input to low voltage, high current

components to be welded.

number of welds in order to compensate for the effects of electrode wear.

through the toroid.

the weld electrodes together.

welded. The current must be large enough to generate sufficient heat to melt the metal and produce a weld.

output.