Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

Rexroth PSx 6xxx R911172825

Edition 02

Technology and timer functions

Description of application
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and Controls

The data indicated below is intended to describe the

product. Should information on its use be provided,
such information represents application examples
and suggestions only. Catalog specifications shall
not be deemed as warranted quality.
This information does not release the user from per­
forming his own assessments and verifications.
Our products are subject to natural wear and aging.

E All rights reserved, including applications for

protective rights by Bosch Rexroth AG.
Reproduction or distribution by any means subject to
our prior written permission.

An example configuration is shown on the cover

page. The delivered product may therefore deviate
from the picture.

Language version of the document: EN

Original language of the document: DE
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and Controls

Contents

Contents

1 Regarding this documentation . . . . . . . . . . . . . . . . 5

1.1 Validity of this documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Additional documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Presentation of information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.2 Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.3 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 General information on damage to property and

products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5 Information on this product . . . . . . . . . . . . . . . . . . . 15

5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6 Program execution . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 Programmable times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Current blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3 Electrode force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1 Schedule modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.1 Single spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.2 Repeat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.3 Seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2 Impulse mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.3 Slope (current increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.4 Welding modes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.4.1 Phase angle (PHA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.4.2 Constant-current regulation (KSR) . . . . . . . . . . . . . . . . . . . . . 30
7.4.3 UI regulation (UIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5 %I prewarning and limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5.1 %I limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5.2 %I warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5.3 Lower %I warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.6 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.6.1 Current monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.6.2 Time monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.6.3 Monitor stepper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.6.4 Measuring loop test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.6.5 Minimum current verification . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.7 Latching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.8 Automatic reweld by timer active . . . . . . . . . . . . . . . . . . . . . . . . 40
7.9 1. Halfcycle limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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Contents

7.10 Post-warming pulse (NWI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.11 Electrode management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.11.1 %I stepping (Stepper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.11.2 Tip dressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.11.3 Warning and end of Stepper . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.11.4 Warning table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.12 Tip dresser result monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.13 Monitoring dresser change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.14 Gun life monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.15 Outputting the electrode force . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.16 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.16.1 Force calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.16.2 Current calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.17 Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.18 KSR changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.19 Close weld contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.20 Weld Circuit Degradation (WCD) . . . . . . . . . . . . . . . . . . . . . . . . 62
7.21 Reference to additional important functions . . . . . . . . . . . . . . . 63
7.21.1 UI regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.21.2 Thin-sheet function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.21.3 Q Stop (Quality Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.21.4 Glue function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.21.5 Static gun resistance compensation . . . . . . . . . . . . . . . . . . . . 63
7.21.6 Force monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

8 List of tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

9 List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

10 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

11 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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and Controls

Regarding this documentation

1 Regarding this documentation

This chapter includes important information on the use of the docu­
mentation.
" Inform yourself about the product before you work with it!

1.1 Validity of this documentation

The present documentation
For which product? • applies to
our weld timers PSx 6xxx.
Except for:
PSI 6xxx.000 (master−slave) and PSI 6xxx.190 (roll seam types)
Target group? • is designed for
planning, programming, start-up personnel, operators, service tech­
nicians, plant operators.
Topics dealt with? • provides information about
• programming principle,
• basics on the definition of a welding schedule and
• important timer functions.

1.2 Additional documentation

Several documents are available for the product which are needed to­
gether for comprehensive information.
" Only start the product when you are familiar with and understand the
documents marked with D.
Table 1: Necessary and supplementary documents

Title Doc. no. Document type

D PST 6xxx: Weld timer with thyristor 1070080029 Operating instruc­
power unit tions
D PST 6xxx.xxx: Weld timer with depending Operating instruc­
thyristor power unit, type-specific on type tions (type-spe­
supplement cific supplement)
D PSI 6xxx: Weld timer with medium- 1070080028 Operating instruc­
frequency inverter tions
D PSI 6xxx.xxx xx: Weld timer with depending Operating instruc­
medium-frequency inverter, type- on type tions (type-spe­
specific supplement cific supplement)
D PSG 3xxx/6xxx: MF welding trans­ 1070087062 Operating instruc­
formers tions
D PSG 3xxx/6xxx: MF-welding trans­ depending Operating instruc­
formers, type-specific supplement on type tions (type-spe­
cific supplement)
D PSx 6xxx: Technology and timer R911172825 Description of ap­
functions plication
D BOS 6000 online help 1070086446 Reference
PSI 6xxx: UI regulation and monit­ 1070087072 Description of ap­
oring plication
D: necessary document
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Regarding this documentation

1.3 Presentation of information

We use uniform icons, terms and abbreviations in this documentation.
They will be explained in the following paragraphs.

1.3.1 Safety instructions

Safety instructions call your attention specifically to danger potentials or
risks.
Where? We distinguish among the following places where safety instructions
may be required:
• Basic safety instructions:
They are related to general important matters and apply to the com­
plete documentation.
These safety instructions are provided in Sections 2 and 3 of operat­
ing instructions „PSI 6xxx: Weld timer with medium-frequency in­
verter“ (doc. no. 1070080028; also refer to page 5).
• Preceding safety instructions:
They refer to topic-related matters and are provided at the beginning
of a chapter or at the beginning of a whole procedure.
• Integrated safety instructions:
They are related exactly to a separate procedure step and are
provided right before the relevant step within the procedure.
Structure? A safety instruction is always structured as follows:
• Warning sign (only in case of personal injury)
• Signal word to indicate the danger level
• Type and source of danger
• Consequences of failure to observe
• Action for averting danger.

Table 2: Example for the structure of a safety instruction

Warning sign + SIGNAL WORD

Type and source of danger!
Consequences of failure to observe!
" Action for averting danger.
" Further action(s) for averting danger.

Integrated safety instructions may be embedded in the format of the

environment so that no ”visual” break in the action sequence is pro­
voked. Therefore they do not necessarily use the layout shown in the
example but they do use the indicated structure.
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Regarding this documentation

Danger levels? The safety instructions are classified into danger levels (danger
classes). The signal word represents the danger level.

Table 3: Danger classes according to ANSI Z535.6-2006

Signal word Meaning

DANGER Dangerous situation where death or serious physical injuries
will occur if it is not avoided.
WARNING Dangerous situation where death or serious physical injuries
may occur if it is not avoided.
CAUTION Dangerous situation where light to moderate physical injur­
ies may occur if it is not avoided.
NOTICE Situation where damage to property or the environment may
occur if it is not avoided.

Table 4: Examples for classification of safety instructions

DANGER
Type and source of danger!
Consequences of failure to observe!
" Action for averting danger.

WARNING
Type and source of danger!
Consequences of failure to observe!
" Action for averting danger.

CAUTION
Type and source of danger!
Consequences of failure to observe!
" Action for averting danger.

NOTICE
Type and source of danger!
Consequences of failure to observe!
" Action for averting danger.
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Regarding this documentation

1.3.2 Icons
The following icons are used to mark text passages specifically.

Table 5: Icons used

Symbol Meaning
This icon indicates a tip or an information. It helps use
and operate the product optimally or understand the
context better.
" This icon indicates the need to observe/perform certain
things.
• This icon indicates an (unsorted) list.
1. This icon indicates a (sorted) list or specific procedure
2. steps where a certain sequence has to be observed.
3.

1.3.3 Designations
The following designations may appear in our documentation:

Table 6: Designations

Name Meaning
BOS Welding user interface
PE Protective Earth. PE conductor.
PG Programming terminal/welding computer
PSG Transformer-rectifier unit for PSI types.
Medium-frequency welding transformer 1000 Hz
PSI Programmable weld timer with inverter.
PSQ 6000 Plug-in module for PSI with UI controller functionality.
XQR Is not needed for PSI 6xCx types.
PST Programmable weld timer with thyristor power unit.
PLC Programmable Logic Controller.
WT Weld timer.
Also referred to as timer or resistance weld timer.

1.3.4 Abbreviations
Refer to Section 10 on page 71 et seq.
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and Controls

Safety instructions

2 Safety instructions
" Please note the section with the identical name in the operating in­
structions for the PSI 6xxx and PST 6xx0 product families
(for information on document numbers, refer to table 1: page 5).
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Safety instructions

Notes:
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and Controls

General information on damage to property and products

3 General information on damage to property and

products
" Please note the section with the identical name in the operating in­
structions for the PSI 6xxx and PST 6xx0 product families
(for information on document numbers, refer to table 1: page 5).
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and Controls

General information on damage to property and products

Notes:
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and Controls

Scope of delivery

4 Scope of delivery
" Please note the section with the identical name in the operating in­
structions for the PSI 6xxx and PST 6xx0 product families
(for information on document numbers, refer to table 1: page 5).
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Scope of delivery

Notes:
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and Controls

Information on this product

5 Information on this product

5.1 General information

Welding systems equipped with our PSx 6xxx timer types normally con­
sist of the following main components:
• weld timer (with integrated MF inverter or with integrated thyristor
power unit)
• suitable welding transformer (including current sensor for secondary
measurement)
• pneumatically or electrically operated electrode gun.
Furthermore, a higher-level controller is required that controls the entire
manufacturing process of the part and also monitors its safety aspects.
Suitable controllers include
• a programmable logic controller (PLC)
• a robot controller
• manual control (e.g. of manual guns), or even
• a combination of these possibilities.

PSx 6xxx
Force control variable
Start O
I
Force feedback Gun
I
I
PLC or Prog. No./
robot spot No.
(WLD) Trans­
Electrodes
former
O Internal
WC
current
sensor
I: input optional external current sensor
O: Output
WC: Weld complete
WLD: Weld time

Fig.1: Main components of a welding plant

The weld timer ensures the controlled performance of the actual weld­
ing process. For this purpose, it must provide open- and closed-loop
control of many functions and physical quantities. Its main tasks in­
clude, e.g.
• Communication with a higher-level PLC or robot controller via I/O
signals.
• Control of a welding gun for influencing the electrode force.
• Ensuring the proper welding schedule by different, technologically
required time intervals (e.g. pre-weld, main weld, post-weld time
etc.) or regulation methods.
• Driving the power unit to generate the proper welding heat.
• Signalling a correct or incorrect weld at the end of the welding pro­
gram schedule.
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Information on this product

Current I Time
Transformer
Start

Primary Force F Power (heat, %I)

circuit

PreSQZ
Secondary circuit + WLD HLD
SQZ

SQZ: Squeeze time (for explanations, refer to Sect. 6.1 starting on page 17)
WLD: Weld time
HLD: Hold time (for explanations, refer to section 6.1)

Fig.2: Physical basic parameters for influencing the weld

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Program execution

6 Program execution
A total of 256 separate welding programs (prog.no. 0 to 255) are avail­
able.
Each welding program contains all of the parameters that are required
for the precise definition of a weld. Basic parameters include, e.g.
• times that are to be subsequently processed
(refer to Section 6.1)
• %I values that are to be effective in different current blocks
(refer to Sect. 6.2 starting on page 20)
• electrode force
(for a description, refer to page 21 et seq.).

6.1 Programmable times

The way in which a welding program is executed depends on the use of
various programmable periods of time. Within the program execution,
each period of time serves a specific purpose.
In timers with MF inverters, the times are programmed in milli­
seconds (in 1 ms grid) and in timers with thyristor power unit in mains
cycles (at 50 Hz system frequency: in 20 ms grid).

1. Current block 2. Current block 3. Current block

Start

MainWLD
PreSQZ SQZ PreWLD PstWLD HLD
1.CT

3.CT

UST DST Time

Current

Time

Fig.3: Example: Time diagram of a welding program execution without impulse operation in 2nd current block
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Program execution

1. Current block 2. Current block 3. Current block

Start
2.CT 2.CT

MainWLD MainWLD MainWLD

PreSQZ SQZ PreWLD PstWLD HLD

1.CT

3.CT
UST DST Time

Current

Time

Fig.4: Example: Time diagram with all programmable periods of time (incl. impulse mode with 3 impulses)

PreSQZ, 1. SQZ (pre-squeeze time):

The electrode gun should entirely close during the PreSQZ. No current
flows during this period of time.
The PreSQZ is processed immediately following the Start signal in all
welding modes (single spot, repeat, and seam).
In the "Repeat" welding mode, the PreSQZ is only executed for the
1st spot weld of a series because the gun does not open as widely for
the subsequent spot welds of the series due to the mostly relatively
short Off time (OFF).

SQZ (squeeze time):

During this time, the working pressure of the electrodes is built up.
No current flows during this period of time.
The electrode gun must be entirely closed at the beginning of SQZ
(refer to PreSQZ).
Shortest possible SQZ: 16 ms.
During the SQZ - if parametrized - the timer checks whether or not
the connected measuring loop is faultless by performing an ohmic
resistance measurement for secondary current measurement.
In the event of a fault, the timer aborts the welding program.

At the end of SQZ, some timer types check the signaled force / pres­
sure for tolerance (”Tolerance force monitoring”) if the correspond­
ing function has been selected via BOS within the electrode
parametrization under ”Pressure/force monitoring”. In case of a
fault, the message ”Welding fault force monitoring: Force too low/too
high” will be generated at the end of SQZ.

At the end of the SQZ, some timer types check whether a high level is
present at the digital input X2/4. Otherwise, the timer extends the
SQZ by max. 5 seconds before the schedule is aborted and a fault
message is output.
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Program execution

PreWLD (pre-weld time, pre-heating time)

Refer to page 20.

1.CT (1.Cool time)

If a value greater than 0 has been programmed, it separates the first
and the second current block. Serves to reduce stress in the parts to be
welded.
Refer to page 20.
The 1. CT can only be programmed if PreWLD is greater than 0.

MainWLD (main weld time)

Refer to page 20.

2.CT (2nd cool time)

If a value greater than 0 has been programmed, it separates the indi­
vidual impulses in impulse mode. Serves to reduce stress in the parts to
be welded.
Refer to page 26.
The 2.CT can only be programmed if impulse mode has been activ­
ated ("Impulse" parameter > 1). Exception: Seam operation.

UST (upslope time / time of current rise)

Refer to page 27.

DST (downslope time / current decrease time)

Refer to page 27.

PstWLD (post-weld time / post-heating time)

Refer to page 20.

3.CT (3rd cool time)

If a value greater than 0 has been programmed, it separates the second
and the third current block. Serves to reduce stress in the parts to be
welded.
Refer to page 20.
The 3. CT can only be programmed if PstWLD is greater than 0.

HLD (Hold time)

Is used to fix the parts welded together while cooling down. No current
flows during this period of time.
The welding schedule is completed at the end of HLD.
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Program execution

6.2 Current blocks

For reasons of process technology, it may be necessary to supply the
amount of heat required for a single spot weld in the form of consecutive
current blocks.
Therefore, a spot weld can be generated from a maximum of three cur­
rent blocks (PreWLD, MainWLD, PstWLD), with each block being sep­
arately programmable in terms of duration and %I.
Cool times (1.CT, 3.CT) can be programmed in between the blocks. If a
cool time is set = 0, the relevant blocks are seamlessly performed.

Start program execution End program execution

PreSQZ PreWLD 1.CT MainWLD 3.CT PstWLD HLD

+ 1.%I 2.%I 3.%I
SQZ
1. Current block 2. Current block 3. Current block
(Pre-heating time) (Post-heating time)

SQZ: Squeeze time (For description refer to Sect. 6.1 on page 17 et seq.).
WLD: Weld time
HLD: Hold time (For description refer to Sect. 6.1)
%I: Power/Heat (%I)

Fig.5: Current blocks

1.WLD (1.weld time / Pre-heating time)

Using this current block, the metal can be pre-heated before the actual
weld is performed (in the 2nd current block) using a suitable heat (1.%I).
This allows you to reduce expulsions or drive out the adhesive.
If you do not want to use the PreWLD, simply program PreWLD=0.

MainWLD (main weld time / 2nd current block))

Welds the actual spot using the command heat (2.%I).
• The MainWLD time has to be programmed in all instances.
• Within the MainWLD, the functions
- ”Impulse mode” (refer to page 26) and
- ”Slope” (refer to page 27) can be used.

PstWLD (post-weld time / post-heating time)

Using this current block, the metal can be post-heated after the actual
weld has been performed (in the 2nd current block) using a suitable
heat (3.%I).
The purpose is to prevent the spot from cooling too fast, e.g., as a result
of electrode cooling. This post-heating will improve the joint between
the parts to be welded and serves to balance stress.
If you do not want to use the PstWLD, simply program PstWLD=0.
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and Controls

Program execution

6.3 Electrode force

Each welding program includes the information concerning the force to
be used by the electrode to squeeze the parts to be welded together
(e.g. in kilo-Newton: kN).
The electrode force needed for a weld may be specified in the „Base
pressure value“ parameter („Programming“ topic, „Schedule“ tab).
For additional information on electrode force, refer to page 56 et seq.
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Program execution

Notes:
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 23/78
and Controls

Functions

7 Functions
Several functions or partial functions described in this section are
only available in certain timer types.
The implementation of some function may vary in detail in the differ­
ent timer types.
" Therefore please always also note the type-specific operating in­
structions of your timer.
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and Controls

Functions

7.1 Schedule modes

In order to perform a welding process, the weld timer can be controlled
automatically by a PLC/robot or manually by the operator via start sig­
nal.
The following welding modes are available for different applications
(type-dependent):
• Single spot
• Repeat
• Seam

7.1.1 Single spot

Suitable for use in connection with robots, welding machines, automatic
welding equipment or manual welding guns; for spot welding, projection
welding, butt welding.
A high level at the start input initiates the welding schedule (the welding
program) exactly once, starting with the pre-squeeze time (1.SQZ).
For the next program start, the Start signal has to be switched off and
back on.

Start

WC

a spot weld another spot weld

is generated is generated

Fig.6: Single spot welding mode; signal sequence

7.1.2 Repeat
Suitable for manual electrode guns and manually operated welding ma­
chines.
The weld timer initially responds to the start signal as in single spot
mode and starts the welding schedule with the PreSQZ.
If the corresponding start input is still high after the end of the hold time
(HLD), the solenoid valve signal will be switched off via discrete output
signal, if available.
The welding gun is opened.
The Off time (OFF) runs. During this time, the operator can pull on the
welding gun towards the next spot.
After the end of the OFF time, the solenoid valve will be energized
again, and the welding schedule will be restarted - this time beginning
with the SQZ. This sequence will be repeated for as long as the relevant
start input is high.
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Functions

When the start signal becomes low, the timer will terminate the actual
current cycle and start the hold time (HLD) instead of the OFF time.

Start

Solen­
oid

a spot weld OFF another spot weld

is generated is generated

Fig.7: Repeat welding mode; signal sequence

7.1.3 Seam
Suitable for roll seam systems.
The parts to be welded are joined by individual spot welds while rolling
electrodes are moved along.
The weld timer initially responds to the start signal as in single spot
mode and starts the welding schedule.
The weld time (MainWLD) and a cool time (2.CT), if programmed, will be
repeated for as long as the start input remains high.
When the start signal becomes low, the timer will cancel the actual cur­
rent cycle and start the hold time (HLD).
In seam operation, a distinction is made between a stitch weld and a
seal weld.
Stitch seam: A series of weld times is separated in time by sufficiently
long cool times (2.CT) so that subsequent spot welds
neither touch nor overlap.
Seal weld: The cool time (2.CT) is configured very short so that sub­
sequent spot welds overlap.

Stitch seam Seal weld Seal weld

ÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
ÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ
2.CT MainWLD
CT very short or 0

Fig.8: Seam operation principle

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Functions

7.2 Impulse mode

In addition to the possibility of providing the amount of heat required for
a single spot through 3 subsequent current blocks (refer to page 20),
impulse mode may be used.
It serves to apply the required amount of heat in the 2nd current block to
the spot weld through up to 9 consecutive impulses.
A cool time (2.CT) can be programmed in between the impulses.
If the 2nd cool time is set = 0, all impulses are seamlessly performed.
You can influence the impulse mode via the "Impulse" parameter.
It determines how often the MainWLD is to be repeated with due regard
to a programmed 2.CT.

2. current block
Example: Impulse mode OFF MainWLD
IMP = 1
MainWLD = 60 ms
2.CT (not relevant because 1 impulse only)

2. current block
Example: 2 Impulses
MainWLD MainWLD
IMP = 2 2.CT
MainWLD = 60 ms
2.CT = 40 ms

2. current block
Example: 3 Impulses
IMP = 3 MainWLD MainWLD MainWLD
2.CT 2.CT
MainWLD = 60 ms
2.CT = 40 ms

Fig.9: Programming examples for impulse mode

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and Controls

Functions

7.3 Slope (current increase)

If slope has been activated, the weld timer automatically generates a
linear current increase/decrease for the 2nd current block within a pro­
grammable period of time.
In this way, switch-on peaks and thus stress on the welding plant can be
reduced.
For programming, you use
• upslope time (UST) to define the period of time during which the cur­
rent is to increase from its "start value" to the commanded current
during the MainWLD (2.%I), and/or
• downslope time (DST) to define the period of time during which the
current is to decrease from the MainWLD (2.%I) to the "final %I".

" Please note:

• The upslope/downslope times are always part of the 2. current
block.
The upslope time starts at the beginning of the 2nd current block.
The downslope time ends at the end of the 2nd current block.
• The upslope and downslope times are not influenced by active
impulse mode and a programmed 2.CT, if any. They are also per­
formed throughout a possible 2.CT.
• If the total time of the UST and DST is longer than the 2nd current
block, the command %I is never reached in the 2nd current block
(2.%I)! Fault messages such as "Low current" will be output.
• In connection with the slope, you should use the fade-out time
(refer to page 35).

2. current block

Example: 3 impulses with slope MainWLD MainWLD MainWLD

UST = 120 ms 2.CT 2.CT
DST = 40 ms
IMP = 3
MainWLD = 60 ms
UST DST
2.CT = 40 ms

Fig.10: Example: Slope in connection with impulse mode

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Functions

7.4 Welding modes:

The timer offers you different welding modes:
• Phase angle (PHA)
• Constant-current-regulation (KSR)
• UI-regulation (UIR).
It is possible to set how and which welding mode is to be used in a pro­
gram:
• Standard mode:
The PHA or KSR welding mode applies to all 3 weld times of the pro­
gram.
• Mixed mode:
The PHA or KSR welding mode can be separately configured for
each weld time.
If activated in a program, UI regulation only applies to the MainWLD.

7.4.1 Phase angle (PHA)

Special case.
PHA mode does not involve regulation of an actual value (e.g. current)
but only controls the power unit.
• In PST the activation of the thyristors is influenced during the sine
half-wave (el. ignition angle: 130 degrees to 30 degrees).
The bigger the ignition angle, the less current flows in the secondary
circuit.
• For PSI, the pulse width is influenced.
PHA features:
• The %I values are programmed as scale values (%I).
Programmable range: 0 to 100 %I.
Programming resolution: 0.01 %I
• No regulation takes place.
• The resulting amount of current in the secondary circuit depends on
the secondary circuit resistance and the secondary voltage.
• A current sensor is not necessary from the point of view of regulation
technology.
Current or time monitoring can be activated in PHA mode.
A current sensor is absolutely necessary for current monitoring. If the
integrated current sensor is not used, a current sensor must be
provided on the secondary side.
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and Controls

Functions

Mains
Welding trans­
Electrodes
former
Programming:
Commanded %I value
in %I
Power unit

Actual current Current sensor

without current for display value (only required with
monitoring purposes only current monitoring on
the secondary side)

with current Actual current value

Measured value
monitoring
preparation

Actual value display

kA actual current
mean phase angle
in %I

Current monitoring

-Status
- Tolerance band -Error
programmable refer­
ence current (in kA)

Fig.11: Principle of open-loop PHA mode

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Functions

7.4.2 Constant-current regulation (KSR)

Standard case.
Current regulation has been activated in KSR mode. For this purpose,
the actual current is scanned by a current sensor (programmable: sec­
ondary or primary side) and permanently compared to the programmed
current. A downstream current controller processes the difference
between actual/programmed value and controls the power unit so that
the programmed current is reached.
KSR features:
• The %I values are programmed in kilo-Amps (kA).
Programmable range: 0.5 to 250 kA
(can be restricted by parameter settings and the power unit used).
Programming resolution: 10 A
• There is closed-loop control of the current in the secondary circuit.
• Eliminates the influence of the secondary circuit resistance on the
weld (e.g. transfer resistance between electrode and part to be wel­
ded).
• A current sensor is absolutely necessary from the point of view of
regulation technology. If the integrated current sensor is not used, a
current sensor must be provided on the secondary side.

Programming:
Commanded current Mains
value in kA Welding trans­
former Electrodes
-
Controller

Power unit

Current sensor
(only required for
Measured value Actual current value measurement on the
preparation
secondary side)

Actual value display

kA actual current
mean phase
angle in %I

Current monitoring

-Status
- Tolerance band -Error
programmable refer­
ence current (in kA)

Fig.12: Principle of KSR regulation mode with secondary current sensor

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and Controls

Functions

7.4.3 UI regulation (UIR)

This function is only available if the "UI Regulation" option has been
activated!

The U/I controller measures not only the welding current, but also the
voltage at the electrodes. In this way, more profound information can be
obtained with respect to the welding process, and an adaptive interven­
tion by the controller can be achieved if influencing variables are
present.
For detailed information refer to description of application „PSI 6xxx:
UI regulation and monitoring“.

7.5 %I prewarning and limitation

The mean phase angle (%I value) generated is checked after each
welding schedule. In case of limit value violations the timer generates a
corresponding warning.
These warnings are reset
• at the next tip dress operation
• at the next electrode change
• at reset of the %I values via BOS (”Warning” window, ”%I warning”
tab).

7.5.1 %I limitation
The "%I Limitation" parameter is used to define the maximum permitted
%I value that may be generated by the inverter.
If the %I limitation responds, the timer will output the message "Max­
imum phase angle".
The input value for %I limitation has an absolute effect!
The "%I correction" (refer to page 60) and "%I stepper" (refer to page
46) functions can trigger a %I limitation response for this reason.
In some timer types, this value cannot be changed in BOS. In these
cases, it is internally fixed to 100 %I.

7.5.2 %I warning
%I values generated which are higher than the ”%I warning” parameter
will trigger the ”Phase angle warning reached” message.
As a result, the timer may draw the operator's attention to an imminent
%I limitation - due to, e.g., line losses in the secondary circuit - in KSR
regulation mode.
The parameter value must be lower than the value for the %I limita­
tion.

7.5.3 Lower %I warning

%I values generated which are lower than the ”Lower %I warning” will
trigger a corresponding message.
The parameter value must be lower than the value for the %I warn­
ing.
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Functions

7.6 Monitoring
The timer is capable of monitoring the weld for the following quantities:
• current (refer to section 7.6.1 on page 33 et seq.)
• time (refer to section 7.6.2 on page 38 et seq.).

Both monitoring functions can be separately turned on and off.

An activated monitoring function checks the relevant actual value
against programmable reference values and tolerance bands.
As the "current" and "time" parameters influence the amount of heat in
the spot, a correct setting of the reference values and activated monit­
oring functions are essential measures and conditions for quality assur­
ance.
The reference values used for current monitoring can be pro­
grammed independent of the regulation parameters! Changing the
regulation command values does not influence the monitoring para­
meters!
If he has suitable access privileges, the user may set new reference
values manually, or accept a measured actual value as the new ref­
erence value.

Further monitoring functions

• Monitor stepper:
Acts in conjunction with Current monitoring if stepper/dressing
curves are active.
Refer to page 38.
• Tip dresser result monitoring:
Acts in conjunction with Tip dressing.
Refer to page 52.
• Monitoring the process quality (UIP), process stability (PSF) and
force (FQF):
Acts in conjunction with UI regulation and the "Q Stop" function.
Refer to page LEERER MERKER.
• Monitoring tip dress (dresser blade):
Refer to page 54.
• Monitoring gun life:
Refer to page 55.
• Monitoring phase angle (%I warning):
Refer to page 31.
• Measuring loop test:
Refer to page 39.
• Minimum current verification:
Refer to page 40.
• Post-warming pulse:
Refer to page 42.
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and Controls

Functions

7.6.1 Current monitoring

Tolerance ranges
In current monitoring, the actual current determined by rms value meas­
urement is compared to the "tolerance band".
Whether or not the timer interprets a measured actual current as "ac­
ceptable" depends on the programming of the tolerance band. The fol­
lowing values are decisive for the definition of the tolerance band:
• Reference current in kA
• positive tolerance in % of the reference current
(upper tolerance band).
Actual values above the upper tolerance band generate the mes­
sage type ”High current ...”.
• negative tolerance in % of the reference current
(Lower tolerance band).
Actual values below the lower tolerance band generate the message
type ”Low current ...” or "No current ...".

ÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎ
High current ...
upper tolerance band
(in %)

tolerance Reference current in kA

band
Current ok

ÎÎÎÎÎÎÎÎÎ lower tolerance band (in %)

ÎÎÎÎÎÎÎÎÎ
Low current... / No welding current...

Fig.13: Principle: tolerance band

Conditional tolerance range

In addition to qualifying welds as “good/bad", it is often also desirable to
be timely informed about the trend of the current actual values. Espe­
cially, an increasing number of actual current values in the lower range
of the tolerance band is of interest: Gradual faults of the system (e.g.
slow increase in cable resistance in the secondary circuit prior to an in­
terruption of a cable) may result in such effects.
For this reason, the following parameters are additionally available in
connection with the tolerance band (BOS: ”Programming” topic,
”Schedule” tab):
• "conditional tolerance band" (in % of the reference current) and
• ”Reweld factor”.
The "conditional tolerance band" parameter defines the program-spe­
cific upper limit of the conditional tolerance range. The lower limit is
defined by the "lower tolerance band" parameter.
The "Reweld factor" determines the program-specific number of con­
secutive welds that may be within the conditional tolerance range. If the
number of consecutive welds within the conditional tolerance range is
higher, the message "Series of welds below lower threshold point ..."
will be output.
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Functions

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
High current ...
upper tolerance band
(in %)

Reference current in kA
with respect to a
single measurement:
Current ok
Conditional tolerance

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
Conditional toler­ band (in %)
ance range

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
lower tolerance band
(in %)
Low current... / No welding current...
"Series of welds below lower
spots welded threshold point" message

Fig.14: Example: principle of the conditional tolerance band with a Reweld factor = 4

Messages can be defined as either "welding faults" or "warnings".

While an event defined as a "warning" does not inhibit the timer, a
"welding fault" must always be followed by "Fault reset" before start­
ing the next welding schedule.

Current monitoring modes

Since a total of 3 independent current blocks can be programmed (refer
to page 20), it is necessary to handle current monitoring with the re­
quired degree of flexibility.
For this reason, a distinction is made between "Standard" and "Mixed"
monitoring modes.

• Standard mode:
The entire current profile (1st, 2nd and 3rd current block including
cool times) is included in rms value measurement.
The complete current profile is represented by a single actual value,
and monitored by a single tolerance band.
Although this simple and often sufficient monitoring mode keeps the
amount of data to be processed low, any cool times that may have
been programmed and different amounts of current in the individual
blocks alter the measured result.
The reference current to be indicated should be determined by test
welds in this case. If you only use the MainWLD without impulse or
slope operation, you can specify the commanded current pro­
grammed for regulation as reference current as well.
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Functions

Tolerance band
Reference
current
1st * * 3rd
block block
PreWLD 3.CT PstWLD
1.CT 2nd block

*: 2.CT
Measuring time

Fig.15: Principle of "Standard" monitoring mode

• Mixed mode:

The rms value is measured separately for each current block and
monitored by individual tolerance bands (for 1st, 2nd and 3rd current
block).
The programmed cool times are not accounted for in the determina­
tion of the actual value for the individual current blocks.
This results in higher transparency of the individual current blocks,
however, the amount of data to be processed is larger.
In mixed mode, you can generally use the commanded currents pro­
grammed for regulation as reference currents as well.

Reference current
Refer­
ence Refer­
current ence
1st current
block 3rd block

t1 t2 t3
Measuring time 1 2nd block Measuring time 3

: Tolerance band Measuring time 2 = t1 + t 2 + t3

Fig.16: Principle of "Mixed" monitoring mode

Fade out time and trail current

In the previous explanations, the current curve as a function of time was

represented by an ideal graph (in rectangular shape). In reality,
however, there is a current upswing and downswing at the beginning
and after the end of any weld time. Due to their very nature, these ef­
fects affect rms value measurements. For this reason, programming dif­
ferent values as the commanded and reference current (in connection
with current monitoring) may be necessary.
The course of measurement can be specifically influenced using the
"fade-out time" and "trail current" functions.
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Functions

• Fade out time:

Indicates the period of time after the start of a weld time during which
the measured current values should not be used in the determina­
tion of the rms value.
The total upswing process can thus be faded out if the setting is
made correctly.

Current
Irms_1
Irms_2

Time

Fade out time

Weld time
Irms_1: Fade out time accounted for
Irms_2: Fade out time not accounted for

Fig.17: Effect of the fade-out time

Use of the fade-out time

• In connection with the "Slope" function (refer to page 27):
you should program the same value for the fade-out time as for
the upslope time (UST).
• When welding very thick sheets and great immersion depths (gun
projects far into the material).
• In connection with current calibration:
Reference ammeters also have a "fade-out function" (e.g. Miya­
chi "First Cycle"; to specify the first cycle of the weld time whose
measured values are to be considered).
In connection with current calibration, you should therefore make
sure that the metering device used has been set to the timer's cur­
rent fade out time setting.
• Trail current:
Indicates whether or not the downswing process at the end of a weld
time is to be included in the calculation of the rms value (trail current
ON).
If trail current is switched off, rms measurement of the current value
will exactly terminate at the end of a weld time.
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Functions

Current

Time

Weld time Trail current

Fig.18: Trail current

Start times of fade-out time and trail current

2nd block

1st
block 3rd block

Fade out time:

Trail current:

Fig.19: Start times of fade-out time and trail current

The programmed fade out time is identical for all weld times and for
all welding programs.
Therefore, you should make sure that the fade out time is always
shorter than the shortest programmed weld time!
The programmed trail current is identical for all weld times and for all
welding programs!

If the only quality criterion for your application is the amount of heat
applied to the spot weld (amount of heat: Q ≈ i2 x t x R), you should
program "0" for the fade-out time and switch the trail current ON.
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Functions

7.6.2 Time monitoring

Time monitoring can be separately configured for each program and
compares the actual time required for the complete current profile to a
programmed reference time.
Actual time: the period of time from the beginning of the first current
block until the end of the last current block including all cool times, if pro­
grammed.

In this way, it can be ensured that no excessive weld time changes can
be made manually in the individual welding programs.
The following values are decisive for programming time monitoring:
• Time monitoring ON/OFF
• Reference time.
• Permitted time tolerance with respect to the programmed reference
time.
Actual times above the permitted time tolerance generate the mes­
sage type ”Weld time too long ...”.
Actual times below the permitted time tolerance generate the mes­
sage type ”Weld time too short ...”.

permitted time tolerance

1st * *
block 3rd block

PreWLD 3.CT PstWLD

1.CT 2nd block

*: 2.CT
Reference time

Fig.20: Principle of time monitoring

7.6.3 Monitor stepper

Is used in conjunction with the electrode management functions
• ”Stepper” (refer to page 46) and
• ”Tip dressing” (refer to page 49)
for monitoring the programmed %I stepping.
In this way, it can be ensured that no excessive changes can be made
manually with respect to the individual stepper or tip dress curves.
If %I stepping is active, the timer changes the programmed %I subject
to the electrode count value.
Using the ”Monitor stepper” function the timer is able to change the per­
taining programmed reference value appropriately, also in dependence
on the electrode wear.
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Functions

7.6.4 Measuring loop test

This function checks the relevant sensor circuit for interruption and
short-circuit during the squeeze time while secondary current measure­
ment is active. Faults in the area of the cables/current sensor can be
detected in time by this function.
The following testing criteria apply:

Ohmic resistance measured Result

< 7 ohms Measuring loop short circuit
12 to 950 ohms Measuring loop ok
> 1100 ohms Measuring loop open

If measured values are in the intermediate ranges, they cannot be

clearly evaluated.

If a fault has been detected, the weld timer will abort the running welding
program before initiating the first programmed weld time, the timer will
be inhibited and generate the "Measuring circuit open" or "Measuring
circuit shorted” message.
To activate the function, switch the "Measuring loop check" parameter
"On".

Conditions:
• Parameter "Inhibit monitoring" has been switched off and
• ”Current monitoring” function (refer to page 33) has been switched
on.

Messages can be defined as either "faults" or "warnings". While an

event defined as a "warning" does not inhibit the timer, a "fault" must
always be followed by "Fault reset" before starting the next welding
schedule.

NOTICE
Incorrect declaration of process-critical messages
Excessive weld current possible!
" Make sure that the messages "Measuring circuit open" or "Mea­
suring circuit shorted" are defined as "faults" in any case.
The controller receives incorrect actual value information, or no
information at all. As a result, the controller may fully activate the
power unit initially.
The point of time in which the timer eventually cancels the welding
schedule with a fault message depends on the "Minimum current
verification" function (refer to Sect. 7.6.5).
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Functions

7.6.5 Minimum current verification

This function checks whether, from the beginning of WLD, a minimum
average current was measurable for a selected period of time (para­
meter "Time to terminate weld time").
Otherwise, the timer interrupts the sequence and outputs the fault mes­
sage ”No welding current”.

7.7 Latching
When the SQZ has elapsed, the timer will start to be latching in the weld­
ing mode "single spot". In latched condition, the PreWLD to PstWLD in­
cluding HLD will continue to be executed even when the start signal has
been reset.
Signal latching can only be cancelled by opening the stop circuit.

Signal latching is not available in "seam" welding schedule. If the

start signal is reset during a weld time in "seam" mode, the timer will
complete the cycle just initiated and continue with the hold time.

7.8 Automatic reweld by timer active

Reweld by timer active is only possible in PHA or KSR welding mode.
This function reduces the need for operator interventions in the event of
sporadic welding faults of the type "Low current ..." or "No current".
Conditions:
• Current monitoring is active and
• "Monitoring stopped" function has been turned off.
Automatic reweld by timer active can be turned on and off separately for
each welding program using the "Reweld" parameter” (BOS: ”Program­
ming” topic, „Schedule“ tab”).
When automatic reweld by timer has been activated, the timer is able to
automatically repeat an improper welding schedule once - starting with
SQZ - if "Low current ..." or "No current" has been signaled. In this case,
the gun will remain closed after the improper schedule, and the pro­
grammed squeeze time, weld times and hold time are repeated.
The event is logged additionally.
If the reweld results in a proper weld, the welding system will continue
running normally afterwards. If the reweld results in another fault, the
corresponding message will be output ("Low current ...", "No cur­
rent...”).
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Functions

It may be a problem that every single spot may have to be rewelded in

the event of bad fits or electrodes that do not have optimum contact with
the metal in extreme cases if reweld has been activated. As a result, the
cycle time may strongly increase without even being noticed.
For this reason, the timer offers the global parameter "Max. rewelds"
(maximum number of rewelds by timer).
An internal counter is reset to 0 whenever a weld is ok after the first at­
tempt. In return, the counter is incremented if the current remains below
the "lower tolerance band" and automatic rewelds have been activated.
Automatic rewelds are carried out only if the internal counter value is
lower than/equal to the "Max. rewelds" parameter. If this is not the case,
the timer will generate the "Series of welds below lower threshold point"
message.

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
High current ...
upper tolerance band
(in %)

Current Reference current in kA

ok

: Weld triggered by
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
lower tolerance band
(in %)

automatic reweld
by timer. ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
Low current... / No welding current...

"Series of welds below lower

Welds threshold point" message

Fig.21: Example: Principle of automatic reweld by timer using "Max. rewelds" = 4.

Messages can be defined as either "faults" or "warnings". While an

event defined as a "warning" does not inhibit the timer, a "fault" must
always be followed by "Fault reset" before starting the next welding
schedule.

NOTICE
Incorrect declaration of process-critical messages
Defective welds may remain undiscovered!
" Make sure that the messages ”Low current ...”, ”No current ...” and
”Series of welds below lower threshold point” are always defined
as "fault".
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7.9 1. Halfcycle limit

The function or the parameter is only available for PST types.

The first current half-cycle value can be limited in order to protect the
welding transformer and thyristor unit.
Example: Input value of 55 %I means
• the 1st half-cycle will not be influenced by welds with low pro­
grammed %I (0 to 55 %I).
• for higher programmed %I values (> 55 %I), the 1st half-cycle will be
limited to 55 %I.
Two parameters are available for programming:
• "1st half-cycle limit":
Parameter acting globally for the weld timer.
Only the first half-cycle of a weld will be limited.
• "1. half-cycle after cool time":
Can be separately set for each welding program.
The first half-cycle of each weld time or each pulse is limited if a cool
time greater than 0 has been programmed before.

7.10 Post-warming pulse (NWI)

The functionality changes the default behavior of the timer
• during monitoring in PstWLD,
• in the case of a fault and
• in the case of reweld.
Program the function in the ”Post-warming pulse” window (”Program­
ming” topic, ”Schedule” tab, ”NWI” command button).
To deactivate the function, the ”Upper tolerance band PstWLD” is set to
the value of the ”Upper tolerance” there.

Monitoring of PstWLD
In addition to the inputs and definitions of the known limit values for
lower, upper and (lower) conditional tolerance, it is possible to define an
”Upper tolerance band” incl. the corresponding repeat factor specific­
ally for PstWLD:

ÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎ High current ...
Upper tolerance (in %)
Upper tolerance band PstWLD (in %)

Reference current in kA

ÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎ
Cond. tolerance band (in %)
Lower tolerance (in %)

ÎÎÎÎÎÎÎÎÎÎ
Low current... / No current
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Functions

”Repeat factor” defines program-specifically how many consecutive

welds of a spot may lie between the ”Upper tolerance band PstWLD”
and the ”Upper tolerance”. If the number of consecutive welds within
this range is higher, the message ”High current in consecutive welds”
will appear.

NOTICE
Incorrect declaration of process-critical messages
Defective welds may remain undiscovered!
" Make sure that the message: ”High current in consecutive welds”
is always defined as "Fault".

Behavior in the case of faults

Fault Reaction without NWI Reaction with NWI

Series of welds below
lower threshold (PstWLD) No automatic spot re­
Low current petition
(UI monitoring) Automatic spot repeti­
High current in consecut­ none because the tion
ive welds (PstWLD) ”Upper tolerance
band PstWLD” is not
relevant in this case.

Behavior in the case of reweld

In order to repeat the welding schedule, the timer increases the %I of
MainWLD by the program-specific ”Increasing factor”.
In the same way as for the correction functions (refer to page 60), an
increase factor of e.g. 0% means: no %I increase.
A reweld principally only takes place if the permitted maximum %I is
not exceeded by the %I increase (also refer to Sect. 7.5, page 31).

The %I increase is effective both in case of a reweld triggered automat­

ically (refer to page 40 et seq.) and a reweld triggered via input signal
(”Fault reset with reweld” signal).

Special features in connection with the ”NWI” function.

• PstWLD is not monitored as soon as at least one UI monitoring para­
meter has been activated in the relevant program.
• PstWLD is not monitored if ”Standard” monitoring mode has been
set in the relevant program instead of ”Mixed”.
• When the UI controller is active and the ”PHA” regulation mode is
used at the same time (in PstWLD), %I values in accordance with the
reference curve will be input to generate the %I for PstWLD.
• The original reference current for monitoring PstWLD can be
entered manually in the ”Post-warming pulse” window for document­
ation purposes. It does not have a functionality within the timer and is
not changed by the timer.
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7.11 Electrode management

In the course of their life, electrodes are subject to process-related wear
(count value; refer to Section "Wear counter and wear (count) factor"),
which manifests itself by a larger contact surface, among other fea­
tures.

Wear

Fig.22: Enlarged contact area through electrode wear

The timer offers two methods of compensating this effect, which can be
used in isolation as well as in combination:
• automatic %I stepping (Stepper, refer to page 46 and
• Tip dressing (refer to page 49).

Wear counter and wear (count) factor

Electrode wear depends on different factors, such as programmed %I,
thickness and material of the parts to be welded.
For as long as only one material type of identical thickness is welded in
the course of an electrode's life with identical %I, the number of welds
that can be performed before an electrode is worn and must be re­
placed can be predicted based on experience.
Electrode wear can be mapped by a "spot counter" in this case. The
spot counter is simply incremented by "1" after each spot welded.
However, if different materials or material thicknesses are welded in the
course of the electrode life, the wear per spot no longer is constant. A
spot counter is inappropriate in this case.
For this reason, the electrode wear is monitored by a "count value (wear
counter)" integrated in the timer.
Using this function, the timer increments the count value after each spot
welded by the "count factor” (BOS: ”Programming” topic, ”Stepper”
tab). As a result, the count value cannot only be incremented by "1" (like
the spot counter), but rather by any desired values.
As it is possible to specify the count factor that fits the weld performed
by each individual program, proper recording of the electrode's wear is
ensured.
Wear per component
The parameter "Wear per component" (BOS: ”Programming” topic,
”Stepper” tab) is used to enter the wear occurring on the electrode when
a single part is welded. This value is used by the timer to calculate the
number of parts that can be welded by an electrode until the End of
Stepper is reached. The number of remaining parts is displayed in the
"Warning table" (refer to page 51).
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Example:
6 welds have to be performed on a part.
Every single spot (P1 to P6) is generated by a separate welding pro­
gram (Prog1 to Prog6).
The upper 3 spots (P1 to P3) have to weld 2 sheets, the lower 3 spots
(P4 to P6) have to weld 3 sheets, each.
Consequently, electrode wear is higher for spot welds P4 to P6 (greater
material thickness). For this reason, the program-specific count factor is
defined by the value "1" for Prog1 to Prog3, and by 1.5 for Prog4 to
Prog6.
The resulting wear per component is 7.5.
The count factors in this example are of an exemplary nature only. In
practice, they are determined in advance with respect to the materi­
als and thicknesses used.

Counts:
0 1 2 3
(new electrodes)

P1. P2. P3.

CF=1 CF=1 CF=1

P6. P5. P4.

CF=1.5 CF=1.5 CF=1.5

CF: Count factor 7.5 6 4.5

Fig.23: Example: Determining the count value

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7.11.1 %I stepping (Stepper)

%I stepping keeps the current density constant in the spot weld
throughout the electrode life although the spot increases in size. For
this purpose the system changes the %I automatically in dependence
on the current electrode wear.
An optimal adaptation of %I stepping to your application is possible by
means of the „Start“, „Stepper“ and „Dressing“ function areas which are
configurable separately (in the „Programming“ topic, „Stepper“ tab).
The resulting %I changes can be monitored using the "Monitor step­
per" function (refer to page 38).

„Start“ function area:

Allows %I to be influenced directly after tip change and - if parametrized
- after each tip dress operation.
Using the „%I for new electrode“ parameter you can determine the per­
centage of the programmed base %I which is to be effective at a tip
wear rate of „0“.
The „Count“ parameter can be used to additionally define up to what
„Actual count“ the %I is to be changed again linearly to 100% of the
programmed base %I.
To deactivate the %I stepper for the „Start“ function area, program
the „Count“ parameter with the value „0“.
If the „Start“ function area is active, this influences the effect of the
„Stepper“ function area.

Power (heat, %I) in %

(with reference to the programmed base %I)

Value in „%I for new

electrode“ para­
meter
Act. count
100%

0% „Count (wear)“
parameter
Count (wear) = 0

1 linear stepper curve

resulting heat (%I)

Fig.24: Operating principle of stepping in the „Start“ function area

„Stepper“ function area:

Using the „%I at end of 1. stepper phase“ parameter it is possible to de­
termine what percentage of the programmed base %I is to be effective
when the „Actual count“ wear counter reaches the „Max. count“ value.
Using the „Stepper curve“ parameter it is possible to additionally select
one out of max. 10 curves (from the „Setup“ topic, „Stepper curves“
tabs).
A stepper curve determines the percentage of the „%I at end of 1. step­
per phase“ parameter value that is to be effective in dependence on the
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Functions

„Actual count“. It thus describes the course of %I in dependence on the

„Actual count“.
To deactivate the %I stepper for the „Stepper“ function area, pro­
gram the „%I at end of 1. stepper phase“ parameter with the value
„100“.

Power (heat, %I) in %

(with reference to the programmed base %I)

Value in the „%I at

end of 1. stepper
phase“ parameter
Act. count
100%

Count (wear) = 0 „Max. count“ parameter

one out of 10 stepper curves

resulting heat (%I)

Fig.25: Operating principle of stepping in the „Stepper“ function area

„Dressing“ function area:

You can use „%I after last dressing“ to determine the percentage of the
programmed base %I that is to be effective when the „Actual count“
wear counter reaches the value of the „Max. count“ parameter and the
„Actual“ tip dress counter reaches the value of the „Dressing steps“
parameter.
The „Tip dress curve“ parameter may be used to additionally select one
out of max. 10 curves (from „Setup“ topic, „Tip dress curves“ tab).
A tip dress curve determines the percentage of the „%I after last dress­
ing“ parameter value which is to be effective in dependence on the „Ac­
tual“ tip dress counter. It thus influences the amount of stepping after a
tip dress operation.
To deactivate the %I stepper for the „Dressing“ function area, pro­
gram the „%I after last dressing“ parameter with the value „100“.
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Power (%I) in %
(with reference to the programmed base %I)

Value in „%I after

last dressing“ para­
meter

100% Act. count

Count (wear) = 0

Tip dress counter: 0 1 2 3 4

one out of 10 tip dress curve shapes Example: Number of dressings

resulting heat (%I) („Dressing steps“ parameter) = 4

Fig.26: Operating principle in the „Dressing“ function area

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7.11.2 Tip dressing

Tip dressing cleans the electrode tip and periodically restores the de­
sired contact surface throughout the electrode life.
For this purpose, the electrodes must be dressed accordingly in an
electrode dressing station whenever a certain count is reached.
A number of type-specific signals are available to inform the robot/the
PLC when the tips of the current gun (=electrode assigned to the selec­
ted welding program) have to be dressed.
These signals are only used if the electrode management functions
have been activated (BOS: ”Programming” topic, ”Stepper” tab,
"Stepper" parameter: ON).

The signal names may vary depending on the timer type.

Therefore use the type-specific operating instructions of your timer
to inform yourself about what signals are available.

The timer requests tip dressing by means of an output signal desig­

nated accordingly.
Using an acknowledgment input (e.g. ACKNOWLEDGE TIP DRESS)
the robot is able to increment the timer-internal tip dress counter and
reset the timer-internal wear counter of the current gun after the dress­
ing operation.
If the electrode 0 has been programmed in the selected welding pro­
gram, the input will influence all internal tip dress and wear counters
in some timer types!

As feedback for the robot some timers reflect the status of the acknow­
ledgment input to a dedicated output.

Other functions in connection with tip dressing

• Start tip dress:

Initial dressing can be activated by the parameter "Dress new elec­
trode" (BOS: ”Programming” topic, ”Electrode” tab).
When start tip dress is active, the timer will immediately request tip
dressing when an electrode has been replaced using an output sig­
nal.
For new electrodes, this serves to, e.g.
- obtain a defined size of plug
- obtain a defined application angle
- remove a protective coating.

• Monitoring the tip dressing result:

Some timers are able to check whether tip dressing was successful.
For detailed information, refer to Section 7.12 page 52.

• Monitoring tip dresser (dresser blade):

Some timer types can monitor whether or not the dresser blades are
replaced in the intervals provided.
For more information on this topic, refer to Section 7.13 page 54.
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• Activating tip dress stations:

A tip dress management for activation of external tip dress stations
has been integrated in some timer types.
For more information on this topic, please refer to the type-specific
operating instructions.

7.11.3 Warning and end of Stepper

When the maximum acceptable count value is reached, new electrode
tips have to be used.
A number of type-specific signals are available to inform the robot/the
PLC when the tips of the current gun (= electrode assigned to the selec­
ted welding program) have to be changed.
These signals are only used if the electrode management functions
have been activated (BOS: ”Programming” topic, ”Stepper” tab,
"Stepper" parameter: ON).
The signal names may vary depending on the timer type.
Therefore use the type-specific operating instructions of your timer
to inform yourself about what signals are available.
The timer requests a tip change by means of an output signal desig­
nated accordingly.
It is set when the ”Max. count” limit value is reached or exceeded (”Pro­
gramming” BOS topic, ”Stepper” tab).
Using an acknowledgment input (e.g. ACKNOWLEDGE ELEC­
TRODES HAVE BEEN CHANGED) the robot is able to reset the timer-
internal electrode-specific tip dress counter and the timer-internal
electrode-specific wear counter of the current gun after changing the
electrode (tip).
This event is interpreted and logged by the timer as „Tip change“.
If the electrode 0 has been programmed in the selected welding pro­
gram, the input will influence all internal tip dress and wear counters
in some timer types!
As feedback for the robot some timers reflect the status of the acknow­
ledgment input to a dedicated output.
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7.11.4 Warning table

The BOS window ”Warning table” provides an overview of and quick ac­
cess to all important information and operations with respect to elec­
trodes whose electrode management function is active (BOS:
”Programming” topic, ”Stepper” tab, parameter ”Stepper”: ON):
• Weld timers to which the individual electrodes have been assigned,
• actual counts (percentage, numerically and graphically).
The graphic representation is color coded. Any imminent warnings,
tip dress requests or the reaching of the end of stepper can be
quickly detected.
• Remaining parts that can still be manufactured using the respective
electrode.
For a correct output of the remaining parts, the electrode-specific
"Wear/Comp." parameter must be adjusted (BOS: ”Programming”
topic, ”Stepper” tab).
• Manual reset of wear counters by the user after a tip change.
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7.12 Tip dresser result monitoring

The ”Tip dresser result monitoring” function checks whether the elec­
trode dressing was performed correctly.
An activation of the monitoring function is always expressed as warn­
ing. As a result, an ”error” does not require user intervention - the robot
can repeat the dressing operation automatically.
Requirements for monitoring:
1. Definition of a welding program (for each electrode).
Both reference welds as well as a subsequent monitoring weld are
performed using this program.
Required settings:
- PreWLD and PstWLD = 0
- MainWLD: PHA mode
- %I stepping (Stepper): OFF
- %I correction = 0
- the electrode to be tested must be assigned to the program
- HLD greater than / equal to 20 ms
- WC start time greater than / equal to 0 ms
2. Execution of 2 reference welds.
They are used to determine the currents that flowed in MainWLD
• following a proper dressing (visual inspection!) of a new electrode
(= case 1) and
• directly before another required dressing (= case 2).
These currents are stored as electrode-specific reference currents
and used as comparison criteria for later monitoring welds of the ac­
tual current measured then.
The currents which flowed are treated as actual values within the
timer and displayed in the ”Programming” BOS topic, ”Electrode” tab
under the ”Tip dresser result monitoring” parameter group.
That is why changes of these values do not appear in the data
change log and are not saved via backup.

The following applies to a subsequent check of a successful electrode

dressing:
• After correct dressing, the actual current of the monitoring weld
should clearly differ from the actual current of the reference weld be­
fore dressing (refer to case 2 above).
• After correct dressing, the actual current of the monitoring weld
should approximately correspond to the actual current of the refer­
ence weld after dressing (refer to case 1 above).

A separate tolerance band must be parametrized for both situations

(”Programming” BOS topic, ”Electrode” tab under the ”Tip dresser res­
ult monitoring” parameter group) which is used for evaluation of the ac­
tual current of the monitoring weld.
Tolerance value inputs are always taken into account in the backup.
Tolerance changes appear in the data change log.
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Iact MON: Actual current during monitoring weld Iact MON

ÎÎÎÎÎÎÎÎÎÎ
Current ok
+toler. before tip

ÎÎÎÎÎÎÎÎÎÎ
dressing
is identified by the refer­ prohibited range
(in %)

ÎÎÎÎÎÎÎÎÎÎ
ence weld directly before
Reference current 1st test
a new required dressing

ÎÎÎÎÎÎÎÎÎÎ
in kA
prohibited range
-toler. before tip dress­
ing
(in %)
ÎÎÎÎÎÎÎÎÎÎ Current ok

Fig.27: ”Tip dresser result monitoring” function: Effect of the tolerance bands -
Testing 1 (for prohibited range)

Iact MON: Actual current during monitoring weld

ÎÎÎÎÎÎÎÎÎÎ
Iact MON

ÎÎÎÎÎÎÎÎÎÎ
prohibited range
+toler. new electrode
(in %)
is identified by the Current ok
reference weld after Reference current 2nd test
dressing in kA

ÎÎÎÎÎÎÎÎÎÎ
Current ok
-toler. new electrode
(in %)
ÎÎÎÎÎÎÎÎÎÎ prohibited range

Fig.28: ”Tip dresser result monitoring” function: Effect of the tolerance bands -
Testing 2 (for permitted range)

The dressing operation is regarded as good when test 1 and test 2 dur­
ing monitoring weld were successful.
Otherwise the timer sets the TIP DRESSING DEFECTIVE output (if
available).
Since phase angle values are programmed for reference and monit­
oring welds as %I input, mains voltage fluctuations may influence the
actual current and thus the test result.
" Therefore the tolerance bands should be dimensioned so that they
compensate normal mains voltage fluctuations safely but do not
overlap!
Relevant signals for the ”Tip dresser result monitoring” function:
• Input REFERENCE WELD FOR NEW ELECTRODE
• Input REFERENCE WELD TIP DRESS
• Input MONITORING WELD
• Output REFERENCE WELD ACTIVE
• Output MONITORING WELD ACTIVE
• Output TIP DRESSING DEFECTIVE
Please refer to the type-specific operating instructions of your timer
for the addresses to which these signals are assigned in the I/O inter­
face.
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Default settings of the ”Tip dresser result monitoring” function:

• both reference currents of each electrode: 0 kA
• all 4 tolerance values of each electrode: 100 %
(”Programming” BOS topic, ”Electrode” tab under the ”Tip dresser res­
ult monitoring” parameter group”).
With the default settings the limit values are chosen at a high level so
that the function does not signal a dressing fault.
If you do not want to use one of the two checks, simply parametrize
their tolerance limits with 100%.

7.13 Monitoring dresser change

This function serves for wear monitoring of the tip dressers used. It
helps to prevent damages resulting from imperfect electrodes or bad tip
dress results caused by worn tip dressers in advance by replacing the
tip dressers in time.
For this purpose, the timer offers not only the ”normal” tip dress counter
(which is reset after each electrode replacement) but also an additional
counter (value ”Act. cutter status”). This tip dresser wear counter is not
reset by an electrode replacement.
The timer increments the relevant cutter status counter whenever
dressing is performed on an electrode. When it reaches its programmed
warning value (value ”Tip dresser change warning”) or maximum value
(value ”Tip dresser end of life”), certain output signals will be set.
To deactivate wear monitoring of a tip dresser, set the ”Tip dresser
end of life” parameter to ”0”.
Tip dresser wear counters can be reset by the programming terminal
(BOS), but also via input signal.
Please refer to the type-specific operating instructions of your timer
for the addresses to which the pertaining signals are assigned in the
I/O interface.
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7.14 Gun life monitoring

This function serves for wear monitoring of the guns used. It helps to
prevent damages resulting from increasing wear of the electrode gun in
advance by replacing the gun in time.
For this purpose, the timer offers not only the ”normal” wear counter
(which is reset after each electrode replacement) but also an additional
counter (value of ”Act. gun life”). This gun life counter is not reset when
the electrode is replaced.
The timer increments the relevant gun life counter whenever a spot is
welded, provided that the maximum value (value "Maximum gun wear")
has been programmed > 0. Once it has reached its programmed warn­
ing value (value "Gun wear warning") or its maximum value (value
"Maximum gun wear"), the related output signals will be set and at the
same time a corresponding message will be displayed by BOS.
To deactivate gun life monitoring of a gun, program "0" for the relev­
ant "Maximum gun wear" parameter.
Gun life counters can be reset by the programming terminal (BOS),
but also via an input signal.
Please refer to the type-specific operating instructions of your timer
for the addresses to which the pertaining signals are assigned in the
I/O interface.
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7.15 Outputting the electrode force

For outputting the force actuating variable, the following options - de­
pending on the timer type - are available:
• an analog signal at X2
Voltage range of values: 0 to 10 VDC
Current range of values: 0 to 20 mA and 4 to 20mA
The type of analog output can be set in the ”Programming” BOS
topic, ”General” tab using the ”Pressure output mode” parameter.
• serial output signals at the digital interface.
Range of values: type-specific
For information on the actuating variables available, please refer to
the type-specific operating instructions of your weld timer.
The value of the output signal that corresponds to the programmed
force is calculated using an internal characteristic. Alternatively, the in­
ternal characteristic can be generated as follows:
• automatically via force calibration (refer to Section 7.16.1 from page
57),
or
• manually by means of parameters
”Conversion factor” and
”Zero adjust”.

" In order to ensure that the programmed force actually acts on the
electrodes in case of servo guns, a proper calibration of the servo
gun circuitry is necessary!
In the course of force calibration, the current values of the ”Conver­
sion factor” and ”Zero adjust” parameters are overwritten!

Other functions in connection with electrode force

• Pressure profile:
For each welding program, 10 different force values can be separ­
ately programmed which are activated at certain points of time within
the welding schedule.
• Pressure stepping:
Depending on the stepper or tip dress curve selected, you can define
the percentage by which the programmed base pressure value is to
be automatically increased subject to the actual electrode count
value.
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7.16 Calibration
" Calibrate force first, and current afterwards!

7.16.1 Force calibration

The "Force calibration" function is used to adjust all components of the
timer system that are involved in force generation to your reference
force meter (e.g. pressure pickup). This feature has the following ad­
vantages:
• Input of gun force in Kilonewton (kN)
• Precise reproducibility of logged force values (ISO 9000)
• The force values of all calibrated systems are comparable to each
other and can be transferred to additional systems.
• Comparable documentation.
Force calibration changes the "Conversion factor" and "Zero adjust"
parameters (in Stepper parameters; also refer to page 21). For this
reason, these parameters must not be manually changed once force
calibration has been completed!

NOTICE
Operating the timer without or with incorrect force calibration
Possibility of damage to the gun / defective welds!
" The base pressure value to be programmed must be determined
empirically - starting with "0" - for each electrode force required
and whenever guns have been replaced if force calibration is not
carried out!
If force calibration is not used, the timer cannot generate a proper
reference between the programmed force and the force actuating
variable to be output (for controlling the gun force).
Therefore, the actual force acting on the gun may differ consider­
ably from the programmed force!

Conditions for force calibration:

• Proportionate control valve, servo gun or other suitable device cap­
able of converting the force actuating variable output by the timer
into a mechanical force at the gun.
• external reference force meter with a suitable measuring range.
• programming terminal with BOS software (for operation and meas­
ured value input) is connected.
For force calibration, specify 2 different values of the force actuating
variable in the % unit of measurement (with respect to the maximum
value that can be output), measure the resulting forces between the
electrodes using the reference force meter and enter the forces meas­
ured in the timer (in kN). The timer will then calculate internally all of the
data required for calibration.
The following things should be especially noted for force calibration:
" The following applies for the 2 values of the force actuating variable
used for force calibration:
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Functions

• if possible, the higher value should generate the force that is max­
imally used for welding (upper end of the force working range).
• The two values should differ by a minimum of 20 %.
• The force used for tip dressing should not be allocated to the nor­
mal working range (because it is usually lower).
• If you do not know the values you have to enter for force calibra­
tion, first perform force calibration using low values in order to
check the forces that are adjusted at the gun, and abort calibra­
tion, if necessary. Thus, you avoid overloading or damaging the
gun during force calibration. Then, you should increase the input
values by new force calibration processes until the higher input
value generates the maximum force used for welding.
" Use the same reference force meter for all plants that should be com­
parable.
" Perform calibration for each gun of the welding equipment and
whenever a gun has been replaced.
" Verify any calibration made by comparing the base pressure values
programmed for test welding programs with the actual values on the
gun.
When doing so, make sure that the test programs work without cur­
rent and that no persons are at risk during the measurements (e.g.
as a result of robot movements).
" Repeat calibration whenever a component that is actively involved in
force generation has been replaced (weld timer, proportionate con­
trol valve, gun, ...).
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and Controls

Functions

7.16.2 Current calibration

The "Current calibration" function is used to adjust the entire measuring
and control loop of the timer system to your reference welding ammeter.
This feature has the following advantages:
• Reproducible, preconfigurable currents with a maximum error of less
than +/-2%
(with respect to the actual value of the reference welding ammeter)
• Precise reproducibility of logged current values (ISO 9000)
• The currents of all calibrated systems are comparable to each other
and can be transferred to additional systems
• Comparable documentation.
The weld timer also works without current calibration.
However, the benefits listed above cannot be achieved unless cur­
rent calibration has been performed.

Conditions for current calibration:

• internal current sensor or external sensor connected to X3
• external reference welding ammeter with a suitable current sensor.
• programming terminal with BOS software (for operation and meas­
ured value input) is connected.
• force calibration properly carried out (refer to page 57).
For current calibration, enter 2 different %I values in scale values (%I),
measure the currents resulting in the secondary circuit with the refer­
ence ammeter, and enter the current values measured in the timer.
The timer will then calculate all of the data required for calibration.

The following things should be especially noted for current calibration:

" The current sensor of the reference welding ammeter must have
been properly installed in the secondary circuit. That means:
- always connect it in the same location
- vertically to the current-carrying conductor
- sensor cable points away from current-carrying conductor
" The following applies for the 2 %I values (in %I) used for current cal­
ibration:
• the higher %I value should be at the upper end of the normal working
range of your welding plant.
" the two values should differ by a minimum of 20 %I.
" Use the same reference welding ammeter for all plants that should
be comparable.
" Set your reference welding ammeter to "DC" type of current and the
appropriate measuring range.
" Programmed fade-out times or an active trail current are also effect­
ive with current calibration!
Therefore, you should check prior to the calibration process whether
the corresponding functions are offered by your reference welding
ammeter, and whether they have been properly set.
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Functions

" Calibration should always be performed without parts to be welded

with the electrodes closed.
" Perform calibration for each gun of the welding equipment and
whenever a gun has been replaced.
" Verify any calibration made by performing a test weld and comparing
the current displayed on the timer with the current displayed on the
reference welding ammeter.
" Repeat calibration whenever a component that is actively involved in
the control loop has been replaced (weld timer, transformer,
sensor ...).

7.17 Corrections
Using the timer's correction function you can change
• the %I, and
• the pressure (electrode force).
Corrections are programmed as a percentage of the corresponding
base values.

Thus, the welding schedule can be quickly adjusted to process-specific

requirements without the need to change the originally programmed
base values.

The following types of correction can be activated

• electrode-specific correction:
acts on a specific electrode/gun (= Corr.(E)), and
• program-specific correction:
acts on a specific program (= Corr.(P)).
The two types of correction always act in addition to one another.

If the %I correction is changed, the reference current to be monitored

is also automatically adjusted - if activated via BOS configuration
tool.
The maximum correction values that can be input can be limited
globally for the whole timer. This limitation can be set to any value in
the range of +/-20% (”Programming” BOS topic, ”General” tab, ”Min/
Max %I corr.” and ”Min/Max pressure corr.” parameters).
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Functions

7.18 KSR changeover

Timers may be equipped with a sensor change-over function that drives
the discrete outputs depending on the active electrode (e.g. KSR
SELECTION x).
The following applies:
• Electrodes 1 to 9 set KSR SELECTION 1 output
• Electrodes 10 to 19: set KSR SELECTION 2 output
• Electrodes 20 to 29: set KSR SELECTION 3 output

If an external change-over box is used, the timer's sensor input can be

changed over to different KSR sensors. Please refer to the following fig­
ure.
Electrodes 0, 30 and 31 are not assigned to a sensor.
Therefore the output signal 'KSR SELECTION x' output last does not
change when one of these electrodes is activated.
Please refer to the type-specific operating instructions of your timer
for the addresses to which the pertaining signals are assigned in the
I/O interface.

KSR SELECTION 3
KSR SELECTION 2
KSR SELECTION 1

Secondary circuit 1
D

X3 external
Toroid input 1 change-
2 over box D
Toroid input
for KSR
Shield 3 D
changeover
4
Secondary circuit 2
5
D

Shield connection to terminal 3 of X3

only !

In addition to the external KSR change-over box, a suitable con­

nection must be provided to change over the secondary circuit
to the individual transformers!
Secondary circuit 3

Fig.29: Principle of KSR change-over; application with 3 separate welding circuits (transformers), for example
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Functions

7.19 Close weld contactor

The timer requests a higher-level monitoring instance to isolate the
weld contactor.
Isolating the weld contactor is useful
• as a safety function during an electrode change
• If no new program start is given within 60 s of the end of a welding
schedule
• in the event of a fault in the welding contactor area
Signals used
• Inputs:
”Weld contactor closed” (discrete signal)
“Weld contactor enable" (serial signal)
• Outputs:
"Close weld contactor" (discrete signal)
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and Controls

Functions

7.20 Weld Circuit Degradation (WCD)

Purpose The WCD function serves to detect anomalies in the welding circuit.
These anomalies may be caused e.g. by changes in the
• mains voltage
• internal resistance of the secondary circuit cable (broken cable)
• electrode contact resistance (contamination).
Mode of functioning The weld timer calculates the normalized actual ratio between welding
current and phase angle at the end of a welding schedule. If the value is
outside the tolerance range around the "Maximum reference current
(WCD)", the timer will generate a corresponding message and set the
"WCD warning" output signal.
Programming The function is programmed - if supported by the present timer type - in
the "Programming" topic, "Electrode" tab using the "WC degradation"
and „WCD tolerance band“ parameter groups.
" Proceed as follows:
1. First perform a weld using the respective electrode under normal
conditions (secondary circuit cable ok, electrodes clean and dressed
correctly, workpiece clean).
2. Write down the actual current of MainWLD (!) and the corresponding
phase angle value in %I (PHA).
3. Calculate the percentage %I using the PHA written down according
to the following equation:
%I = (PHA * 100/106) + 5.5
4. Calculate the theoretical current at 100% %I on the basis of the ac­
tual current written down and the %I calculated in the preceding
step, according to the following equation:
Max. reference current (WCD) = actual current (kA) * 100% / %I
5. Enter the result in the "Max. reference current" parameter (para­
meter group "WC degradation").
6. Define the tolerance band using the „WCD tolerance band“ para­
meter group.
If tolerances are too narrow, this may lead to unintended activation
of WCD monitoring in the case of mains voltage fluctuations.
Therefore we recommend to set the tolerance limits to 75% initially
and to optimize them to the respective application environment by
suitable tests.
7. Set the „WCD monitoring“ parameter ("WC degradation" parameter
group) to the value ON.
8. Send the new value to the timer.

Signals used:
• Outputs:
”WCD warning”
Upon delivery (or after deletion of the timer memory), the function is
deactivated, the "Max. reference current" parameter ("WC degrada­
tion" parameter group) is preset to 3 kA and the WCD tolerance band
parameter to 100%.
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7.21 Reference to additional important functions

A series of important and helpful functions are available as options and
are not included in timer types without these options.
The present document gives a description of these additional functions
for the sake of completeness.

7.21.1 UI regulation
The UI regulation protects your welding process against interfering vari­
ables much better than e.g. a constant-current regulation.
Higher process reliability and fewer user interventions in the system are
required as a result.
The function is described in detail in the manual „PSI6 xxx: UI regula­
tion and monitoring“ (for document number refer to table 1: page 5).

7.21.2 Thin-sheet function

The thin-sheet function activates a regulation algorithm which was op­
timized specifically for thin-sheet connections (sheet thickness less
than 1 mm) and feeds energy to the spot weld as early as possible.
The function is described in detail in the manual „PSI 6xxx: UI regula­
tion and monitoring“ (for document number refer to table 1: page 5).

7.21.3 Q Stop (Quality Stop)

Using the "Q Stop" function, the type PSI 6xxx weld timers can detect
any problems occurring in the technologically important process stabil­
ity (PSF), process quality (UIP) or force (FQF) monitoring variables and
signal them to the operator and/or the PLC.

7.21.4 Glue function

When the function is active, the controller defines the length of PreWLD
required to drive the glue out and adapts itself automatically to the
breakthrough time of the adhesive.
The function is described in detail in the manual „PSI 6xxx: UI regula­
tion and monitoring“ (for document number refer to table 1: page 5).

7.21.5 Static gun resistance compensation

The function is suited for compensation of static resistance deviations
between initial gun (gun used to record the reference curve) and the
currently connected gun.
The interpretation of different process variables is more difficult without
this compensation.
The function is described in detail in the manual „PSI 6xxx: UI regula­
tion and monitoring“ (for document number refer to table 1: page 5).
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Functions

7.21.6 Force monitoring

The "„Force monitoring“ " function allows the analysis of the force acting
on the electrodes in the course of a weld.
You can thus draw conclusions about the thermal and mechanical pro­
cesses taking place during the welding process and derive an assess­
ment of the welding quality.
The function is described in detail in the manual „PSI 6xxx: UI regula­
tion and monitoring“ (for document number refer to table 1: page 5).
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Notes:
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and Controls

List of tables

8 List of tables
Table 1: Necessary and supplementary documents . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2: Example for the structure of a safety instruction . . . . . . . . . . . . . . . . . . . . . 6
Table 3: Danger classes according to ANSI Z535.6-2006 . . . . . . . . . . . . . . . . . . . . . 7
Table 4: Examples for classification of safety instructions . . . . . . . . . . . . . . . . . . . . . 7
Table 5: Icons used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 6: Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 7: Abbreviations and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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and Controls

List of figures

9 List of figures
Fig.1: Main components of a welding plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fig.2: Physical basic parameters for influencing the weld . . . . . . . . . . . . . . . . . . . 16
Fig.3: Example: Time diagram of a welding program execution without impulse
operation in 2nd current block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fig.4: Example: Time diagram with all programmable periods of time
(incl. impulse mode with 3 impulses) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fig.5: Current blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fig.6: Single spot welding mode; signal sequence . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fig.7: Repeat welding mode; signal sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fig.8: Seam operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fig.9: Programming examples for impulse mode . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fig.10: Example: Slope in connection with impulse mode . . . . . . . . . . . . . . . . . . . . 27
Fig.11: Principle of open-loop PHA mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fig.12: Principle of KSR regulation mode with secondary current sensor . . . . . . 30
Fig.13: Principle: tolerance band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fig.14: Example: principle of the conditional tolerance band with a
Reweld factor = 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fig.15: Principle of "Standard" monitoring mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fig.16: Principle of "Mixed" monitoring mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fig.17: Effect of the fade-out time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fig.18: Trail current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fig.19: Start times of fade-out time and trail current . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fig.20: Principle of time monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fig.21: Example: Principle of automatic reweld by timer using
"Max. rewelds" = 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fig.22: Enlarged contact area through electrode wear . . . . . . . . . . . . . . . . . . . . . . 44
Fig.23: Example: Determining the count value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fig.24: Operating principle of stepping in the „Start“ function area . . . . . . . . . . . . 46
Fig.25: Operating principle of stepping in the „Stepper“ function area . . . . . . . . . 47
Fig.26: Operating principle in the „Dressing“ function area . . . . . . . . . . . . . . . . . . . 48
Fig.27: ”Tip dresser result monitoring” function: Effect of the tolerance bands -
Testing 1 (for prohibited range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fig.28: ”Tip dresser result monitoring” function: Effect of the tolerance bands -
Testing 2 (for permitted range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fig.29: Principle of KSR change-over; application with 3 separate welding circuits
(transformers), for example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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and Controls

Abbreviations

10 Abbreviations

Table 7: Abbreviations and definitions

Abbreviation Meaning
%I General abbreviation for heat (%I).
May be specified in %I (scale values) or kA.
%I Scale values (%I)
With thyristor power units: Measure for the electrical phase
value.
For MF inverters: Measure for the pulse width.
AC Alternating Current
BOS Welding user interface
BQR User interface for U/I controller
CAN Controller Area Network; data bus
CT Cool time
Time between the current impulses/blocks (1., 2., 3. CT)
Cyc Cycles. Refer to P.
Cyc. Refer to P.
daN Deka-Newton. 1 daN = 10 N
DC Direct current
dimmed The relevant object or its text is shown in grey color. In this
condition, the relevant functionality is inhibited, or cannot
be activated for reasons of the very system.
DST Downslope time.
Time in which the %I decreases until the end of the Main­
WLD.
ELMO Electromotive.
EMC Electromagnetic compatibility
EOS End of Schedule. Refer to WC.
ESD ElectroStatic Discharge.
Abbreviation of all references to electrostatic discharge,
e.g. ESD protection, ESD hazard.
ESD-sensit­ Electrostatically Sensitive Devices
ive compon­
ents
FPO Freely programmable output.
Is not offered for all timers.
FQF Force Quality Factor.
Value for the welding quality, derived from the character­
istic of the counterforce to the electrodes during a weld.
HLD Hold time.
Time after the last weld time in which the parts to be wel­
ded can cool down.
HSA (main Main switch trip.
switch trip)
Ignition Ignition.
Firing pulses for triggering the power unit are switched on
and off.
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Abbreviations

Abbreviation Meaning
IMP Number of impulses.
Number of impulses, impulses forming the MainWLD.
IP Internet Protocol
kA Kilo-Ampere (amount of current)
kN Kilo-Newton (force)
KSR Constant-current regulation (CCR).
Keeps the current in the welding circuit constant.
KUR Constant-voltage regulation.
Compensates line voltage fluctuations.
LT Power unit (thyristor or inverter)
MF Medium Frequency
ms Milliseconds.
NBS Mains load limitation control.
Monitors and influences the mains load.
NWI Post-warming pulse.
OFF Off time.
Time between two spot welds in which the solenoid valve
is not driven. Relevant for Repeat mode only.
Option button Round object on the user interface for toggling a function
on/off.
P Cycles (mains cycles)
With a line frequency of 50 Hz: 1 P -> 20 ms.
With a line frequency of 60 Hz: 1 P -> 16.6
PE Protective Earth. PE conductor.
PG Programming terminal/welding computer
PHA Phase angle.
PLC Programmable Logic Controller.
Post-Heat Post-heating time,
also referred to as PstWLD.
Pre-heat Pre-heating time,
also referred to as PreWLD.
PSF Process stability.
Value for the consistency between the current resistance
characteristic and the resistance characteristic of the refer­
ence curve.
PSG Transformer-rectifier unit for PSI types.
Medium-frequency welding transformer 1000 Hz
PSI Programmable weld timer with inverter.
PST Programmable weld timer with thyristor power unit.
Radio Refer to "Option button".
button
REPEAT Repeat mode.
Operating mode for manually operated systems.
RO Relay output
SINGLE Single spot operating mode.
For automatic and manual systems
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and Controls

Abbreviations

Abbreviation Meaning
Slope Current increase.
Current increases/decreases from an initial to a final heat
value.
Solenoid Solenoid valve.
Drives the cylinders for closing the electrodes.
SQZ Squeeze time.
Time that runs before the weld time. The electrodes
squeeze the parts to be welded together.
Stepper %I stepping in order to compensate for electrode wear.
TCP Transmission Control Protocol.
TCP controls the way in which data is exchanged between
computers. It is a link-oriented, packet-switching transport
protocol and belongs to the range of Internet protocols
(IP).
Temp. Temperature.
Timer Weld timer.
Also referred to as timer or resistance weld timer.
Tool tip Explanatory text.
Appears when the mouse pointer remains on an input
field/object for a moment.
ÜK Monitoring contact
e.g. for monitoring the pressure cylinder that closes the
electrodes or monitoring of the electrode position (e.g. gun
closed”).
UIR UI regulation
UIP Process quality.
Value for the welding quality, derived from the resistance
characteristic of the current weld.
UST Up-slope time.
Time in which the %I increases from the beginning of the
MainWLD.
WLD Weld time.
A distinction is made between PreWLD (pre-heating time),
MainWLD (main weld time), and PstWLD (post-heating
time).
All 3 weld times can be programmed separately in terms of
duration and %I.
Impulses and slope values can only be programmed for
the MainWLD.
WC Weld complete (contact).
This signal is output when the schedule has been com­
pleted.
WCD Weld circuit degradation
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Abbreviations

Notes:
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and Controls

Index

11 Index
% H
%I limitation, 31 HLD (Hold time), 19
%I stepping, 46 HSA (main switch trip), 71
%I warning, 31
%I warning, lower, 31 I
Icons, 8
1 Impulse mode, 26
1.CT (cool time), 19
1st half-cycle, 42 K
KSR, 30, 72
A KSR changeover, 61
Abbreviations, 71 KUR, 72
AC, 71
L
Automatic reweld by timer active, 40
Latching, 40
B Lower %I warning, 31
BOS, 8
M
C Manual electrode guns, 24
Calibration, 57 Measuring loop test, 39
Close weld contactor, 62 MF, 72
Conditional tolerance range, 33 Minimum current verification, 40
Constant-current regulation, 30 Minimum current, Verification, 40
Corrections, 60 Mixed mode
CT (cool time), 19 Monitoring, 35
Current blocks, 20 Regulation, 28
Current calibration, 59 Monitor stepper, 38
Current monitoring, 33 Monitoring, 32
Monitoring dresser change, 54
D Monitoring gun life, 55
Damage to products, 11 Monitoring modes, 34
Damage to property, 11
DC, 71 N
NBS, 72
Designations, 8
NWI, 42
Downslope time (DST), 27
Dresser change monitoring, 54 O
Dressing, 49 OFF, 72
DST (downslope time), 27
P
E PG, 8, 72
Electrode force, 21 PHA, 28
ELMO, 71 Phase angle, 28
EMC, 71 PLC, 8, 72
End of Stepper, 50 Post-heating time, 20
EOS, 71 Post-warming pulse (NWI), 42
ESD, 71 Pre-heating time, 20
ESD-sensitive components, 71 Pressure profile, 56
Pressure stepping, 56
F PSF, 72
Fade out time, 35 PSG, 8, 72
Force, 21 PSI, 8, 72
Force calibration, 57 PST, 8, 72
Force monitoring, 65
Q
G Q Stop, 64
Glue function, 64
Gun life monitoring, 55 R
Gun resistance compensation, 64 Repeat, 24
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Index

Reweld by timer active, 40 Tip dresser result monitoring, 52

Reweld factor, 33 Tip dressing, 49
Robots, 24 Tip dressing monitoring, 52
Roll seam, 25 Tip dressing result, 52
Tolerance ranges, 33
S Trail current, 35
Schedule modes, 24
Scope of delivery, 13
U
Seal weld, 25
UI regulation, 64
Seam operation, 25
UIP, 73
Single spot, 24
UIR, 31, 73
Slope, 27, 73
ÜK, 73
Solenoid, 73
UST (upslope time), 27
SQZ (squeeze time), 18
Standard mode
Monitoring, 34 W
Regulation, 28 Warning, 50
Stepper, 46, 73 Warning table, 51
Stepper monitoring, 38 WCD, 63
Stitch seam, 25 Wear (Count) factor, 44
Wear per component, 44
T Weld Circuit Degradation, 63
Thin-sheet function, 64 Welding modes, 28
Time monitoring, 38 WLD (weld time), 20
Timer , 73 WT, 8
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Notes:
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Tel. +49 9352 18 0
Fax +49 9352 18 8400
www.boschrexroth.com/electrics

DOK-PS6000-TECH*******-AP02-EN-P