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Maintenance

PSI 6XXX.190 W1

12-1

1070 080 086-101 (01.01) GB

12

Maintenance

WARNING!

-

Danger of life through electrical voltage!
Prior to any maintenance work - unless described otherwise - the system must
always be switched off! If the system had been active shortly before, wait until the
system is totally de-energized before starting the maintenance work (e.g. because
of charged capacitors, etc.). For the duration of the maintenance work the system
must always be protected against re-closing.
In the event of necessary measurement or test procedures at the active system,
the applicable safety and accident 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 on the timer components is reserved
to the Bosch service department or to repair/maintenance units authorized by
Bosch!

-

Only use spare parts/replacement parts approved by Bosch!

-

Spent batteries or accumulators must be disposed of as hazardous waste.

The connections and termination points of all connecting cables must be checked in reg-
ular intervals for firm sit. Check all cables for damages.

!

!

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Summary of Contents for WT PSI 6 Series

Page 1: ...PSI 6XXX 190 W1 Technical Information PSI 6000 101 Edition Description of Timer and I O Level ...

Page 2: ...1070 080 086 101 01 01 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: ...fied 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 Block diagram of timer 1 4 1 3 Programming and operating the timer 1 5 2 Technical data 2 1 2 1 Welding timers 2 1 2 2 Power unit 2 3 3 Hardware 3 1 3 1 Structure 3 1 3 2 Module fron...

Page 5: ... 1 5 External device X5 7 6 7 1 6 Stop circuit 7 6 7 1 7 DC link voltage 7 6 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 15 7 3 1 Parallel inputs 7 15 7 3 2 Parallel outputs 7 23 8 Control diagrams 8 1 9 BOS 5000 9 1 9 1 Programming the Basic Setup 9 1 9 2 Programming the Welding Parameters 9 3 9 3 Input ranges of the Welding Parameters ...

Page 6: ... 10 7 Activating monitoring 10 9 10 8 Other adjustments and programs 10 9 10 9 Saving the Welding Parameters 10 10 11 Messages 11 1 11 1 Fault and Status Messages 11 1 11 2 Ranges of Messages 11 2 11 2 1 A Communication Messages 11 2 11 2 2 B Electrode Stepper Messages 11 3 11 2 3 C Messages Concerning the Timer Status 11 3 11 2 4 D Messages for Current Monitoring 11 4 12 Maintenance 12 1 12 1 Cha...

Page 7: ...Contents PSI 6XXX 190 W1 IV 1070 080 086 101 01 01 GB Your notes ...

Page 8: ...pliance 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 190 W1 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 circumstance...

Page 9: ...vere 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 making...

Page 10: ...pared to the previous edition Proper use The present manual contains information on the proper use of the weld timer type PSI 6XXX 190 W1 In connection with the intended power supply and the specified welding equipment the weld timer type PSI 6XXX 190 W1 serves for resistance welding of metals is suitable for operation in industrial environments in accordance with DIN EN 50082 2 and DIN EN 50081 2...

Page 11: ... 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 las...

Page 12: ...r 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 pacema...

Page 13: ...mission 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 f...

Page 14: ... 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: ...sufficient protection type The protection type of the PSI 6XXX 190 W1 modules is IP 00 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...

Page 16: ...ropriate 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 appropr...

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 applica...

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: ...G 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 190 W1 using third party equipment This is the only way to determine whether these parts are suitable for use...

Page 20: ...opriate 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 080 086 101 01 01 GB Your notes ...

Page 22: ...F inverter PSI A programming terminal with BOS 5000 software for data entry operation and monitoring Field bus for progr option Electrodes Current sensor toroid Local PC programming logging diagnostics fault display Host PC programming logging diagnostics fault display Welding transformer PSI 6XXX 190 W1 parallel I O interfaces A D R X 10 X 1 U 1 V 1 W 1 U 2 V 2 2 2 P E U2 V2 U1 V1 W1 3 P E Cautio...

Page 23: ... welding programs can be programmed and called up In the basic setup seam operation is preselected 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: ...l principle 1000 Hz Medium frequency 50 60 Hz 3 PSI Timer MF inverter Transformer Rectifier Welding equipment Figure 2 Block diagram of functional principle Welding current The Bosch medium frequency welding system uses DC current for welding The duration of the welding current is programmed in milliseconds ms The welding process is per formed more evenly than with 50 Hz welds The range of good we...

Page 25: ...4 see sect 7 1 1 Field bus 24V BUS more timers Programming terminal Output thyristor unit KSR I O interface Pressure valve Battery see sect 12 1 1 2 3 4 5 see section 7 2 see section 7 3 see section 7 1 2 Figure 4 Block diagram of timer 1 Constant current regulation 2 RAM for storing the welding parameters 3 Flash Memory for storing the operating system 4 V24 interface for connecting a PC or a BT ...

Page 26: ...ramming 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 27: ...System PSI 6XXX 190 W1 1 6 1070 080 086 101 01 01 GB Your notes ...

Page 28: ...pprox 0 5 to 1 0 A Power losses approx 8 5 VA 2 4 VA per active input Environmental conditions Operation Storage Transport Air pressure Humidity 0 C to 55 C 25 C to 70 C 25 C to 70 C 0 to 2000 m above sea level No dew point excursion allowed Number of programs 32 access to each program indivi dually from program selection each program with a maximum of 7 current blocks Parallel inputs E0 to E8 24 ...

Page 29: ...Bosch BT operating terminal via internal V24 RS232 interface isolated Connection 9 pin Cannon connector Field bus for programming option Profibus FMS or Interbus PMS Operating system in Flash Memory can be loaded through V24 RS232 or field bus Program memory RAM memory battery buffered Backup battery Lithium battery Typ AA S to buffer RAM data and internal clock during power loss Battery life appr...

Page 30: ...C nominal voltage Overvoltage protection MOV Temperature monitoring heat sink Cooling water 4 liters min max 40 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...

Page 31: ...Technical data PSI 6XXX 190 W1 2 4 1070 080 086 101 01 01 GB Your notes ...

Page 32: ...omprises the following functional units CPU with centralized control function I O module parallel inputs and outputs Field bus interface Profibus FMS or optionally Interbus PMS MF inverter PSI All settings required for operation can be made at the front side or through a connected programming terminal ...

Page 33: ...em OFF ON X 4 X 5 X 9 X 3 X 2 A D R X 1 X 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 1 2 3 1 2 1 2 3 4 5 6 1 2 3 4 5 U1 V1 W1 U2 V2 2 2 PE U2 V2 U1 V1 W1 3 PE Caution Warning 1 2 3 5 4 8 10 11 6 7 13 9 12 14 15 16 17 18 19 type specific I O interface Slot for field bus module Figure 5 CPU front panel ...

Page 34: ...de 8 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 control outputs set to zero 9 X1 9 pin D shell plug V24 ...

Page 35: ... in terminal no function 15 X3 8 pin plug in terminal transformer temperature floating contact 16 Battery compartment use only batteries with Bosch P N 1070 914 446 17 Blanking plate on slot for field bus module 18 Elements of type specific I O interface 19 Blanking plate ...

Page 36: ...1 0 1 2 3 4 24V 24V 0V 0V A0 1 2 3 4 5 6 7 8 9 10 11 12 0V X 1 2 14 15 16 17 18 19 20 24V X 1 3 E0 1 2 3 4 5 6 7 8 9 10 11 12 24V 13 24V A0 M1 6A A1 12 M1 6A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 1 2 3 1 2 1 2 3 4 5 6 1 2 3 4 5 U1 V1 W1 U2 V2 2 2 PE U2 V2 U1 V1 W1 3 PE Caution Warning Slot for field bus module Figure 6 Type specific I interface ...

Page 37: ...6 A A1 to A6 miniature fuse 5 x 20 M 1 6 A 2 X13 16 pin plug in terminal inputs 3 5 mm spacing 3 X12 8 pin plug in terminal inputs 3 5 mm spacing 4 X11 14 pin plug in terminal outputs 3 5 mm spacing 5 X10 4 pin plug in terminal 24 VDC voltage supply 3 5 mm spacing for types of connection see sections 7 3 1 and 7 3 2 ...

Page 38: ... sawing out openings within switch cabinets metal burr may get inside 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 w...

Page 39: ...0 1 2 3 4 5 6 7 8 9 10 11 12 0V X 1 2 14 15 16 17 18 19 20 24V X 1 3 E0 1 2 3 4 5 6 7 8 9 10 11 12 24V 13 24V A0 M1 6A A1 12 M1 6A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 1 2 3 1 2 1 2 3 4 5 6 1 2 3 4 5 U1 V1 W1 U2 V2 2 2 PE U2 V2 U1 V1 W1 3 PE Caution Warning Slot for field bus module Figure 7 CPU and I O module in power unit ...

Page 40: ...perature unshielded cable VDE 0281 0812 e g Ölflex 0 5 mm2 X4 power supply unshielded cable VDE 0281 0812 e g Ölflex 0 75 mm2 up to 10 m 1 5 mm2 up to 75 m X5 external device unshielded cable VDE 0281 0812 e g Ölflex 0 75 mm2 up to 10 m 1 5 mm2 up to 75 m X10 power supply unshielded cable VDE 0281 0812 e g Ölflex 0 75 mm2 up to 10 m 1 5 mm2 up to 75 m X11 parallel outputs A0 unshielded cable VDE 0...

Page 41: ...Cables PSI 6XXX 190 W1 5 2 1070 080 086 101 01 01 GB Your notes ...

Page 42: ...inity 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 D...

Page 43: ...Suppression of RF noise PSI 6XXX 190 W1 6 2 1070 080 086 101 01 01 GB Your notes ...

Page 44: ...ber of features to be 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 appropriatel...

Page 45: ... selection_1 not used Block selection_1 not used E7 E8 E9 E10 E11 E12 E13 not used not used E6 24V 24V Reset fault with WC Weld No weld external not used E14 E15 E16 E17 E18 E19 Monitoring contact not used 24V D D D D X12 not used not used E20 Block start A0 A1 A2 A3 A4 A5 Solenoid 24 VDC 1 A max Welding fault Weld No weld w o monitoring not used not used Weld complete WC not used Control ready no...

Page 46: ...Cables see 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 10 Connection of the V24 RS232 interfa...

Page 47: ...24 signal 20 mA at input X2 4 serves as an input to the WT by which an external force and comparison device signals that the specified pressure force value has been reached at the electrodes This Pressure input signal is linked by a logic AND with the Moni toring contact in the WT and acts together with it as a condition for Start of the SQZ When operated without this external force measuring and ...

Page 48: ...re reached Pressure control valve 0V 4 5 Figure 11 Connection of pressure control valve with feedback Example 24VDC from this terminal Druck D 0V X4 5 8 D D 24 VDC X2 D 1 2 3 4 5 Pressure Pressure input 24 VDC 20 mA 0V 0V to 10 VDC max 20 mA Pressure control valve Figure 12 Connection of pressure control valve without feedback or operation without pressure control valve ...

Page 49: ... No Start is possible 7 1 4 Power supply X4 see section 7 2 7 1 5 External device X5 24 V DC are output at interface X5 for supplying an external unit maximally 2A depend ing on the external supply 7 1 6 Stop circuit A fault in the stop circuit is automatically reset when corrected 7 1 7 DC link voltage The DC link voltage is permanently monitored A fault in the DC link voltage is automati cally r...

Page 50: ... 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 possible Preferably used with stand alone systems e g suspended welding stations The Stop function is ensured by means of a floating contact which is to be con nected t...

Page 51: ...E12 E13 24 V D D D D X13 X12 X11 24 V External unit reference potential for parallel inputs outputs 0 V 24 VDC Jumper 24VDC int power supply Configuration A Power supply to weld timer logics firing inputs and outputs and the external unit by internal 24 VDC power Jumper 0 V internal power supply Jumper 24VDC int power supply Jumper 0 V internal power supply Electrical power supply of logics 1 stop...

Page 52: ...d to X5 continuous current approx 1 5 A plus the current of the inputs and outputs and the current of the external unit 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 communication between the timer and the programming term...

Page 53: ...VDC 0 V Configuration B Power supply to weld timer logics firing inputs and outputs and the external unit by an external 24 VDC power supply unit PSI 6XXX 190 W1 X5 24 VDC 0 V D D A11 A12 0 V E19 E20 24 V E12 E13 24 V D D D X13 X12 X11 24 V D 24 VDC 0 V 24 VDC 0 V Power supply unit Electrical power supply of logics Jumper between X10 0 V X4 2 Jumper between X10 24 V X4 1 External unit reference po...

Page 54: ...ance 15 20 Making current approx 2 0 A duration approx 10 ms plus the current of the external unit connected to X5 continuous current approx 1 5 A plus the current of the external unit con nected to X5 NOTE For determining the power supply rating sum up the individual loads required Functions When the welding network is switched off the following interfaces will be inter rupted no communication vi...

Page 55: ...el inputs and outputs by internal 24 VDC power Power supply to weld timer logics and the external unit by an external power supply unit 1 24 VDC 0 V D D A11 A12 0 V E19 E20 24 V E12 E13 24 V D D D X13 X12 X11 24 V D 24 VDC 0 V 24 VDC 0 V Jumper between X10 0 V X4 2 Jumper between X10 24 V X4 1 External unit reference potential for parallel inputs outputs Electrical power supply of logics Jumper 24...

Page 56: ... of the inputs and outputs In configuration D the external power supply unit 2 must satisfy the following require ments maximum ripple 5 tolerance 15 20 Making current approx 2 0 A duration approx 10 ms plus the current of the external unit connected to X5 continuous current approx 1 5 A plus the current of the external unit con nected to X5 NOTE For determining the power supply rating sum up the ...

Page 57: ...arallel inputs and outputs by an external 24 VDC power supply 1 Power supply to weld timer logics and the external unit by a second external 24 VDC power supply unit 2 1 2 2 D D A11 A12 0 V E19 E20 24 V E12 E13 24 V D D D X13 X12 X11 24 V D 24 VDC 0 V 24 VDC 0 V 24 VDC 0 V Jumper between X10 0 V X4 2 Jumper between X10 24 V X4 1 External unit reference potential for parallel inputs outputs Power s...

Page 58: ...k selection Each seam program consists of a basic program Program selection and up to 7 block programs Block selection The higher level welding parameters have been programmed in the basic programs The current block parameters required for the sequence are programmed in the block pro grams refer to sections 9 1 and 9 2 All seam programs work with electrode number 0 Changing the Block selection can...

Page 59: ... 47 6 48 49 to 55 7 56 57 to 63 8 64 65 to 71 9 72 73 to 79 10 80 81 to 87 11 88 89 to 95 12 96 97 to 103 13 104 105 to 111 14 112 113 to 119 15 120 121 to 127 16 128 129 to 135 17 136 137 to 143 18 144 145 to 151 19 152 153 to 159 20 160 161 to 167 21 168 169 to 175 22 176 177 to 183 23 184 185 to 191 24 192 193 to 199 25 200 201 to 207 26 208 209 to 215 27 216 217 to 223 28 224 225 to 231 29 232...

Page 60: ... the program number the analog pressure output is driven with the pro grammed pressure force value Block selection 0 to 7 Block program A Block selection is made through parallel signals with a binary value in the range of 0 to 7 This selection serves to select a block program that has been permanently assigned to the basic program If the Block start becomes active in connection with the selected ...

Page 61: ...Block selection is read and the block delay time BDT is started This process is followed by the weld times and cool times of the block program until the Block selection is available without any changes and Start is active For programming of BDT weld times and cool times refer to section 9 2 If the Start is cleared during a current block the sequence of the seam program is finished in the current b...

Page 62: ... 7 19 1070 080 086 101 01 01 GB 1 SQZ SQZ BDT n x 2 WLD HLD Start t t t Block start Sequence Figure 20 Block start during squeeze times 1 SQZ SQZ BDT n x 2 WLD HLD Start t t t Block start Sequence Figure 21 Block start after squeeze times ...

Page 63: ...t circuitry and the sequence in the PSI 6XXX 190 W1 results in the following re sponse time to a change of the Block selection TRMAX THW TAB TPROZ TO TPROG TRMAX maximum response time to a change in the Block selection THW fixed hardware response time of 3 ms depending on the type of I O module TAB variable software response time of 0 to 4 ms TPROZ variable process response time 0 to total time of...

Page 64: ...he program will remain identical to the sequence with activated firing However no welds are performed there is no weld ing current No weld external 0 signal Weld external 1 signal External weld Weld internal For all timers Program related firing off off off off off on off on off off on on on on on Sequence without welding current Sequence without welding current Sequence without welding current Se...

Page 65: ... signal will be output when Start has been cleared the weld ing timer is switched into ready state A new sequence can be started Monitoring contact When the 1 SQZ has elapsed the Monitoring contact is scanned It signals to the weld timer that the electrodes are closed The 24VDC signal at the input is linked by a logic AND with the Pressure input and is a condition for the start of the SQZ refer to...

Page 66: ...p menu a battery fault that has been defined as a fault in the Fault Allocation in the Basic Setup menu etc Page 11 3 Messages concerning the timer status page 11 4 Messages concerning current 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 ...

Page 67: ...at the programming terminal Firing settings Weld No weld external Programming of weld no weld internal for all programs in the menu Programming Basic Setup Sequence Setup Programming of program related weld no weld for one program in the menu Pro gramming Basic Setup Sequence Setup External weld For all timers Program related firing off off off off off on off on off off on on on on on Sequence wit...

Page 68: ...ring function on without current monitoring on without current monitoring on without current monitoring off with current monitoring Figure 24 Current monitoring NOTE Monitoring stopped is activated and deactivated for all timers for all programs of the selected timer in the Basic Setup in the menu Sequence Setup Current monitoring is activated and deactivated for specific programs with the Welding...

Page 69: ... at the end of the seam Start 1 2 3 Example With Start deleted and with operation mode Seam WC start 1 cycle before HLD end WC period according to programming WC period value value HLD 3 cycles WLD t t t Figure 25 Example on Programming of the Weld complete contact WC Output of the Weld complete signal is possible even if the weld was not performed correctly by appropriate programming in the Basic...

Page 70: ...ady state is restored by the Reset Fault with WC signal please refer to page 7 22 or an operation in the BOS 5000 software e g in the Diagnostics Timer window or the green button on the front panel of PSI 6XXX 190 W1 Also refer to Control ready signal page 7 23 The Welding fault output is signaled when a fault has occurred in the seam The schedule is not interrupted At the end of the schedule open...

Page 71: ...Electrical connection PSI 6XXX 190 W1 7 28 1070 080 086 101 01 01 GB Your notes ...

Page 72: ...Control diagrams PSI 6XXX 190 W1 8 1 1070 080 086 101 01 01 GB 8 Control diagrams ...

Page 73: ...É Start duration programmable before end of HOLD Solenoid Block selection_1 Block selection_2 Block selection_4 Block start 1st block delay time 2nd block with I output 2nd Slope time 2nd weld time 2nd cool time 2nd block delay time 3rd block with I output 3rd Slope time 3rd weld time 3rd cool time 3rd block delay time Weld external Figure 26 Example of a normal schedule sequence with weld on seam...

Page 74: ...duration programmable before end of HOLD Solenoid Block selection_1 Block selection_2 Block selection_4 Block start 1st block delay time 2nd block with I output 2nd Slope time 2nd weld time 2nd cool time 2nd block delay time 3rd block with I output 3rd Slope time 3rd weld time 3rd cool time 3rd block delay time Weld external ÍÍÍ ÍÍÍ Figure 27 Example of a schedule sequence with delayed start of bl...

Page 75: ...tart duration programmable before end of HOLD Solenoid Block selection_1 Block selection_2 Block selection_4 Block start 1st block delay time 2nd block without I output 2nd Slope time 2nd weld time 2nd cool time 2nd block delay time 3rd block without I output 3rd Slope time 3rd weld time 3rd cool time 3rd block delay time Weld external Figure 28 Example of a normal schedule sequence with No weld o...

Page 76: ... duration programmable before end of HOLD Solenoid Block selection_1 Block selection_2 Block selection_4 Block start 1st block delay time 2nd block without I output 2nd Slope time 2nd weld time 2nd cool time 2nd block delay time 3rd block without I output 3rd Slope time 3rd weld time 3rd cool time 3rd block delay time Weld external no meaning no meaning Figure 29 Example of sequence cancellation d...

Page 77: ...Control diagrams PSI 6XXX 190 W1 8 6 1070 080 086 101 01 01 GB ...

Page 78: ...the current blocks which are required for the schedule are pro grammed in the block programs 9 1 Programming the Basic Setup Generally for all seam programs Safe Delete Delete Memory Safe Delete Delete Memory Fault Allocation Fault Allocation for faults of the 2nd Weld time 2 WLD I O Parameters Weld complete WC Thyristor Power Unit Setup Power unit parameters Weld Transformer Selection Weld transf...

Page 79: ...imary side Program specific start inhibit Electrode number fixed 0 Program specific weld no weld Schedule Welding modes fixed seam Regulation fixed mixed Monitoring Spot Repeat fixed Off Other windows in the Basic Setup window The Basic Setup of the seam welding timer is performed without the Basic Setup of the following windows A programmed Basic Setup of these windows will not be used Global Ste...

Page 80: ... on off x x Pre Squeeze Time 1 SQZ x Squeeze Time SQZ x Block delay time BDT as Pre Squeeze Time 1 SQZ x 1st Weld Time 1 WLD with I and Regulation Mode 1st Cool Time 1 CT Up Slope Time UST x 2nd Weld Time 2 WLD with I and Regulation Mode x Down Slope Time DST with I 2nd Cool Time 2 CT x 3rd Cool Time 3 CT 3rd Weld Time 3 WLD with I and Regulation Mode Hold Time HLD x OFF Time OFF Impulse Current M...

Page 81: ...Profile Pressure values for the pressure profile Other windows in the Welding Parameters menu A seam weld is programmed without the Welding Parameters of the following windows Programmed Welding Parameters contained in these windows are not used Stepper Time Monitoring Monitor Stepper Pressure Stepper Freely Programmable Outputs ...

Page 82: ...0 ms 1st to 7th Block delay time 0 to 2000 ms as Pre Squeeze Time 1 SQZ in the block programs 1st to 7th Current slope time 0 to 2000 ms 1st to 7th Weld time 1 to 2000 ms 1st to 7th Cool Time 0 to 2000 ms 1st to 7th Regulation mode PHA or KSR 1st to 7th I KSR depends on the welding transformer used 1st to 7th I PHA 0 to 100 SKT Hold Time 1 to 2000 ms ...

Page 83: ...ue can be defined as the monitoring value with the Act Com command button on the operator interface 9 5 Current monitoring in the block programs For each current block programmed in a block program which consists of the 2nd Weld time 2 WLD an upper and lower tolerance band and as well as a monitoring current value can be programmed Each current block is monitored separately and monitoring can be i...

Page 84: ... V24 interface cable cf section 7 1 1 suitable field bus cables for field bus installa tions Communication between the programming terminal and the timers is via the V24 or field bus interfaces e g Profibus In Online mode all Welding Parameters are saved to the timer Saving the Welding Parameters in the programming terminal for preparative commis sioning offline timer is possible D The BOS 5000 so...

Page 85: ... 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 resis...

Page 86: ...st 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 The following signals must be present for the Start Monitoring contact MC Pressure input at connector X2 NOT...

Page 87: ...art Inhibit T off Basic program Weld No weld internal T off Control Stopped on Start Inhibit P off Weld No weld internal P off Sequence Seam Regulation Mixed Regulation Mode Phase angle Slope off Block program Pre Squeeze Time 1 SQZ 60 milliseconds Basic program Squeeze Time SQZ 350 milliseconds Block delay time BDT 60 milliseconds Block program 2nd Weld Time 2 WLD 100 milliseconds Block program H...

Page 88: ...ou have not transferred any other Basic Setup and Welding Parameters NOTE The All Welding Parameters memory area contains the entire programming If you de lete this memory all Welding parameters 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 Thyristo...

Page 89: ...ibit Firing setting depending on the requirements of the commissioning work with without welding current CAUTION When Weld external has been activated and Weld internal has been switched on Se quences can be performed with welding current D Check and or adjust maximum Weld Times D Deactivate Control Stopped for KSR mode Suggestion concerning the settings for the selected program D Deactivate Start...

Page 90: ...d Sequence D Check the sequence parameters in particular the Weld Times and the I values I or kA Current Monitoring D Turn Current Monitoring on For as long as you do not know the real condi tions you should use fairly large tolerances initially NOTE For the subsequent production process you should define smaller tolerances for moni toring in order to assure the quality of your products Pressure R...

Page 91: ... factor for pressure output zero shift for pressure output D Select e g Starting Window Scaling 10 6 Adjusting the program to your welding task D Check the quality of your spot welds The actual current values of the spots welded are displayed in various windows e g in the Programming Sequence Actual Values window D If necessary adjust the following programmed values to your requirements I and Weld...

Page 92: ...he definition of the reference current and tolerance band this window shows an Actual value display 10 8 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 the Basic Setup by defining user levels A systems disk is needed for this purpose D Use the BOS 5000 Set up in the System...

Page 93: ... 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 Compar...

Page 94: ...e 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 Fault messages and warnings for Current Prewarning and Maximum I are cleared with every new program start ...

Page 95: ...Explanation 93 94 95 96 Communication with weld timer cannot be established 97 Communication with weld timer was disconnected 98 Upload or Download active in Timer 99 Objects are not accessible 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 applications 193 Error during checking of paramete...

Page 96: ...e 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 93 Synchronization fault 94 Sequence inhibited Program no 99 Welding process cf D Monitoring code 100 Supply voltage fault 102 No weld ex...

Page 97: ...sages for Current Monitoring Code Explanation 1011 to 1017 No current mixed mode block 1 to 7 1021 to 1027 Current too low mixed mode block 1 to 7 1031 to 1037 Current too high mixed mode block 1 to 7 1051 to 1057 Current measuring range exceeded mixed mode block 1 to 7 ...

Page 98: ...cident 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 o...

Page 99: ...ents 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 ob...

Page 100: ... unit X5 STKK 2 pin 3 5 mm 1070 914 564 12 no function X8 STKK 3 pin 3 5 mm 1070 916 798 13 Pressure X2 STKK 5 pin 3 5 mm 1070 916 910 14 Analog output X9 STKK 6 pin 3 5 mm 1070 916 554 15 Measuring system X3 STKK 8 pin 3 5 mm 1070 916 553 x type specific I Os please refer to section 3 3 2 Inputs X13 STKK 16 pin 3 5 mm 1070 916 795 3 Inputs X12 STKK 8 pin 3 5 mm 1070 916 553 4 Outputs X11 STKK 14 ...

Page 101: ...X1 9 pin female D shell connector housing 1070 313 723 finished cable V24 X1 for connecting PC to timer length 1 5 meter 1070 066 749 shielded cable 2 x 2 x 0 75 mm2 LiYCY 1070 913 494 16 Battery compartment with cover 1070 917 004 16 Battery 1070 914 446 X please refer to section 3 3 1 Fuse M 1 6 A type 5 x 20 1070 900 844 1 Fuse holder with cover type 5 x 20 FAB 1070 910 588 ...

Page 102: ...unit HEAT Heat in Ht or kA same as current HLD HOLD Hold time last time 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 w...

Page 103: ...during which the Current HEAT stops 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 C...

Page 104: ...anging Batteries 12 2 Compare 10 10 Connecting lines XII Connection XIII 7 1 Control ready 6 23 Current Monitoring 9 3 9 6 Current monitoring 6 25 D Data buffering 12 2 DC link voltage 7 6 Degree of protection 2 1 Delete Memory See Safe Delete E Electrical connection XIII Electrode number 6 15 Electrode Setup 9 1 10 5 Electrostatics V EMERGENCY STOP XVII 12 1 EMERGENCY STOP facilities 12 1 EU Mach...

Page 105: ...onitoring contact 7 4 Monitoring current value 9 6 Monitoring stopped 6 25 Monitoring value 9 6 N Noise suppression devices 6 1 NOTE VI O Operating mode 3 3 Operating system 1 4 Operating voltage 2 1 Operation XIV Outputs 6 23 P Pacemaker IX Parallel inputs 6 15 Parallel outputs 6 23 Part no 13 1 PE conductor V Personal protection XIV Power losses 2 1 Power supply 3 3 7 1 7 6 6 7 Power Unit Setup ...

Page 106: ... 9 4 Stepper Setup See Electrode Setup Stepper Curves 9 2 Stop circuit 7 6 Storage XI Structure 3 1 Synchronization voltage 7 6 System voltage 2 3 7 1 T Temperature 2 1 Temperature monitoring 7 6 Test procedures 12 1 Thyristor Unit Setup See Power Unit Setup Time Monitoring 9 4 Timer module 1 1 Tipdress curves 9 2 Tolerance band 9 6 Training Courses X Transformer temperature 7 6 Transients peaks 6...

Page 107: ...PSI 6XXX 190 W1 Annex A 6 1070 080 086 101 01 01 GB Your notes ...

Page 108: ...1070 080 086 101 01 01 GB TB AT VWS Printed in Germany ...

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