Bosch PSI 6XXX.350 L1 Series Technical Information Download | Manualshive

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Safety instructions

and reader’s information

Automationstechnik

XVII

1070 080 067-101 (2001.03) GB

Maintenance and repair

WARNING!

-

Danger of life through electrical voltage of power units!
Prior to any maintenance work - unless described otherwise - the system must
always be switched off! In the event of necessary measurement or test procedures
on the active system, the applicable safety and accident prevention regulations
must be strictly observed. In any case, suitable insulated tools must be used!

-

Danger of life through inappropriate EMERGENCY-STOP facilities!
EMERGENCY-STOP facilities must be operative in all modes of the system. Re-
leasing the EMERGENCY-STOP facility must by no means result in an uncontrol-
led restart of the system!

-

Danger of explosion of batteries!
Do not forcefully open batteries, do not attempt to charge, solder or incinerate the
battery.
Empty batteries should always be replaced by new ones!

CAUTION!

-

The right to perform repair/maintenance work on the PSI 6XXX.350 L1 compo-
nents is reserved to the Bosch service department or to repair/maintenance units
authorized by Bosch!

-

Only use spare parts/replacement parts approved by Bosch!

-

The applicable regulations on the disposal of empty batteries or accumulators
must be observed.

!

!

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Summary of Contents for PSI 6XXX.350 L1 Series

Page 1: ...PSI 6XXX 350 L1 Technical Information PSI 6000 101 Edition Description of Timer and I O Level ...

Page 2: ...070 080 067 101 2001 03 GB DIN ISO 9001 Reg no 16149 01 2 E 2001 This manual is the exclusive property of Robert Bosch GmbH also in the case of Intellectual Property Right applications Without their consent it may not be reproduced or given to third parties Discretionary charge DM 20 ...

Page 3: ......

Page 4: ...cemakers IX Qualified personnel X Storage and Transport XI Installation and assembly XII Electrical connection XIII Operation XIV Retrofits and modifications by the user XVI Maintenance and repair XVII 1 System 1 1 1 1 General 1 1 1 2 Programming and operating the timer 1 4 2 Technical data 2 1 2 1 Welding timer 2 1 2 2 Power unit 2 3 3 Hardware 3 1 3 1 Structure 3 1 3 2 Module front panel without...

Page 5: ...es X12 X13 X14 X15 7 5 7 1 6 Stop circuit 7 5 7 1 7 DC link voltage 7 5 7 2 Power supply 7 7 7 2 1 Internal power supply 7 7 7 2 2 External power supply 7 9 7 3 I O functions 7 11 7 3 1 Serial inputs 7 12 7 3 2 Serial outputs 7 37 8 Control diagrams 8 1 9 Commissioning 9 1 9 1 Preparations 9 2 9 2 Testing the welding program 9 3 9 2 1 Suggestions for a welding test 9 4 9 3 Basic Setup 9 5 9 4 Weld...

Page 6: ...10 2 Ranges of Messages 10 2 10 2 1 A Communication Messages 10 2 10 2 2 B Electrode Stepper Messages 10 3 10 2 3 C Messages Concerning the Timer Status 10 3 10 2 4 D Messages for Current and Weld Time Monitoring 10 4 10 2 5 E Messages concerning automatic scaling monitoring 10 5 11 Maintenance 11 1 11 1 Changing batteries 11 2 12 Ordering 12 1 A Annex A 1 A 1 Abbreviations Terms A 1 A 2 Regulatio...

Page 7: ...PSI 6XXX 350 L1 Contents IV 1070 080 067 101 2001 03 GB Your notes ...

Page 8: ...mpliance with the fundamental safety requirements of the EU Machinery Directive Nevertheless there is some residual risk The present manual describes the following functions timer module PSI 6XXX 350 L1 I O level Explanation of pictographs and symbols The following warnings and notes may be attached to the individual hardware compo nents which are designed to inform the user of certain circumstanc...

Page 9: ...evere injury personal injury CAUTION The term CAUTION will be used wherever a dangerous situation is possible The possible consequences include death severe or light injury personal injury dam age to property destruction of modules or environmental hazards In any case the failure to observe comply with these instructions will result in the loss of guaranty NOTE The term NOTE will be used for makin...

Page 10: ...mpared to the previous edition Proper use The present manual contains information on the proper use of the weld timer type PSI 6XXX 350 L1 In connection with the intended power supply and the specified welding equipment the weld timer type PSI 6XXX 350 L1 serves for resistance welding of metals is suitable for operation in industrial environments in accordance with DIN EN 50082 2 and DIN EN 50081 ...

Page 11: ...l frequency 1 6 Hz WARNING When using manual welding guns the limit values may be exceeded for the extremities In this case additional work protection measures must be taken So far no problems have been reported Nevertheless the possible influences are lower with medium frequency welding than with AC welding NOTE The strong magnetic fields arising in connection with resistance welding may cause la...

Page 12: ...or protecting persons with cardiac pacemakers be cause the function of these devices may be disturbed impulse failure total failure and a negative influence on the pacemaker programming or even a total program destruction may occur We recommend posting a warning of the type shown below at all entrances to factory halls containing resistance welding equipment No entry for persons with cardiac pacem...

Page 13: ...mmission earth and label electrical circuits and equipment systems in compliance with the standards of safety technology operating personnel who have been instructed in operating installations in resist ance welding technology and who know the contents of the present documenta tion as far as operation is concerned WARNING An exception are persons with cardiac pacemakers Due to the strong magnetic ...

Page 14: ...a section to avoid damages Static discharges may destroy components of the weld timer Therefore the original packaging should be used for storage and transport The equipment must be protected against humidity NOTE CDs and floppies must be protected against negative external influences of dust or mois ture by suitable packaging They must never be exposed to the influence of magnetic fields ...

Page 15: ...XXX 350 L1 modules is IP 20 The modules shall be installed together with a power supply as a single unit in a housing with a suffi cient degree of protection at least IP54 Danger of injury and of damage to property through incorrect installation The weld timer and especially the operating elements must be installed so as to be sufficiently protected against unintentional operation or contact Dange...

Page 16: ...propriate handling include death severe bodily injury and damage to property Therefore the electrical connection may only be made by a skilled electrician who observes the valid safety regulations the mains voltage and the maximum current consumption of the modules The mains voltage must be identical with the nominal voltage indicated on the nameplate of the product The mains system must be approp...

Page 17: ... rules of electrical engineering must be observed Danger of injury and of damage to property through missing or false interpretation of fault messages Danger of bruises through electrode movement All users line designers welding machine manufacturers and welding gun produ cers are obliged to connect the output signal of the Bosch weld timer which initiates the electrode movement so that the applic...

Page 18: ... begin which may result in dangerous machine movements Therefore before remote starting it must be en sured that nobody is in the dangerous area of the welding machine CAUTION Damage to property through excessive welding current The maximum welding current of the welding hardware used must not be exceeded No liability is accepted in the event of non compliance ...

Page 19: ...NG Retrofits or modifications may have negative effects on the safety of the unit The possible consequences include death severe or light bodily injury personal injury damage to property or environmental hazards Therefore please contact us prior to retrofits or modifications to the PSI 6XXX 350 L1 using third party equipment This is the only way to determine whether these parts are suitable for us...

Page 20: ...ropriate EMERGENCY STOP facilities EMERGENCY STOP facilities must be operative in all modes of the system Re leasing the EMERGENCY STOP facility must by no means result in an uncontrol led restart of the system Danger of explosion of batteries Do not forcefully open batteries do not attempt to charge solder or incinerate the battery Empty batteries should always be replaced by new ones CAUTION The...

Page 21: ...Automationstechnik Safety instructions and reader s information XVIII 1070 080 067 101 2001 03 GB Your notes ...

Page 22: ...welding tansformer A programming terminal with BOS 5000 software for data entry operation and monitoring U1 V1 W1 U2 V2 D 64711 Erbach 107 Made in Germany U1 V1 W1 U2 V2 3 PE 2 2 PE A D R BOS 5000 V24 Mains BOS 5000 PSI 6000 Heat sink type specific I O system Slot for Q module Slot for field bus module Field bus for progr option Electrodes Local PC programming logging diagnostics fault display Hos...

Page 23: ...ograms can be programmed and called up Single spot SING re peat mode REPT or seam operation can be selected The welding parameters are stored in a RAM memory The RAM memory has battery backup to prevent loss of data The condition of the battery and the data is being moni tored ...

Page 24: ...Hz medium frequency 50 60 Hz 3 PSI Timer MF inverter Transformer Rectifier Welding equipment Figure 2 Basic functional diagram Welding current The Bosch medium frequency welding system uses DC current for welding The duration of the welding current is programmed in milliseconds ms Because welds turn out to be more uniform than at 50 Hz a higher output of correct welds is obtained The medium freque...

Page 25: ...gramming terminal with one of the following operating systems Windows 3 1x Windows 95 Windows 98 Windows NT3 x NT4 0 Software BOS 5000 Technical documentation Operating and programming instructions volume 1 part no 1070 078 217 Operating and programming instructions volume 2 part no 1070 078 218 V24 interface cable see section 7 1 1 suitable installation for field bus interfaces ...

Page 26: ...to 70 C 25 C to 70 C 0 to 2000 m above sea level No dew point excursion allowed Number of programs 256 access to each individually from spot selection Load cell input Analog input 0 to 5V 1V equivalent to 1 kN Load cell reset output 24VDC I O bus INTERBUS S optical waveguide Field bus for programming in combination with I O bus Proportional control valve 8 bits equivalent to 0 through 10 bar Progr...

Page 27: ...battery Lithium battery Typ AA S to buffer RAM data and internal clock during power loss Battery life approx 2 years Current sensor input for toroid coils for secondary current measurement Stop function stop circuit via floating contact stops schedule Fan connection 24VDC ...

Page 28: ...o 680 V DC nominal voltage Overvoltage protection MOV Temperature monitoring heat sink Cooling air max 45 C Nominal current system side max thermal con tinuous current depending on type of power unit Switching current see load diagram in power unit description Mains connection U1 V1 W1 potential earth frame terminals conductor area depending on type of power unit Transformer connection U2 V2 frame...

Page 29: ...Technical data PSI 6XXX 350 L1 2 4 1070 080 067 101 2001 03 GB Your notes ...

Page 30: ...comprises the following functional units CPU with centralized control function I O interfaces serial I O interface INTERBUS S optical waveguide Quality module slot prepared for subsequent retrofit All settings required for operation can be made on the front panel or from a connected programming terminal ...

Page 31: ...FF ON 1 2 3 4 5 6 7 8 X 4 X 5 X 2 X 9 X 8 1 X 3 2 3 4 5 7 8 6 1 2 3 4 5 7 8 9 10 11 12 13 14 6 1 2 3 4 5 1 2 3 4 5 6 1 2 3 1 2 X 1 A D R 1 3 5 7 4 6 10 11 12 13 14 15 16 17 18 19 20 8 9 2 U1 V1W1 U2 V2 3 PE 2 PE U1 V1 W1 V2 U2 type specific I O system Slot for Q module Slot for field bus module Figure 4 Front panel ...

Page 32: ...ands timer is in boot mode Off timer is in operating mode 9 Recessed key switching from operating mode to boot mode D Pressing this key turns the system to boot mode You should only turn to boot mode for loading a new operating program firmware CAUTION This key may only be operated by authorized personnel Never operate this key during a welding operation Program execution will be stopped and all c...

Page 33: ...5 V analog signal load cell 1 V equivalent to 1 kN zero voltage ext signal GND 16 8 pin plug in terminal for measuring system connection for current sensor toroid 17 Battery compartment use only batteries with Bosch P N 1070 914 446 18 Blanking plate on slot for field bus module 19 Elements of type specific I O system 20 Blanking plate on slot for retrofitting a quality module ...

Page 34: ...odule front panel type specific I Os U1 V1 W1 V2 D 64711 Erbach 107 Made in Germany U1 V2 2 PE U2 2 U2 3 PE W1 V1 1 2 3 4 5 IB S IN UL RD FO2 TR CC BA FO1 X 1 5 X 1 4 X 1 3 X 1 2 OUT Heat sink Slot for field bus module Slot for Q module Figure 5 Type specific I Os ...

Page 35: ...US S data transmission is active FO1 Message F01 IN Interface o k Yellow LED UL Unit Supply the green LED indicates that the supply voltage is available at the bus drop RD Remote Disable the red LED indicates that the downstream optical wave guide has been switched off FO2 Message F02 OUT Interface o k Yellow LED 2 Connection of optical waveguide IB S IN output from timer 3 Connection of optical w...

Page 36: ...side modules that have already been installed It is also possible that water may emerge during the installation of the cooling water lines and may enter the modu les The possibility of short circuits and a destruction of the units cannot be entirely ru led out Therefore the modules should be well partitioned prior to any additional work No liability is accepted in the event of non compliance NOTE ...

Page 37: ...Installation PSI 6XXX 350 L1 4 2 1070 080 067 101 2001 03 GB Your notes ...

Page 38: ...3 current sensor shielded cable 0 75 mm2 up to 100 m 2 x 2 x 0 75 mm2 LiYCY corresponding to Bosch part number 1070 913 494 X4 power supply unshielded cable VDE 0281 0812 z B Ölflex 0 75 mm2 up to 10 m 1 5 mm2 up to 75 m X5 load cell X9 load cell shielded cable min 0 2 mm2 e g 3x2x0 2 mm2 LifYCY Metrofunk X12 X13 IBS OUT optical waveguide IAW INTERBUS S specifica tion IAW INTERBUS S specifica tion...

Page 39: ...Cables PSI 6XXX 350 L1 5 2 1070 080 067 101 2001 03 GB Your notes ...

Page 40: ...cinity of the timer require noise suppres sion Because of inherent vibrations of the machine the mounting of all noise suppression de vices must be resistant to fracture GND MP Diode suitable for small DC relays RC element for AC relays and AC motors DIODE RC ELEMENT GND DI ZD attenuation element for large DC contactors and defined drop out times RC element for spark quenching of in ductive loads ...

Page 41: ...Suppression of RF noise PSI 6XXX 350 L1 6 2 1070 080 067 101 2001 03 GB Your notes ...

Page 42: ... strictly ob served The system voltage is associated with considerable dangers The possible consequences of inappropriate handling include death or most se vere injuries personal injuries and damage to property For this reason the electrical connection must always be made by an electrical expert in compliance with the valid safety regulations The equipment must be appropriately fused at the mains ...

Page 43: ...cuit floating contact load 24 VDC max 3A 1 2 3 4 5 6 7 8 9 10 Jumper 0 V internal power supply D D D D 11 12 13 14 1 2 X5 1 Jumper 24 VDC int power supply Jumper 0 V internal power supply 1 2 3 4 5 6 7 8 24 VDC 0 V For power supply options see Section 7 2 24 VDC I O 0 V X8 1 2 3 X9 1 2 3 4 5 6 Terminals without a descrip tion have no function Toroid input X14 IBS IN X15 IBS OUT X12 X13 24 VDC fan ...

Page 44: ...th please refer to the cable table Section 5 Both ends of the shield conductor must be connected to the conductive connector shell The connector should be screwed to the unit to improve the shielding efficiency 1 2 3 4 5 6 7 8 9 RXD TXD GND RXD TXD 1 2 3 4 5 6 7 8 9 Cannon connector Connect shield to large area of metal shell GND X1 Programming terminal Cannon connector Timer Figure 8 Connection o...

Page 45: ...n measurements scal ings should be made in each case using a suitable welding current meter The maximum cable length between the KSR sensor and the PSI 6XXX 350 L1 is 100 meters This limit must not be exceeded The connection between the KSR sensor and the PSI 6XXX 350 L1 consists of a shielded cable The shield must be connected to X3 3 of the PSI 6XXX 350 L1 The shield at the sensor end is left un...

Page 46: ...log ram force input signal calibrated 1 V being equivalent to 1 kN shielding 7 1 5 INTERBUS S interfaces X12 X13 X14 X15 Signal communication of I O signals see Section 7 3 programming data 7 1 6 Stop circuit A fault in the stop circuit or the 24VDC power supply is automatically reset when cor rected 7 1 7 DC link voltage The DC link voltage is permanently monitored A fault in the DC link voltage ...

Page 47: ...Electrical connection PSI 6XXX 350 L1 7 6 1070 080 067 101 2001 03 GB Your notes ...

Page 48: ...e mains voltage Several jumpers have to be positioned to enable the internal power supply When the welding network is switched off the 24 V DC supply is interrupted no communication via I O interfaces possible no communication between the timer and the programming terminal e g programming and visualization Preferably used with stand alone systems e g suspended welding stations The Stop function is...

Page 49: ...uts and outputs and the load cell by internal 24 VDC power 1 stop circuit floating contact load 24 V DC max 3 A 1 2 3 4 5 6 7 8 9 10 Jumper 0 V internal power supply D D D D 11 12 13 14 1 2 X5 1 24VDC 0 V Jumper 24VDC int power supply Jumper 0 V internal power supply PSI 6XXX 350 L1 load cell Electrical power supply of logics Figure 9 Internal power supply ...

Page 50: ...ox 10 ms plus the current of the load cell connected to X5 continuous current approx 1 5 A plus the current of the inputs and outputs and the current of the load cell connected to X5 NOTE For determining the power supply rating sum up the individual loads required Functions No interfaces are interrupted when the welding network is switched off communication via I O interfaces is possible communica...

Page 51: ...D D 11 12 13 14 1 2 1 Jumper 24VDC ext power supply Jumper 0 V external power supply Configuration B Power supply to weld timer logics inputs and outputs and the load cell by an external 24 VDC power supply unit PSI 6XXX 350 L1 X5 24VDC 0 V D D load cell 24VDC 0 V Electrical power supply of logics Power supply unit Figure 10 External power supply ...

Page 52: ...are subject to the Cables table in section 5 The timer has an INTERBUS interface for I O signal and programming data communica tion via the very same bus system IB S and PCP Optical waveguides are used as trans mission media The INTERBUS S port of the timer operates according to profile specification C0 with specific enhancements Inputs All inputs are served by the INTERBUS S interface Outputs All...

Page 53: ...p change 4 Reset fault 5 Fault reset with weld complete 6 Fault reset with Reweld 7 External Weld ON with welding current 8 Current Scaling 9 Current Scaling Primary 10 Reduced current scaling 11 Current check 12 Pressure calibration 13 Pressure check 14 not used to 23 not used 24 Type ID bit 0 to 27 Type ID bit 3 28 Spot selection bit 0 to 47 Spot selection bit 19 Example of inputs applies corres...

Page 54: ... electrode no 1 through 31 The wear counters will be reset and the tip dress counters will be in cremented by 1 the Acknowledge Tip change signal becomes active this will have an effect on the wear and tip dress counters of either all electrodes if Spot selection 0 or just one specific electrode if Spot selection elec trode no 1 through 31 The wear and tip dress counters will be reset to 0 When th...

Page 55: ...s Spot selection will activate the proportional control valve at its programmed pressure value If Spot selection cannot find a spot because it is not listed in the spot table the pres sure value assigned to the spot that was active last will be read out This is to avoid high pressure fluctuations between welding events if selection 0 which would tend to reduce the life of pressure valves considera...

Page 56: ... tip dress and wear counters of the electrode selected with the signals for Spot selection are reset If electrode number 0 is selected with the Spot selection signals and a Tip dressed signal becomes high the tip dress counters of all electrodes are incremented and the wear counters are set to a defined value If an electrode number 1 through n n maximum number of electrodes is selected with the Sp...

Page 57: ...o interrupt the started Sequence The Sequence becomes modal only upon the beginning of the 1 WLD with the exception of seam operations which are non modal 1 SQZ SQZ 1 WLD 1 CT 2 WLD 3 CT 3 WLD HLD OFF Modal phase Start t t Figure 12 Modal phase of program execution in the case of single spot mode and repeat mode A Sequence can be started with or without firing Start with firing turned on Sequence ...

Page 58: ...vated However no welding operation is performed because there is no weld current Weld No weld external 0 signal external firing switched ON via I O interface Weld No weld external 1 signal external firing switched OFF via I O interface Weld No weld external Weld internal For all timers Program specific firing off off off off off on off on off off on on on on on Sequence without welding current Seq...

Page 59: ...lete This signal resets the displayed fault The cause of the fault must be cleared first If the Start_1 signal is active the Weld complete WC signal is output and the welding timer is switched to ready state Fault reset with reweld This signal is required if the fault was caused by insufficient welding current The spot is rewelded This signal resets the displayed fault The cause of the fault must ...

Page 60: ... with the Spot selection signals and a Tip dressed signal becomes high the tip dress counters of all electrodes will be incremented and the wear counters will be set to a defined value If electrode number 1 through n n maximum number of electrodes is selected with the Spot selection signals and a Tip dressed signal becomes high the tip dress counter is incremented by 1 and the wear counter is set ...

Page 61: ...Counter stepper section 10 0 Count wear factor 1 0 Tipdressing request 1 0 Counts wear last tipdressing before End of Stepper tipdressing Curve Stepper Curve Tipdressing request Tip dressed no Tip dressed further sequence is stopped because of no Tip dressed signal Tipdressing necessary message Tipdressing request message Example Figure 15 Example Tipdressing NOTE In the BOS 5000 software the tip ...

Page 62: ...d an Acknowl edge Tip change signal becomes high the tip dress and wear counters of all elec trodes are reset If an electrode number 1 through n n maximum number of electrodes is selected with the Spot selection signals and an Acknowledge Tip change signal becomes high the tip dress and wear counters of the electrode selected with the signals for Spot selection are reset Setting the wear and tip d...

Page 63: ...ounter stepper section 10 0 Count wear factor 1 0 Prewarning 1 0 Counts wear tipdressing curve 1 Stepper Curve number of tipdressing events Prewarning Counts wear End of Stepper Example Figure 17 Example of electrode replacement NOTE The desired weld timer response stop or continued program execution when the max number of welds end of stepper is reached must be programmed in Global Stepper Setup ...

Page 64: ... End of Stepper Tipdress request Figure 18 Signaling of electrode conditions to outputs NOTE If electrode number 0 is selected with the Spot selection signals and a Request electrode condition signal becomes high the states of all electrodes are requested group signal and signaled through the respective outputs If an electrode number 1 through n n maximum number of electrodes is selected with the ...

Page 65: ... unit with current sensor Schk reference current meter NOTE A current meter is required to measure the reference current U1 V1 W1 U2 V2 D 64711 Erbach 107 Made in Germany U1 V1 W1 U2 V2 3 PE 2 2 PE A D R Electrodes Current sensor Schk V24 local PC optional input of actual current values Isec Mains kA Reference current meter BOS 5000 reference current Iref Reference current Iref Current sensor Sref...

Page 66: ...erequisites The external weld current meter must be connected to the V24 interface The secondary current meter must be connected Sequence The electrode to be selected must be entered in the I O field The respective welding gun must be closed The current scaling input signal must be set The V24 log is switched over to the welding current meter log Now the timer is in current scaling mode No start c...

Page 67: ...e 24V log is switched back from the weld current meter Upon correct completion of the scaling operation the Current scaling check finished signal becomes high and is held until the Current scal ing signal is reset Current scaling involves the re determination of 2 values 1 Toroid sensitivity Scaling of the primary current to the external weld current meter 2 2nd toroid sensitivity Scaling of the s...

Page 68: ... any mismatch between the primary and the secondary currents that go beyond a specified tolerance band BOS scaling mask an error message is generated This error must be reset just like any other error A few new parameters have been introduced for the current check function Current Check Tolerance Band command current Program Number Previous Check actual current Secondary Current Previous Check act...

Page 69: ...s started Primary and secondary currents are measured Subsequently the primary current is checked for any deviation beyond a specified limit stated in from the secondary current which is the reference current in this case If the primary current exceeds the tolerance limit an error message is transmitted Upon correct completion of the Current Check the Current scaling check finished signal becomes ...

Page 70: ...rd current scaling However there is no external weld current meter required because only the primary and the secondary currents are measured In this case the secon dary current is the reference current to which the primary current is scaled Upon correct completion of the reduced current scaling process the Cur rent scaling check finished signal becomes high and is held until the Reduced Current Sc...

Page 71: ...or pro gram selections entered in the I O field will be accepted This sequence is the same as the sequence of standard current scaling However only the primary and secondary currents are measured with the weld current meter The current of the weld current meter is used as the ref erence current to which the primary current is scaled Upon correct completion of the primary current scaling process th...

Page 72: ...essure to pressure regulator with the effect that the programmed force Fcom in kN Fact is applied at the weld gun NOTE A calibrated load sensing device is required to provide reference load values U1 V1 W1 U2 V2 D 64711 Erbach 107 Made in Germany U1 V1 W1 U2 V2 3 PE 2 2 PE A D R electrodes with load cell LCmon programmed pressure value Pcom V24 Local PC optional input of actual force values Fact M...

Page 73: ...ections entered in the entry field are accepted The timer waits until the start signal level equals 0 essential for error han dling The lower command pressure value is output Subsequently the Oper ate signal becomes high and the timer waits for the Start signal The robot sets the Start input signal and simultaneously closes the weld gun The timer waits for two seconds Then the load is measured and...

Page 74: ...ues are displayed You can overwrite them and save your entries Now you may cancel Pressure calibration manually The command values you have just entered for the respective electrode are saved If an error occurs If an error of any type occurs during Pressure calibration the calibration operation will be aborted the Ready signal reset and an error message transmitted The error message transmitted wi...

Page 75: ... tolerance band command value Pressure check before weld time command value Program number of last check actual value Command pressure command value Final value of output pressure actual value Time to pressure actual value Additionally Graphical pressure profile of last pressure check CAUTION Please make sure that all individuals stay clear of the danger zone of the welding gun NOTE Please make su...

Page 76: ...he Final value of output pressure is then defined as the mean of the measured values from the end up to the Time to pressure If the desired pressure is not reached an error message is transmitted just like if the Time to pres sure is too long or to short The lower time limit is the pre squeeze time the upper time limit is the pre squeeze time plus the squeeze time minus the pressure check before t...

Page 77: ...ssure gauging by setting the parameter Export pressure value First the Operate signal is set Every time the Actual pressure parameter is ac cessed the pressure is measured When the Export pressure value parameter is re set the Operate signal is reset and pressure gauging is terminated The normal end of a program sequence or a pressure check calibration will also terminate the gauging routine ...

Page 78: ... or without stepper values 7 Weld No weld with welding current 8 Proportional control valve selection_1 9 Proportional control valve selection_2 10 Proportional control valve selection_4 11 Proportional control valve selection_8 12 Proportional control valve selection_16 13 Proportional control valve selection_32 14 Proportional control valve selection_64 15 Proportional control valve selection_12...

Page 79: ...the Fault Allocation in the Basic Setup menu etc Cf page 10 3 Messages concerning the timer status page 10 4 Messages con cerning current and time monitoring NOTE The programming terminal signals the cause of the fault in the Timer Status Message window Detailed information is displayed by calling up diagnostics for I Os or timer diag nostics When the cause of the fault has been cleared the ready ...

Page 80: ... programming terminal Firing settings Weld No weld external signal Programming of weld no weld internal for all programs in the menu Programming Basic Setup Sequence Setup Programming of program specific firing for one program in the menu Program ming Basic Setup Sequence Setup Weld internal For all timers Program specific firing off off off off off on off on off off on on on on on Sequence withou...

Page 81: ... deactivated you should always check the qual ity of your welds off on off off on on on off Current monitoring Monitoring stopped for all timers Weld process monitoring function on without monitoring on without monitoring on without monitoring off with monitoring Figure 23 Monitoring NOTE Monitoring stopped is activated and deactivated for all timers for all programs of the selected timer in the B...

Page 82: ...scaling page 7 24 Successful completion of a Current check operation is indicated at the output level by a Current scaling check finished signal which stays high until the Current check input signal is reset No WC signal is output during a Current check Cf Current check page 7 27 Pressure calibration check finished Successful completion of a Pressure calibration operation is indicated at the outpu...

Page 83: ..._1 cleared in single spot repeat and seam modes WC starts 20 ms before the end of the hold time HLD and stays high for the period as programmed WC period value value HLD n milliseconds WLD ms ms Start_1 0 WC period value value WLD ms ms ms ms HLD n milliseconds Example With Start_1 set in single spot mode WC starts upon the end of the hold time HLD and stays high until Start_1 is reset Figure 24 W...

Page 84: ...es are started NOTE The earliest WC start time that may be programmed is as follows number of milliseconds HLD minus 1 ms but no earlier than 1000 ms before the end of the hold time HLD An output of the Weld complete WC signal in the event of a welding fault can be pro grammed in I O Parameters under Basic Setup The Weld complete signal can be output manually in the Diagnostics Simulate menu under...

Page 85: ...ogramming terminal No new sequence can be started before the Dressing message has been acknowl edged by the Tip dressed signal Tipdress request Tip dressed Example 9 0 2 0 9 0 2 0 9 0 2 0 Prewarning End of Stepper Acknowledge Tip change 1 1 1 9 0 10 0 Initial Start Tipdress request Current Counter starting section 2 0 Counter stepper section 10 0 Count wear factor 1 0 Tipdress request 1 0 Dressing...

Page 86: ...Sequence This signal indicates that the End of Stepper maximum electrode life will soon be reached The signal is reset when the End of Stepper is actually reached NOTE The wear limit may be programmed in the Stepper window of the Welding Parameters menu The Prewarning signal may also be output on request by the Request electrode condition signal End of Stepper This signal indicates that the End of...

Page 87: ...t with reweld signal cf page 7 18 an operation in the BOS 5000 software e g in the Diagnostics Timer window or using the reset push button on the front panel cf page 3 2 See also the Control ready signal description page 7 38 This signal is output in single spot mode when the spot has been welded A fault reset signal is required before any other spot can be welded repeat mode upon completion of th...

Page 88: ...Control diagrams PSI 6XXX 350 L1 8 1 1070 080 067 101 2001 03 GB 8 Control diagrams ...

Page 89: ... fault Weld No weld external Spot selection Start_1 Proportional valve selection Pre squeeze time Squeeze time 1st Cool time 1st Weld time 2nd Weld time 3rd Cool time 3rd Weld time Hold time ÉÉ Start duration programmable before end of HOLD Fault reset with WC Figure 26 Example of a normal schedule sequence single spot ...

Page 90: ...roportional valve selection Pre squeeze time Squeeze time 1st Cool time 1st Weld time 2nd Weld time 3rd Cool time 3rd Weld time Hold time latching 2 2 possible range for schedule interruption by cancelling start ÉÉ ÉÉ ÉÉ ÉÉ Start duration programmable before end of HOLD Fault reset with WC Figure 27 Example of possible range for schedule sequence interruption single spot ...

Page 91: ...eeze time 1st Cool time 1st Weld time 2nd Weld time 3rd Cool time 3rd Weld time Hold time 1 1 The time between the squeeze time and the hold time corresponds to the total time of 1st weld time 1st cool time 2nd weld time 3rd cool time and 3rd weld time The schedule is performed without welding current Start duration programmable before end of HOLD ÉÉ Fault reset with WC Figure 28 Example of no wel...

Page 92: ...on Start_1 Proportional valve selection Pre squeeze time Squeeze time 1st Cool time 1st Weld time 2nd Weld time 3rd Cool time 3rd Weld time Hold time Off time t 0 switch off 1st spot 2nd nth spot É Start duration programmable before end of HOLD É ÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ no start no off time Fault reset with WC Figure 29 Example of normal schedule sequence repeat mode ...

Page 93: ...Reset fault Weld No weld external Spot selection Start_1 Proportional valve selection Pre squeeze time Squeeze time 1st Cool time 1st Weld time 2nd Weld time 3rd Cool time 3rd Weld time Hold time Start duration programmable before end of HOLD ÉÉ Fault reset with WC Figure 30 Example of normal schedule sequence seam ...

Page 94: ... Pre squeeze time Squeeze time 1st Cool time 1st Weld time 2nd Weld time 3rd Cool time 3rd Weld time Hold time Off time with Repeat mode 1 2 1 possible weld schedule termination time 2 weld schedule hold time Termination time hold time Start duration programmable before end of HOLD ÉÉ ÉÉ Fault reset with WC Figure 31 Example of possible termination time hold time between program selection and star...

Page 95: ...ection Start_1 Proportional valve selection Pre squeeze time Squeeze time 1st Cool time 1st Weld time 2nd Weld time 3rd Cool time 3rd Weld time Hold time Off time no meaning Start duration programmable before end of HOLD ÉÉ ÉÉ XXX XXX XXX Fault reset with WC Figure 32 Example of schedule sequence cancellation during squeeze times 1 SQZ SQZ before latching ...

Page 96: ... Proportional valve selection Pre squeeze time Squeeze time 1st Cool time 1st Weld time 2nd Weld time 3rd Cool time 3rd Weld time Hold time Off time t 0 Start duration programmable before end of HOLD ÉÉ ÉÉ earliest new start new program selection and parity change no meaning XXX XXX Fault reset with WC Figure 33 Example of schedule sequence interruption during latching ...

Page 97: ...Control diagrams PSI 6XXX 350 L1 8 10 1070 080 067 101 2001 03 GB ...

Page 98: ...7 1 1 suitable field bus cables for field bus installa tions Communication between the programming terminal and the timers is via the V24 the I O interface as the programming terminal interface or via the field bus interfaces e g Profi bus In Online mode all Welding Parameters are saved to the timer You can save the Welding Parameters in the programming terminal in preparation of commissioning off...

Page 99: ...roup and user password D Select Operation D Check in the plant layout whether there is a link V24 timer or field bus interface board timer between the programming terminal and the timer If the timer is not linked to the programming terminal gray timer symbol in plant layout check the connection cable or the address settings with Profi bus installations also check the circuitry of the terminating r...

Page 100: ... Sequence without welding current for example one can first examine the I O signal exchange with the higher level control unit and the positioning of robot electrode guns D Select welding program CAUTION Before you start Always make sure beforehand that there is no person in the danger zone of the robot s electrode gun D Start the welding program NOTE If the sequence is not completed or if it is a...

Page 101: ...T off Control Stopped on Start Inhibit P off Weld No weld internal P off Sequence Single Spot Regulation Standard Regulation Mode Phase angle Stepper off Slope off Pre Squeeze Time 1 SQZ 60 ms Squeeze Time SQZ 340 ms 1st Weld Time 1 WLD Without 1st Cool Time 1 CT Without 2nd Weld Time 2 WLD 100 ms Number of impulses 1 impulse 3rd Cool Time 3 CT Without 3rd Weld Time 3 WLD Without Hold Time HLD 100...

Page 102: ...rs have to be transferred again Fault Allocation Used to determine the timer response to events within the Sequence Fault Timer will lose its ready status Warning Timer will not lose its ready status D Check the programmed values for the duration and start time of the Weld Complete contact WC or adjust them to the higher level control unit Thyristor Power Unit Setup Weld Transformer Selection D Co...

Page 103: ...nternal has been switched on Sequences can be performed with welding current D Check and or adjust maximum Weld Time for 1st Weld Time 2nd Weld Time and 3rd Weld Time D Deactivate Control Stopped for KSR mode D Set maximum number of repeats This number will only be active in those programs in which spot repetition reweld has been activated Suggestion concerning the settings for the selected progra...

Page 104: ...pper Recommendation First use a simple Sequence without electrode mainte nance stepping The Steppers can be programmed towards the end of commissioning Current and Time Monitoring D Turn Current and Time Monitoring on For as long as you do not know the real conditions you should use fairly large tolerances initially NOTE For the subsequent production process you should define smaller tolerances fo...

Page 105: ...g Sequence Actual Values window D If necessary adjust the following programmed values to your requirements I and Weld Time Type and number of Weld Times Current upslope and downslope times Slope 9 7 Activating Stepper electrode maintenance The I Stepper refers to the Amount of current and the Pressure The stepper values are experimental values it may not be possible to enter these values before ha...

Page 106: ...finition of the reference time and the admissible time tolerance this window shows an Actual value display D Program Monitor Stepper Select Programming Welding Parameters Monitor Stepper and enter the moni toring values 9 9 Other adjustments and programs When commissioning has been completed you may protect access to the BOS 5000 software in order to restrict changing the Welding Parameters and th...

Page 107: ...p files will be replaced You may enter a new file name for the new Upload Backup file using the File Reference function When the Upload Backup has been completed we recommend using the Compare function in order to check whether the saved Welding Parameters and Basic Setup are identical with the timer values D Performing Compare Select Operation Services Compare File Timer NOTE When using the Compa...

Page 108: ...atus Messages Messages Warnings The ready status of the timer remains further sequences are not inhibited Faults The timer is no longer ready further sequences are inhibited NOTE Internally the timer works with coded numbers All messages are output on the program ming unit in text format ...

Page 109: ... 2 1 A Communication Messages Code Explanation 93 94 95 96 Communication with weld timer cannot be established 97 Communication with weld timer was disconnected 98 Upload Backup or Download Restore active in timer 99 Access to objects denied 100 Incorrect timer type wrong timer in Ref Table 146 Fatal error layer 8 Error when starting the status message possibly not enough RAM memory Close other ap...

Page 110: ...essages Concerning the Timer Status Code Explanation Additional code 80 Stop Open circuit no 24V 83 Thyristor unit not ready 84 Battery low 85 Memory deleted RAM checksum error 86 Data Restore active 87 No weld program invalid parameter Program no 88 Hardware fault H W fault bitcode 89 I O bus fault only for WT with serial I O bus 90 91 Main switch tripped 93 Synchronization fault 94 Sequence inhi...

Page 111: ... mode 1023 Current too low 3 WLD mixed mode 1030 Current too high standard mode 1031 Current too high 1 WLD mixed mode 1032 Current too high 2 WLD mixed mode 1033 Current too high 3 WLD mixed mode 1040 Series of welds below lower threshold standard mode 1041 Series of welds below lower threshold 1 WLD mixed mode 1042 Series of welds below lower threshold 2 WLD mixed mode 1043 Series of welds below...

Page 112: ...ch results in a program abort Emergency Stop e g Additionally a welding fault message is displayed with the addi tional code Scaling aborted Current out of range The deviation of the primary or secondary current is more than 30 from the command value Difference primary secondary current too large Current monitoring shows that the difference between the pri mary and the secondary current is outside...

Page 113: ...Messages PSI 6XXX 350 L1 10 6 1070 080 067 101 2001 03 GB ...

Page 114: ...ccident prevention regulations must be strictly ob served In any case suitable insulated tools must be used Danger of life through inappropriate EMERGENCY STOP facilities EMERGENCY STOP facilities must be operative in all modes of the system Re leasing the EMERGENCY STOP facility must by no means result in an uncon trolled restart of the system CAUTION The right to perform repair maintenance work ...

Page 115: ...vents the next start and the Ready message turns off The Sequence can resume after changing the battery and resetting the fault If a low battery is defined as warning the control will issue the appropriate mes sage but Sequence will not be disabled To change the battery first remove the cover to the battery compartment with CCW mo tion and remove the old battery Then insert the new battery while o...

Page 116: ...0 916 798 13 no function X2 STKK 5 pin 3 5 mm 1070 916 910 14 Analog output load cell X9 STKK 6 pin 3 5 mm 1070 916 554 15 Current sensor X3 STKK 8 pin 3 5 mm 1070 916 553 Not included in shipment Part no X please refer to section 3 2 9 V24 X1 9 pin female D shell connector 1070 912 981 9 V24 X1 9 pin female D shell connector housing 1070 313 723 finished cable V24 X1 for connecting PC to timer le...

Page 117: ...Ordering PSI 6XXX 350 L1 12 2 1070 080 067 101 2001 03 GB Your notes ...

Page 118: ...ime of the welding schedule time following the last weld time during which the parts just welded are allowed to cool down HSA Main switch trip IMP Number of pulses forming the 2 WLD LT Power Unit thyristor or inverter NBS Mains load limitation control for monitoring and influencing the mains load OFF Off time time between 2 spot welds during which the solenoid valve is not activated Avail able onl...

Page 119: ... after beginning of 2 WLD WC Weld Complete contact signal is output when the spot has been completed WLD Weld time WT Weld timer also called resistance weld timer A 2 Regulation terms Ht Specification of heat in Ht represents the electrical phase angle same as I I Specification of current in I represents the electrical phase angle same as Ht kA kilo Amperes KSR Constant current regulation the curr...

Page 120: ...Current scaling check finished 7 41 Current sensor 3 4 7 4 D Data buffering 11 2 DC link voltage 7 5 Degree of protection 2 1 Delete Memory See Safe Delete Dressing 7 19 E Electrical connection XIII Electrode condition 7 12 Electrode Setup 9 5 Electrostatics V EMERGENCY STOP XVII 11 1 EMERGENCY STOP facilities 11 1 End of sequence See Weld complete End of Stepper 7 21 7 37 7 45 EOS See WC EU Machi...

Page 121: ... 5 Pressure 9 7 Pressure calibration 7 31 7 37 Pressure calibration check finished 7 41 Pressure check 7 34 7 37 Pressure regulating valve 3 3 Prewarning 7 37 7 45 Profile specification C0 7 11 Program 255 7 25 Programming terminal 1 1 3 3 7 3 Programs 2 1 Proper use VII Proportional control valve 2 1 Proportional control valve selection 7 37 Proportional valve selection 7 41 Q Qualified personnel...

Page 122: ...t sensor Toroid sensitivity 7 25 Trail current 7 25 Training Courses X Transients peaks 6 1 Transport XI Two handed start XIV Typographic conventions VII U Upload See Backup V V24 interface 3 3 W WARNING V VI WC 7 42 Weld complete 7 37 Weld complete contact 7 42 Weld current sensor 7 4 Weld process monitoring 7 37 Weld time monitoring 10 4 Weld Transformer Selection 9 5 Weld No weld 7 17 7 37 7 39...

Page 123: ...Annex PSI 6XXX 350 L1 A 6 1070 080 067 101 2001 03 GB Your notes ...

Page 124: ...Annex PSI 6XXX 350 L1 A 7 1070 080 067 101 2001 03 GB Your notes ...

Page 125: ...Annex PSI 6XXX 350 L1 A 8 1070 080 067 101 2001 03 GB Your notes ...

Page 126: ...Annex PSI 6XXX 350 L1 A 9 1070 080 067 101 2001 03 GB Your notes ...

Page 127: ...Annex PSI 6XXX 350 L1 A 10 1070 080 067 101 2001 03 GB Your notes ...

Page 128: ...1070 080 067 101 2001 03 GB TI AT VWS Printed in Germany ...

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