Entron IPAK2v2 Manuel utilisateur

User Manual

iPAK2v2 Weld Control

Firmware Version

V2.10

May 22

Document No. 700253-2

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Product Model: iPAK2v2

Firmware Version: V2.10

May 22 | Doc No 700253-2

DISCLAIMER

Information contained in this document is believed to be accurate and reliable. The manufacturer does not provide any

representations or warranties, expressed or implied, as to the accuracy or completeness of such information and shall

have no liability for the consequences of use of such information. The manufacturer reserves the right to make changes

to information published in this document, including without limitation specifications and product descriptions, at any

time and without notice.

BF ENTRON accepts no liability for any injury, loss or damage caused by improper installation, use or application of its

products. The user shall only use the product for purposes that are proper and in accordance with all applicable laws,

rules, and regulations.

means, including photocopying, recording, or other electronic or mechanical methods, without the prior written

permission of the publisher.

TRADEMARKS

BF ENTRON and/or its affiliates’ trademarks may not be used in connection with any product or service that is not BF

ENTRON’s, in any manner this 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.

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Product Model: iPAK2v2

Firmware Version: V2.10

May 22 | Doc No 700253-2

Document Revisions

Languages

This document is only published in the English language.

Date

Document

Number

Approved

Document Changes

14-01-2022

700253-0

Kelby

Henn

Initial release of iPAK2v2 Manual on new template

22-03-2022

700253-1

Sean

Simmons

Added New Images.

05-05-2022

700253-2

Sean

Simmons

Added Programming Parameters section. Added Valve Delays

feature.

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Product Model: iPAK2v2

Firmware Version: V2.10

May 22 | Doc No 700253-2

Table of Contents

1BACKGROUND .................................................................................................................................................. 9

1.1 Description of the User .............................................................................................................................. 9

1.2 Conventions Used in This Manual.............................................................................................................. 9

1.3 Explanation of Symbols............................................................................................................................ 10

1.4 Important Safety Instructions .................................................................................................................. 11

1.5 Technical Support .................................................................................................................................... 13

1.5.1 Internet...............................................................................................................................................................13

1.5.2 Documentation Request.....................................................................................................................................13

1.5.3 Service and Technical Support............................................................................................................................13

2INTRODUCTION .............................................................................................................................................. 14

2.1 Weld Control ............................................................................................................................................ 14

2.2 Features ................................................................................................................................................... 14

2.3 Product Specifications.............................................................................................................................. 15

2.3.1 Power Specifications...........................................................................................................................................16

2.3.2 Function and Monitoring Specifications.............................................................................................................17

2.3.3 iPAK2v2 Weld Timer Specifications ....................................................................................................................17

2.3.4 Environmental Specifications .............................................................................................................................18

2.4 Main Component Overview ..................................................................................................................... 19

2.5 Wiring Diagrams...................................................................................................................................... 20

2.5.1 Customer Connections Diagram (3U3661).........................................................................................................21

2.5.2 Wiring Diagram (3U3719)...................................................................................................................................22

2.6 Standard Machine ................................................................................................................................... 23

2.7 Multi-Welding Machine........................................................................................................................... 24

2.8 Modes of Current Control ........................................................................................................................ 26

2.8.1 Pulse Width Mode “P/W”...................................................................................................................................27

2.8.2 Constant Current Uncalibrated Mode “CCu”......................................................................................................27

2.8.3 Constant Current Calibrated Mode “CCC”..........................................................................................................27

2.9 Installation............................................................................................................................................... 28

2.9.1 Installation Instructions......................................................................................................................................28

2.9.2 Configure the Control .........................................................................................................................................33

2.9.3 Current Calibration .............................................................................................................................................41

2.10 Force Calibration...................................................................................................................................... 56

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2.10.1 Force Calibration Procedure...............................................................................................................................58

2.11 Preventative Maintenance....................................................................................................................... 60

3COMMUNICATIONS SETUP ............................................................................................................................ 61

3.1 Overview .................................................................................................................................................. 61

3.2 Set the IP Address of the Control ............................................................................................................. 62

3.3 Ethernet Communications ....................................................................................................................... 65

3.3.1 Connect via NetFlash™ Programming Software.................................................................................................65

3.3.2 Configure for EtherNet/IP (EIP) ..........................................................................................................................67

3.3.3 Configure for MODBUS-TCP/IP...........................................................................................................................68

3.4 MODBUS-RTU .......................................................................................................................................... 69

3.5 WSP3 Pendant ......................................................................................................................................... 71

4ENTRON PROGRAMMING TOOLS................................................................................................................... 72

4.1 NetFlash™ ................................................................................................................................................ 72

4.1.1 System requirements..........................................................................................................................................72

4.1.2 Installing NetFlash™............................................................................................................................................73

4.1.3 Removing NetFlash™..........................................................................................................................................73

4.1.4 Running NetFlash™.............................................................................................................................................73

4.1.5 Main window components.................................................................................................................................73

4.1.6 The target IP address..........................................................................................................................................75

4.1.7 Restart control....................................................................................................................................................76

4.1.8 Control type........................................................................................................................................................76

4.1.9 Networks window...............................................................................................................................................77

4.1.10 Edit Control Parameters .....................................................................................................................................79

4.1.11 Editing Parameters .............................................................................................................................................81

4.1.12 Log Tab................................................................................................................................................................82

4.1.13 Flash Programming Tool.....................................................................................................................................83

4.1.14 Setup NetFlash™ Users/Security ........................................................................................................................85

4.2 WSP3........................................................................................................................................................ 87

4.2.1 Keypad ................................................................................................................................................................87

4.2.2 Diagnostic Screen ...............................................................................................................................................88

4.2.3 Menus.................................................................................................................................................................89

5PROGRAMMING WELD PROGRAMS .............................................................................................................. 90

5.1 Overview .................................................................................................................................................. 90

5.2 What is a weld program? ........................................................................................................................ 90

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Firmware Version: V2.10

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5.3 Parameters .............................................................................................................................................. 91

5.4 Weld Program Types................................................................................................................................ 97

5.5 Programming a Spot Weld with the WSP3 ............................................................................................ 104

5.6 Programming a Spot Weld with NetFlash ............................................................................................. 110

5.7 Program Selection.................................................................................................................................. 115

5.7.1 Internal Program Selection...............................................................................................................................115

5.7.2 External Program Selection ..............................................................................................................................115

5.7.3 Program Selection for Spot Welding ................................................................................................................115

5.7.4 Program Selection for Seam Welding...............................................................................................................115

6FAULTS & TROUBLESHOOTING .................................................................................................................... 116

6.1 Fault and Status Messages .................................................................................................................... 116

6.2 LED Indicators on Timer ......................................................................................................................... 118

6.2.1 Heartbeat LED...................................................................................................................................................118

6.2.2 Ready LED .........................................................................................................................................................119

6.2.3 Sequence LED ...................................................................................................................................................119

6.2.4 Weld LED...........................................................................................................................................................119

6.2.5 Data Send/Receive LEDs...................................................................................................................................119

6.2.6 Network Status / Module Status LEDs..............................................................................................................119

6.3 How to Reset Faults ............................................................................................................................... 120

6.3.1 WSP3 Pendant ..................................................................................................................................................120

6.3.2 NetFlash™ Software..........................................................................................................................................120

6.3.3 Discrete Input ...................................................................................................................................................121

6.3.4 Fieldbus Input ...................................................................................................................................................121

7INPUTS & OUTPUTS...................................................................................................................................... 122

7.1 Inputs ..................................................................................................................................................... 122

7.2 Outputs .................................................................................................................................................. 124

7.3 Discrete Connections ............................................................................................................................. 125

7.3.1 Inputs................................................................................................................................................................125

7.3.2 Outputs.............................................................................................................................................................125

7.3.3 Analog Signals (0 to 10V) ..................................................................................................................................125

7.3.4 Discrete Connections Schematic ......................................................................................................................126

7.3.5 Softstart............................................................................................................................................................127

8READ & WRITE DATA WITH EXTERNAL DEVICES.......................................................................................... 128

8.1 Overview ................................................................................................................................................ 128

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8.2 MODBUS ................................................................................................................................................ 128

8.2.1 Function Codes .................................................................................................................................................128

8.2.2 Inputs................................................................................................................................................................128

8.2.3 Outputs.............................................................................................................................................................130

8.2.4 Programming Parameters.................................................................................................................................137

8.3 Ethernet/IP (EIP) .................................................................................................................................... 149

8.3.1 Implicit Messaging............................................................................................................................................149

8.3.2 Explicit Messaging.............................................................................................................................................150

9ADVANCED FEATURES.................................................................................................................................. 152

9.1 History Log ............................................................................................................................................. 152

9.1.1 Currents............................................................................................................................................................152

9.1.2 Force.................................................................................................................................................................152

9.1.3 Viewing the Log ................................................................................................................................................153

9.1.4 Exporting History Log........................................................................................................................................154

9.1.5 Resetting History Log........................................................................................................................................154

9.2 Security Settings..................................................................................................................................... 155

9.2.1 PIN Codes..........................................................................................................................................................156

9.2.2 Edit Switch ........................................................................................................................................................156

9.2.3 NetFlash™ User Security...................................................................................................................................157

9.3 Updating the Firmware.......................................................................................................................... 158

9.4 Backup & Restoring ............................................................................................................................... 160

9.4.1 WSP3 Pendant ..................................................................................................................................................160

9.4.2 NetFlash............................................................................................................................................................165

9.5 Electrode Management ......................................................................................................................... 166

9.5.1 Steppers............................................................................................................................................................166

9.5.2 Counters ...........................................................................................................................................................169

9.5.3 Calibration ........................................................................................................................................................171

9.6 Seam Welding........................................................................................................................................ 172

9.6.1 Programming a Seam Weld with NetFlash.......................................................................................................172

9.7 Multi-weld Operations........................................................................................................................... 177

9.7.1 Electrode & Transformer Assignment ..............................................................................................................177

9.7.2 Linking Programs ..............................................................................................................................................179

9.7.3 Multi-Electrode Operation................................................................................................................................180

9.7.4 Cascade Operation............................................................................................................................................184

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May 22 | Doc No 700253-2

9.8 Analog Control Mode............................................................................................................................. 186

9.9 Valve Control.......................................................................................................................................... 187

9.10 Valve Delays........................................................................................................................................... 188

9.10.1 Programming Valve Delay Parameters using NetFlash.....................................................................................189

9.10.2 Programming Valve Delay Parameters using WSP3 .........................................................................................192

9.11 Current Limits......................................................................................................................................... 194

9.12 Duty Cycle Limiter .................................................................................................................................. 196

10 TUTORIALS.................................................................................................................................................... 197

10.1 Controlling an Air over Oil System ......................................................................................................... 197

10.2 Using Valves to Control a Multi-Head Machine..................................................................................... 199

10.2.1 Configure Control for Extended Mode .............................................................................................................199

10.2.2 Configure the Control for Multi-Electrodes......................................................................................................200

10.2.3 Program the WAV Output for Each Weld Program in the Cascade Sequence .................................................201

10.2.4 Link Programs Together (Cascade) ...................................................................................................................203

10.3 Controlling a Multi-Welder/Cascade ..................................................................................................... 205

10.3.1 Configure Control for Extended Mode .............................................................................................................205

10.3.2 Assign Electrode to a Transformer ...................................................................................................................207

10.3.3 Programming a Multi-Welder/Cascade Sequence ...........................................................................................207

10.4 Configuring & Calibrating iPAK2v2 with the WSP3 Pendant ................................................................. 209

10.4.1 Configure the Weld Control..............................................................................................................................210

10.4.2 Reset & Turn Off Electrode Stepper .................................................................................................................212

10.4.3 Calibrate Current (Toroid / Rogowski coil) .......................................................................................................213

10.4.4 Calibrate CCC –Constant Current Calibrated ...................................................................................................216

10.4.5 Set the Regulation configuration setting to Secondary....................................................................................219

11 TERMINOLOGY ............................................................................................................................................. 220

12 ADDITIONAL WIRING DIAGRAMS................................................................................................................. 222

12.1 Customer Connections Diagram (3U3661) ............................................................................................ 222

12.2 3U3721................................................................................................................................................... 223

12.3 3U3722................................................................................................................................................... 224

12.4 3U3723................................................................................................................................................... 226

BACKGROUND

Description of the User

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Product Model: iPAK2v2

Firmware Version: V2.10

May 22 | Doc No 700253-2

1BACKGROUND

1.1 Description of the User

This manual has been written to inform qualified custom equipment manufacturers, integrators, control engineers, weld

engineers, and/or maintenance technicians how to safely install, setup, operate, and maintain the weld control.

Qualified Personnel Only

The information contained in this manual is intended for Qualified Personnel, as defined

by the National Electrical Code (NEC). Always follow Electrical Safety in the Workplace

per NFPA 70E or equivalent standard in your location.

This manual has been written for the iPAK2 MFDC weld control product line with an iPAK2v2 weld timer. The manual

applies to the V2.09 version of firmware on the iPAK2v2 timer.

This document should be carefully read before installing and operating the weld control. Failure to follow the

instructions defined in this manual could create a safety hazard or impact the warranty on the product.

1.2 Conventions Used in This Manual

The following style conventions are used in this document:

Bold Italics type font is used for emphasis

•Bulleted lists generic lists and do not define a sequence or procedures

1) Numerical lists define a sequence or procedures

Courier text is used for system output, such as an error message or script

URLs, complete paths, filenames, prompts, and syntax

BACKGROUND

Explanation of Symbols

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Product Model: iPAK2v2

Firmware Version: V2.10

May 22 | Doc No 700253-2

1.3 Explanation of Symbols

This section defines the symbols used throughout this document.

DANGER!

Danger indicates a hazard with a high level of risk which, if not avoided, will result in

immediate, serious personal injury or loss of life. Examples are: exposed high voltage;

exposed fan blades.

WARNING!

The Warning symbol indicates a hazard with a potential hazard which could result in

personal injury or loss of life. Examples are: not using proper personal protect; removal

of guards.

CAUTION!

The Caution symbol indicates a hazard which could result in non-life threating personal

injury or damage to equipment. CAUTION may also be used to alert against unsafe

practices.

PACEMAKER

Individuals with cardiac devices should maintain a safe distance due to strong magnetic

fields arising from resistance welding. The function of cardiac pacemakers and

defibrillators may be disturbed, which may cause death or considerable health

damages! These persons should avoid the welding system unless authorized by a

licensed physician.

NOTICE

The Notice symbol is used for making recommendations on use or supplementary

information. Non-compliance with these recommendations may result in damage to the

control, welding machine or workpiece and voiding of the warranty.

HELPFUL TIP

The Helpful Hint symbol is used to provide additional information on a topic that may be

helpful to the user.

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