Entron iPAK2v2 User manual

User Manual
iPAK2v2 Weld Control
Firmware Version
V2.10
May 22
Document No. 700253-2

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Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
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.
Copyright © 2022 by BF ENTRON
All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any
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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Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
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
By
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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Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
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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Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
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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Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
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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Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
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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Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
Product Model: iPAK2v2
Firmware Version: V2.10
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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Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
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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Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
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.

BACKGROUND
Important Safety Instructions
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Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
1.4 Important Safety Instructions
Before installing, starting up, or operating the iPAK2v2, carefully read all safety instructions to ensure safe use of
the product.
SAVE THESE INSTRUCTIONS
The safety instructions are part of the product. Keep the instructions in a safe and easily accessible place near
the product.
Never open the enclosure door when the breaker is in the ON position.
Never operate control with the door open.
Always disconnect power to the weld control before servicing or establishing electrical
connections with the product.
Use product only as described in this manual.
Stop Operation if any problems occur. If the equipment is not working as it should, has
been dropped, damaged, left outdoors, or has been in contact with water, contact
ENTRON.
Only apply the specified power. Application of a voltage or current beyond the specified
range can cause electric shock or fire.
Upon receipt of unit, inspect unit for damage from shipping. Before applying power to
product, inspect electrical connections to verify the connections are secure.

BACKGROUND
Important Safety Instructions
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Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
Except for the internal water-cooling system, keep water and water containers away
from product. Water ingress can cause a short circuit, electric shock, or fire.
Keep free of dust and debris.
Do not install the product in any of the following environments:
damp environments where humidity is 90% or higher;
dusty environments; environments where chemicals are handled;
environments near a high-frequency noise source;
hot environments where temperatures are above 40° C / 104° F;
cold environments where temperatures are below 0° C / 32° F;
environments where water will condense.
It is not recommended that holes be drilled into the cabinet. Metal debris inside the
cabinet can cause a short circuit, electric shock, or fire. If holes must be drilled is
imperative that all components are protected from debris. Drilling holes in the cabinet
may allow dust and other materials to enter the cabinet.
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.
Always ensure cooling water is adequately flowing at the proper rate, temperature, and
is of sufficient quality. For water quality requirements, refer to AWS J1.2M/J1.2.2016
Guide Installation and Maintenance of Resistance Welding Machines.

BACKGROUND
Technical Support
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Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
1.5 Technical Support
1.5.1 Internet
The latest version of the documentation and other helpful resources in the ENTRON Document Library page found in the
Resource section of the ENTRON website: https://www.entroncontrols.com
1.5.2 Documentation Request
Documentation, user instructions and technical information can be requested by emailing ENTRON Controls at
[email protected] or suppo[email protected]
Please include your name and email
1.5.3 Service and Technical Support
For service and technical support, we request that customers fill out the Technical Support Form found on our website
at link below:
TECHNICAL SUPPORT FORM LINK
https://www.entroncontrols.com/resources/technical-support.html
After the web form has been completed, your case will be assigned to one of our technical specialists who will contact
you directly.
For all other questions, our customer service team is available to assist. The contact information for each our
manufacturing and service sites is shown in the table below. Please contact the site for your specific region.
Manufacturing Site
Country
Phone
Email
Regions Supported
ENTRON UK
England
[phone]
[email protected]
Europe, Asia, Africa, Rest of
World
ENTRON US
USA
[phone]
[email protected]
USA, Canada
ENTRON MX
Mexico
[phone]
[email protected]
Mexico, Central America

INTRODUCTION
Weld Control
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Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
2INTRODUCTION
2.1 Weld Control
The iPAK2v2 Weld Control is a Medium Frequency Direct Current (“MFDC”) electronic inverter that controls the
energizing power for a medium frequency welding transformer. The inverter control is powered from a standard 3 Phase
50/60 Hz supply and provides a 1 kHz output.
MFDC weld controls are commonly used in many resistance welding applications. They are more energy efficient and
can produce a higher quality weld process than AC weld controls.
Advantages of MFDC relative to AC welding:
•Reduced cost per weld
•True 3 phase load distribution with reduced primary currents
•Better power factor
•Capacitive mains loading
•High rate of heat input, resulting in reduced weld times
•Lower peak currents making expulsion (ie weld splash) less likely
•High secondary current capability
•High speed constant current response
•Longer electrode life due to shorter weld times
•Requires smaller welding transformer size
2.2 Features
The iPAK2v2 weld control is designed for a number of resistance welding processes. These include spot, spot repeat,
projection, multi-welding, roll-spot, and seam welding. The iPAK2v2 weld controller is available in a range of current
outputs, ranging from 360 Amps up to 6,000 Amps primary current. The iPAK2v2 product portfolio covers a number of
industrial resistance welding applications ranging from precision micro-welding of thin sheets all the way to heavy
industrial applications such as coil joining in steel mills.
The primary features are:
•Store up to 256 weld schedules (Programs)
•Data log for up to 6,000 welds
•Real time clock
•3 weld intervals: Pre-Heat + Main Heat + Post Heat
•Secondary or Primary constant current regulation
•Built in Ethernet/IP
•2 Analog Inputs (0 –10 V)
•1 Analog Output
•16 Discrete Inputs & Outputs (24 V dc short circuit protected, monitored guided contact relay)
•Aux Valves (7)

INTRODUCTION
Product Specifications
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Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
•Four modes of programming control (WSP3 Hand Held Pendant, NetFlash™ Software, MODBUS,
Ethernet/IP)
•Analog control mode
•Force profiling
•Electrode management (stepper functions)
•Current and Force monitoring
•C-Monitor checks secondary circuit for shunting or wear conditions
•Communication via Ethernet/IP, RS232 for WSP3 Pendant, RS485, MODBUS TCP/IP, or MODBUS RTU
An iPAK2v2 weld control is also available in Multi-Welder (Cascade) configurations. This configuration type allows a user
to control multiple weld transformers and multiple weld actuators with a single control. The features of the multi-weld
configuration are:
•Control up to 8 weld transformers
•Control up to 8 weld valves (WAV)
•7 auxiliary valves under program control
•Electrode manager (stepper function) for up to 8 electrodes
For more information on multi-welding refer the section Multi-Welding Machine of this manual.
2.3 Product Specifications
The iPAK2v2 Weld Control is available in various current outputs and the product specifications for the standard iPAK2v2
product line is defined in this section.

INTRODUCTION
Product Specifications
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Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
2.3.1 Power Specifications
Description
Value
Standard Voltage
3 Phase AC 380V –480V (+10% / - 20%)
Alternate Voltage –LV
3 Phase AC 230 (+/- 10%)
Line Frequency
50 / 60 Hz
Output Current Options 20% Duty Cycle
360 A Water Cooled
600 A Water Cooled
1000 A Water Cooled
1500 A Water Cooled
3000 A Water Cooled
4500 A Water Cooled
6000 A Water Cooled
DC BUS Levels at Line Voltage
305V 1000Hz at 220 VAC Line
525V 1000Hz at 380 VAC Line
650V 1000 Hz at 480 VAC Line
Maximum Power at 480VAC 20% Duty
234kVA (360 A)
390kVA (600 A)
650kVA (1000 A)
975kVA (1500 A)
1,950kVA (3000 A)
2,925kVA (4500 A)
3,900kVA (6000 A)
Current Rise Time
Less than 4 ms into Resistive Load
Table 1: iPAK2v2 Power Specifications Table

INTRODUCTION
Product Specifications
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Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
2.3.2 Function and Monitoring Specifications
Description
Value
Fixed Pulse Firing
Pulse Width Modulation
Current Control Primary
Primary Constant Current Percent Primary Limit
Current Control Secondary
Secondary Toroid (Rogowski Coil) Feedback
Primary Current Range
36A to 360A
60A to 600A
100A to 1000A
150A to 1500A
300A to 3000A
450A to 4500A
600A to 6000A
Timing Control
Milliseconds
Duty Cycle Limit
20% at rated capacity over 2000 ms time period
Table 2: iPAK2v2 Functions and Monitoring
2.3.3 iPAK2v2 Weld Timer Specifications
Description
Value
Communications
Ethernet IP 100 BaseT
Modbus TCP/IP 100 BaseT
R485
RS232 for WSP3 Pendant
Local Inputs
16 Inputs 24VDC
Local Outputs
16 Outputs 24VDC
Number of Weld Programs
256
Number of Steppers
8 Steppers with 10
Programmable Steps
Language
English
Table 3: iPAK2v2 Weld Timer Specifications Table

INTRODUCTION
Product Specifications
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Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
2.3.4 Environmental Specifications
Description
Value
Operating Temperature
The cabinet internal ambient temperature must not
rise above 104 degrees Fahrenheit or 40 degrees
Centigrade under normal operation conditions
Humidity
The cooling water temperature must NOT be low
enough to cause the formation of condensation
inside the inverter.
Table 4: iPAK2v2 Environmental Specifications
2.3.4.1 Cooling Water Specifications
Description
Inverter
Size
Value
Maximum Water
Temperature
All
must not exceed 77 degrees Fahrenheit or 25 degrees
Centigrade
Water Quality
All
pH-7-8.5
Hardness max 12.5(UK) 10.5(US)
Chlorides 20mg/l max
Nitrates 10mg/l max
Sulphates 100mg/l max
Insoluble substances 250mg/l max
Deposits in cooling water may cause corrosion/abrasive wear
Tap water may meet requirements.
An algaecide is recommended.
Water Flow Rate
360A
1 gal/min or 5 liters/min
600A
1.5 gal/min or 7.5 liters/min
1000A
2 gal/min or 10 liters/min
1500A
2 gal/min or 10 liters/min
3000A
4 gal/min or 20 liters/min
4500A
6 gal/min or 30 liters/min
6000A
8 gal/min or 40 liters/min
Table 5: iPAK2v2 Cooling Water Specifications

INTRODUCTION
Main Component Overview
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Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
2.4 Main Component Overview
The iPAK2v2 weld control is an assembled unit. The major components of the standard 600 Amp iPAK2v2 configuration
are identified below and in Figure 1: iPAK2v2 600 Amp Control Layout.
Figure 1: iPAK2v2 600 Amp Control Layout
The flexible design of the iPAKV2 product line allows users to configure the product to meet their specific application.
Therefore, the major components and their location identified in this document may not be accurate for all controls.
Description
Function
iPAK2v2 Weld Timer
The weld timer is the programmable device that controls the welding sequence and can communicate with
external devices.
iPAK Inverter Module
The inverter module converts the 3 phase 380-480V 50/60 Hz AC line input into a 1kHz output high voltage
AC square wave output to the welding transformer. The unit is water cooled.
Circuit Breaker
A 3 Phase thermal magnetic breaker. This switches on the electrical voltage to the MFDC inverter and
internal PSUs. This will trip and interrupt the current flow when a short circuit fault is detected. This helps
to minimize damage caused by excessive current or a short circuit.
Isolation Contactor (Optional)
Optional device recommended for manual weld guns and robotic applications. The isolation contactor is an
interrupt device between the inverter module and welding transformer and can be controlled by the weld
timer.
Contactor Relay (optional)
The contactor relay energizes the Isolation Contactor.
24V Power Supply
The 24V Power Supply for the I/O
Fuses
The fuses protect the Control TX Module
Control TX
The Control TX is a universal voltage control module.
Water Manifold
The water manifold contains the connection points for the cooling water circuit. This comes standard.
Thread size is ¼ BSSP.

INTRODUCTION
Wiring Diagrams
20 | P a g e
Copyright © 2021 BF ENTRON and/or its affiliates. All rights reserved
Product Model: iPAK2v2
Firmware Version: V2.10
May 22 | Doc No 700253-2
2.5 Wiring Diagrams
The iPAK2v2 Timer is designed to be drive various size iPAK inverter modules and up to 8 transformers. This section
provides the schematic for customer connections on the iPAK2v2 Weld Timer and a generic Weld Control wiring
diagram. The drawing is applicable for the following product specifications:
Part Number
Part Description
Wiring
Drawing
Number
Issue
No.
No.
of
Pages
See
Page
10-58-B0-10-01-03-00-05
10-58-C0-10-01-03-00-05
10-58-C1-00-01-03-00-05
iPAK2v2-360AWBv2-125ET-1SW-BCM
iPAK2v2-600AWBv2-160ET-1SW-BCM
iPAK2v2-600AWBv2-175A-1SW-UL-BCM
3U3719
1
2
22
10-58-B0-10-01-03-10-00
10-58-30-10-01-03-10-00
10-58-C0-10-01-03-10-00
10-58-C0-10-01-13-10-01
10-58-40-10-01-03-10-00
10-58-41-00-01-03-10-00
iPAK2v2-360AWBv2-125ET-1SW
iPAK2v2-600AWB-160ET-1SW
iPAK2v2-600AWBv2-160ET-1SW
iPAK2v2-600AWBv2-160ES (SCHN/ETS/INT EIP)
iPAK2v2-1000AWB-250ET-1SW
iPAK2v2-1000AW-250A-1SW-UL
3U3721
1
2
223
10-58-C0-10-21-03-00-00
10-58-C0-10-31-03-00-00
10-58-C0-10-41-03-00-00
10-58-C0-10-21-13-00-01
10-58-30-10-41-13-00-01
10-58-40-10-41-13-00-00
10-58-D0-10-41-13-00-00
iPAK2v2-600AWBv2-160ET-2MUX-1SW
iPAK2v2-600AWBv2-160ET-3MUX-1SW
iPAK2v2-600AWBv2-160ET-4MUX-1SW
iPAK2v2-600AWBv2-160ES-2MUX (SCHN/ETS/INT EIP)
iPAK2v2-600AWB-160ES-4MUX (SCHN/ETS/INT EIP)
iPAK2v2-1KAWB-250ET-4MUX-1SW
iPAK2v2-1KAWBv2-250ET-4MUX-1SW
3U3722
2
4
224
10-58-50-20-01-13-00-00
10-58-60-20-01-13-00-00
10-58-60-20-01-13-00-00
iPAK2v2-LMI-1500A-400E-1SW
iPAK2v2 LMI 1500A-400E-ISO
iPAK2v2-LMI-3000A-800E-1SW
3U3723
1
5
226
Table 6: Standard Product Wiring Diagram List by Part Number