Industrial Electric Drives Linear Motion and Service Mobile

Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

Rexroth PSx 6xxx.624 1070087027

Edition 02
Timer and I/O Level

Technical Information
II Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Title Rexroth PSx 6xxx.624

Timer and I/O Level

Type of Documentation Technical Information

Document Typecode DOK-PS6000-E/A624*****-FK02-EN-P

Purpose of Documentation The content of this manual refers to

D the mechanical structure
D the electrical connection (24 V supply and I/O) and
D the functionality
of the PSI/PST integrated weld timer.

Record of Revisions Description Release Notes

Date
DOK-PS6000-E/A624*****-FK01-EN-P 08.2003
DOK-PS6000-E/A624*****-FK02-EN-P 09.2003

Copyright E Bosch Rexroth AG, 2003

Copying this document, giving it to others and the use or
communication of the contents thereof without express authority, are
forbidden. Offenders are liable for the payment of damages. All rights
are reserved in the event of the grant of a patent or the registration
of a utility model or design (DIN 34-1).

Validity The specified data is for product description purposes only and
may not be deemed to be guaranteed unless expressly confirmed
in the contract. All rights are reserved with respect to the content
of this documentation and the availability of the product.

Published by Bosch Rexroth AG

Postfach 11 62
D-64701 Erbach
Berliner Straße 25
D-64711 Erbach
Tel.: +49 (0) 60 62/78-0
Fax: +49 (0) 60 62/78-4 28
Abt.: BRC - WS/VTR
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG III
and Controls

Contents

Contents
Page

1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Possible Safety Markings on the Product . . . . . . . . . . . . . . . 1-1
1.2 Safety Instructions in this Manual . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Installation and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.7 Operation of the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.8 Retrofits and Modifications by the User . . . . . . . . . . . . . . . . . 1-11
1.9 Maintenance, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.10 Working Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.11 CE mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Features of PS 6000 series . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Programming and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Hardware Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4.1 Timer front (without I/O module) . . . . . . . . . . . . . . . . . . . . . 2-7
2.4.2 Front of the I/O module ”DEV-NET” . . . . . . . . . . . . . . . . . . 2-9

3 Timer functions . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Main components of a welding station . . . . . . . . . . . . . . . . . . 3-1
3.2 Welding Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.1 Single Spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.2 Seam mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.1 Programmable Current Blocks . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.2 Impulse Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.3 Slope (Current Ramp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.3.4 Programmable Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4 Regulation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.1 Phase Angle (PHA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.2 Constant Current Regulation (KSR) . . . . . . . . . . . . . . . . . . 3-12
3.5 Current Prewarning and Limitation . . . . . . . . . . . . . . . . . . . . . 3-14
3.5.1 Current Prewarning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.5.2 Current Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.6 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6.1 Current Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6.2 Time Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6.3 Monitor Stepper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.7 Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.8 Measuring Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.9 Limitation of the 1st Half Cycle (for PST only) . . . . . . . . . . . 3-23
3.10 Automatic Spot Repetition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
IV Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

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3.11 Electrode Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.11.1 Wear Factor and Wear per Welded Part . . . . . . . . . . . . . . 3-25
3.11.2 %I Stepper (Stepper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.11.3 Electrode Tipdressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.11.4 Prewarning and End of Stepper . . . . . . . . . . . . . . . . . . . . . . 3-28
3.11.5 Prewarning Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.12 Electrode Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.13 Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.13.1 Force Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.13.2 Current Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.14 Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.15 Weld Transformer Selection (PSI only) . . . . . . . . . . . . . . . . . 3-34

4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Integrated weld timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 I/O Module ”DEV-NET” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

5 Electrical connection . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Suppression of RF noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Integrated weld timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.1 Output of the Internal 24 VDC Voltage Source (X4) . . . . . 5-2
5.2.2 Supply of the Timer Logics (X4) . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2.3 Supply of External Devices (X5) . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.4 24 VDC Voltage Distribution (X4) . . . . . . . . . . . . . . . . . . . . 5-4
5.2.5 Pressure Control and Feedback (X2) . . . . . . . . . . . . . . . . . 5-7
5.2.6 KSR Sensor (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.2.7 Fan Connection (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.2.8 Programming Device (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.3 I/O Module ”DEV-NET” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.3.1 Power Supply (X10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.3.2 DeviceNet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.3.3 Signal outputs and inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

6 I/O Signal Descriptions . . . . . . . . . . . . . . . . . . . 6-1

6.1 Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.1 Alphabetical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.2 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.3 Welding Circuit Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.1.4 Welding Circuit Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.1.5 Spot Selection, Program Selection . . . . . . . . . . . . . . . . . . . 6-4
6.1.6 Weld On External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.1.7 Reset Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.1.8 Reset Fault with WC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.1.9 Reset Fault with Spot Repeat . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.1.10 Acknowledgment ”Tips have been dressed” . . . . . . . . . . . 6-9
6.1.11 Acknowledgment “Electrodes have been replaced” . . . . . 6-11
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Contents

6.2 Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6.2.1 Alphabetical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.2.2 Pressure Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.2.3 Initial Dressing Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.2.4 Weld complete (WC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.2.5 Control Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.2.6 Welding Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.2.7 Weld/No Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.2.8 Tipdress Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.2.9 Prewarning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.2.10 End of Stepper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.2.11 Without Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.2.12 New Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.2.13 Welding Circuit Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.2.14 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

8 Status and Error Messages . . . . . . . . . . . . . . . 8-1

9 CE Declaration of Conformity . . . . . . . . . . . . . 9-1

10 Timer Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

A Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.2 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
VI Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Contents

Notes:
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and Controls

Safety Instructions

1 Safety Instructions
The products described were developed, manufactured and tested in
compliance with the fundamental safety requirements of the EU machi-
nery directive. These products normally pose no danger to persons or
property if used in accordance with the handling stipulations and safety
notes prescribed for their configuration, mounting, and proper operation.

Nevertheless, there is some residual risk!

Therefore, you should read this manual before installing, connecting or

commissioning the products or programming the welding system.
Store this manual in a place to which all users have access at any time!

The content of this manual refers to

D the mechanical structure
D the electrical connection (24 V supply and I/O) and
D the functionality
of the PSI/PST integrated weld timer.

The - according to the type of the product - integrated power sup-

ply units have their own manuals. They complete this manual!
L Therefore, please pay attention to the following documentation as well:
D For PST 6xxx:
Thyristor power unit, technical information (1070 080 059)
D For PSI 6xxx:
Medium-frequency inverters, technical information (1070 080 058)

1.1 Possible Safety Markings on the Product

Warning of dangerous electrical voltage!

Warning of hazards associated with batteries!

Electrostatically sensitive components!

Lug for connecting PE conductor only!

Function ground, ground with low parasitic voltage

Connection of shield conductor only

1-2 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Safety Instructions

1.2 Safety Instructions in this Manual

DANGEROUS ELECTRICAL VOLTAGE

This symbol is used to warn of dangerous electrical voltage. The fail-
ure to observe the instructions in this manual in whole or in part may re-
sult in personal injury.

DANGER
This symbol is used wherever insufficient or lacking compliance with in-
structions may result in personal injury.

CAUTION
This symbol is used wherever insufficient or lacking compliance with in-
structions may result in damage to equipment or data files.

. This symbol is used to draw the user’s attention to special circumstan-

ces.

L This symbol is used if user activities are required.

Modifications in this manual as compared to a previous edition are mar-

ked by black vertical bars in the margin.
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 1-3
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Safety Instructions

1.3 Intended Use

The product described
D serves in connection with a welding transformer and the appropriate
power supply unit for
- resistance welding of metals
and
D is suitable for operation in industrial environments in accordance with
the following standards:
- EN 50178
- EN 50081-2
- EN 50082-2
- EN 60204-1

In residential environments, in trade and commerce as well as small

enterprises class A equipment may only be used if it does not inad-
missibly interfere with other equipment.

It is not intended for any other use!

DANGER
Any use other than for the purpose indicated may result in perso-
nal injury of the user or third parties or in damage to equipment,
the workpiece to be welded, or environmental damage.
Therefore, our products must never be used for any other than
their respective intended purpose!

. For operation in residential environments, in trade and commercial

applications and small enterprises, an individual permit of the na-
tional authority or test institution is required; in Germany, please
contact the Regulierungsbehörde für Telekommunikation und
Post (RegTP) or its local branch offices.

The faultless, safe functioning of the product requires proper transport,

storage, assembly and installation as well as careful operation.
1-4 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Safety Instructions

1.4 Qualified Personnel

The requirements as to qualified personnel are based on the require-
ment profiles defined by the ZVEI (Zentralverband Elektrotechnik und
Elektronikindustrie - German Electrical and Electronic Manufacturers’
Association) and the VDMA (Verband deutscher Maschinen- und Anla-
genbau - German Engineering Federation) in:

Weiterbildung in der Automatisierungstechnik

edited by: ZVEI and VDMA
Maschinenbau Verlag
Postfach 71 08 64
D-60498 Frankfurt.

This manual is designed for technicians and engineers with special wel-
ding training and skills. They must have a sound knowledge of the soft-
ware and hardware components of the weld timer, the power supply
used, and the welding transformer.

Project engineering, programming, start and operation as well as the

modification of program parameters is reserved to properly trained per-
sonnel! This personnel must be able to judge potential hazards arising
from programming, program changes and in general from the mechani-
cal, electrical, or electronic equipment.

Interventions in the hardware and software of our products, unless des-

cribed otherwise in this manual, are reserved to specialized personnel.
Tampering with the hardware or software, ignoring warning signs atta-
ched to the components, or non-compliance with the warning notes gi-
ven in this manual can result in serious bodily injury or property damage.

Only skilled persons as defined in IEV 826-09-01 (modified) who are fa-
miliar with the contents of this manual may install and service the pro-
ducts described.

Such personnel are

D those who, being well trained and experienced in their field and fami-
liar with the relevant standards, are able to analyze the work to be car-
ried out and recognize any hazards.
D those who have acquired the same amount of expert knowledge
through years of experience that would normally be acquired through
formal technical training.

DANGER!
An exception are persons with cardiac pacemakers!
The strong magnetic fields occurring in resistance welding may
affect the proper functioning of pacemakers. This may be fatal or
cause serious personal injury!
Therefore, persons with pacemakers must stay clear of resistance
welding systems.
We recommend that warning sings as per DIN 40023 are posted at
every entrance to manufacturing shops housing resistance-wel-
ding equipment.
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Safety Instructions

No entry for persons with cardiac

pacemakers!
Danger!

Please note our comprehensive range of training courses. More infor-

mation is available from our training center (Phone: +49 (6062) 78-258).
1-6 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Safety Instructions

1.5 Installation and Assembly

DANGEROUS ELECTRICAL VOLTAGE

Danger of life during installation work while systems are switched
on!
Make sure that all plant sections undergoing operations during
the installation are de-energized and sufficiently protected
against accidental reclosing!

DANGER
Non-workmanlike installation or mounting may lead to personal
injury or damage to property.
Therefore, it is essential that you take the technical data (environ-
mental conditions) into account for installation or mounting.
Installation or mounting must be carried out by skilled personnel
only.

DANGER
Insufficient degree of protection may be life-threatening or cause
damage to property!
The degree of protection of the products described is IP 20.
They must be installed in switchgear cubicles providing a degree
of protection of no less than IP 54.

DANGER
Danger of injury and of damage to property through incorrect in-
stallation!
Devices and, in particular, operating means, must be installed so
as to be properly safeguarded against unintentional operation or
contact.

DANGER
Danger of personal injury and damage to property through inade-
quate fastening!
The place for installing the modules, and their method of faste-
ning, must be suitable for their weight!

DANGER
Injuries and bruises may be caused by lifting weights which are
too heavy or by sharp metal edges!
Due to the heavy weight of individual modules several persons are
required for installation and assembly.
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Safety Instructions

DANGER
The safety and accident prevention regulations as amended shall
be observed!
Wear a protective helmet, safety shoes and gloves!

CAUTION
Short circuits!
When cut-outs are drilled or sawed in switchgear cubicles, metal
burr may get into modules already installed there. Or, when coo-
ling water lines are connected, water may leak into the modules in-
stalled.
The possibility of short circuits occurring in the process or even
the destruction of the devices cannot be entirely ruled out.
Therefore, guard any existing modules well before you install a
new module! Any and all warranty excluded in case of non-com-
pliance.

CAUTION
Heat accumulation!
Modules must be mounted with a minimum clearance of 100 mm
on top and at the bottom. Without this minimum clearance, heat
may accumulate and cause inverter failure.

CAUTION
Leaks in the cooling water circuit may cause consequential da-
mage!
Cooling water leaks may damage adjacent components. There-
fore, when mounting water-cooled modules, always ensure that
other devices in the switchgear cabinet are well protected against
leaking cooling water.
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Safety Instructions

CAUTION
Damage to property through insufficient water quality in the pos-
sibly required cooling water circuit!
Deposits in the cooling system may reduce the water flow, thus im-
pairing the performance of the cooling system with time.
Therefore, you should ensure that your cooling water has the fol-
lowing properties:
D pH value : 7 to 8.5
D Degree of hardness Dmax : 10 German degrees
(1 German degree = 1.25 British degrees = 1.05 US degrees =
1.8 French degrees)

D Chlorides : max. 20 mg/l

D Nitrates : max. 10 mg/l
D Sulfates : max. 100 mg/l
D Insoluble substances : max. 250 mg/l
Tap water usually meets these requirements. However, an algicide
should be added.

L For information about dimensions and installation accessories of the

product as a whole as well as information about the cooling system,
please refer to the manuals of the power supply units (see page 1-1).
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Safety Instructions

1.6 Electrical Connection

DANGER
Danger of personal injury and damage to property through mis-
sing or false interpretation of fault messages!
Therefore, closing of the transformer temperature contact (ther-
mostatic switch, break contact) must inhibit the connected timer!
As regards fault analysis, see also section 8.

DANGER
Danger of life through inappropriate EMERGENCY-STOP facili-
ties!
EMERGENCY-STOP facilities must be operative in all modes of the
system. Releasing the EMERGENCY-STOP facility must by no
means result in an uncontrolled restart of the system! First check
the EMERGENCY-STOP circuit, then switch the unit on!

CAUTION
Connecting lines and signal lines must be laid so as to avoid nega-
tive effects on the function of the units through capacitive or in-
ductive interference!Interference is frequently coupled and de-
coupled in long cables.
Therefore, power and control cables must be routed separately.
The influence of interfering cables on cables susceptible to inter-
ference can be minimized by keeping the following distances:
> 100 mm if cables are run in parallel for < 10 m,
> 250 mm if cables are run in parallel for > 10 m.
The product should be mounted close to the welding systems so
as to avoid cable lengths of more than 25 m.

L In addition, please comply with all safety regulations regarding electrical

connections and the EMC of the system as a whole in the manuals of the
power supply units (see page 1-1).

L Make sure that all contact surfaces are bright, i.e. free of paint, plastic
coating or dirt/oxidation.
1-10 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Safety Instructions

1.7 Operation of the Product

DANGER
In the environment of resistance welding systems, magnetic field
strengths have to be expected which are above the limit values
specified in VDE 0848 Part 4. Especially if manual guns are used,
the limit values for extremities may be exceeded.
In cases of doubt, you should measure the field strength and take
additional measures to ensure safety and health at work. Please
comply with regulation BGV B11 of the German Berufsgenossen-
schaft (professional association) ”Unfallverhütungsvorschrift
elektromagnetische Felder”.

DANGER
The strong magnetic fields occurring in resistance welding may
affect the proper functioning of pacemakers. This may be fatal or
cause serious personal injury!
Therefore, persons with pacemakers must stay clear of resistance
welding systems.
We recommend that warning sings as per DIN 40023 are posted at
every entrance to manufacturing shops housing resistance-wel-
ding equipment:

No entry for persons with cardiac

pacemakers!
Danger!

DANGER
Danger of personal injury and damage to property if devices are
operated before they have been properly installed!
The devices are designed to be installed in housings or switch-
gear cabinets and must not be operated unless properly installed
and switchgear cabinet doors are closed!
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 1-11
and Controls

Safety Instructions

DANGER
Danger of bruises through electrode movement!
All users, line designers, welding machine manufacturers and
welding gun producers are obliged to connect output signals
which initiate the electrode movement so that the applicable sa-
fety regulations are complied with.
For example, by means of ”Two-handed start”, fences, light bar-
riers etc. the risk of bruises can be considerably reduced.

CAUTION
Overheating through inappropriate or insufficient cooling.
The temperature inside the housing must stay within the specified
range.
Air
cooled medium-frequency inverters must always be operated
under forced
air cooling conditions. Convection cooling will not
be sufficient!
Water-cooled medium-frequency inverters may only be operated
when the cooling water circuit is active! Condensation on water-
carrying components must be prevented.

1.8 Retrofits and Modifications by the User

DANGER
Modifications to the product may have negative effects on the
safety of the unit!
The possible consequences include death, severe or light injury
(personal injury), damage to property or environmental hazards.
Therefore, please contact us prior to making any modifications.
This is the only way to determine whether changes can be made
without any problems.

1.9 Maintenance, Repair

DANGEROUS ELECTRICAL VOLTAGE

Prior to any maintenance work - unless described otherwise - the
system must always be switched off and sufficiently secured!
In the event of necessary measurement or test procedures on the
active system, these have to be performed by skilled electrical per-
sonnel.
1-12 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Safety Instructions

DANGER
Lithium batteries can cause skin burns or explode in case of im-
proper handling!
Therefore, do not forcefully open batteries, do not attempt to
charge or heat up batteries over 1005C!

CAUTION
Please use only spare parts approved by us!
Use only original replacement batteries! In any case, spent batte-
ries and accumulators should be disposed of as hazardous waste!

CAUTION
Danger to the module!
All ESD protection measures must be observed when using the
module! Prevent electrostatic discharges!

The following protective measures must be observed for modules and

components sensitive to electrostatic discharge (ESD)!
D Personnel responsible for storage, transport, and handling must have
training in ESD protection.
D ESD-sensitive components must be stored and transported in the
prescribed protective packaging.
D ESD-sensitive components may only be handled at special ESD-
workplaces.
D Personnel, working surfaces, as well as all equipment and tools
which may come into contact with ESD-sensitive components must
have the same potential (e.g. by grounding).
D Wear an approved grounding bracelet. The grounding bracelet must
be connected with the working surface through a cable with an inte-
grated 1 MW resistor.
D ESD-sensitive components may by no means come into contact with
chargeable objects, including most plastic materials.
D Beim Einsetzen von EGB in Geräte und bei ihrer Herausnahme muß
das Gerät spannungsfrei sein.
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 1-13
and Controls

Safety Instructions

1.10 Working Safely

DANGER
If the start signal is present on fault reset (acknowledge), the weld
timer immediately starts the program sequence! Hazardous ma-
chine movements may be the result!
Therefore, before fault reset, you should make sure that there are
no persons in the danger zone of the welding equipment!

DANGER
During operation of the welding equipment welding splashes are
to be expected! They may cause eye injuries or burns. Therefore:
- wear protective goggles
- wear protective gloves
- wear flame-retardant clothes

DANGER
Danger of injury from sheet metal edges and danger of burns from
weld metal!
Therefore: - wear protective gloves

CAUTION
The strong magnetic fields occurring in the resistance welding
process may cause permanent damage to wrist watches, pocket
watches, or cards with magnetic stripes (e.g. EC cards).
Therefore, you should not carry any such items on you when wor-
king in the immediate vicinity of the welding equipment.

1.11 CE mark

CAUTION
The CE mark for thyristor unit - welding transformer combinations
(see section 9) refers to industrial applications.
For other combinations/applications, the certificate must be deri-
ved from the above, or a new certificate must be issued, if neces-
sary, by the line designer / user.
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Safety Instructions

Notes:
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and Controls

Overview

2 Overview
The PS 6000 series combines the following devices in one housing:
D Weld timer and
D Power supply unit.

The integrated weld timer is used for controlling the integrated power
supply unit and is suitable for
D Spot welding (e.g. in connection with a robot)
D Projection welding
D Repeat mode (e.g. manual welding guns) and
D Seam welding (e.g. roll seams).

In addition to a variation of timers whose main differences lie in their I/O

connection to the higher-level PLC/robot unit and in their functionality,
there are also
different power supply units (MF inverters/thyristor power supply
units) with different cooling systems (air/water) of several different per-
formance classes available for controlling the welding transformers.

2.1 Type code

The product name contains information about the corresponding pro-
duct variation:

PS_ 6_ _ _ . _ _ _ _ _
Mains voltage
(only for MF inverters):
1: 400-480 VAC
2: 480-690 VAC
Cooling:
L: Air
W: Water
Type of timer
first number I/O connection:
1: 24 V
2: PROFIBUS
3: INTERBUS
6: Device Net
7: Ethernet
2nd+3rd number: Number of version
Performance class of the power
supply unit
Type of power supply unit:
T: Thyristor power supply unit
I: Medium frequency inverter
Example:
PSI 6100.100 L1: Weld timer with 24 V I/O
MF inverter
Air cooling
Mains supply 400-480 VAC

Type code of PS 6000 series

2-2 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Overview

2.2 Features of PS 6000 series

. For information about dimensions, mains connection, cooling or

welding current, please refer to the manual of the power supply unit
in use (see page LEERER MERKER).

D User interface for operation, programming and diagnosis:

- Standard: complete for graphic user interface BOS-5000; runs on
PCs with Windows 95/98, NT4, or W2000 operating system.
- Optional and with limited functions: via operating and diagnostic
terminal BT 220 with PLC function (CL500) or BT 6. Connection:
via V24.
D Optional access limitation for operation/programming
- By password (interlocking disk)
D Programming connection to PC (BOS-5000):
- Standard: for one single timer via V24
(e.g. for programming on location)
- Optional: contemporary connection of more than on timer via field-
bus interface: PROFIBUS-FMS
INTERBUS-PMS
Ethernet
D I/O connection (communication with e.g. robot/PLC):
Available connections:
- parallel (discrete I/O wiring)
- serial (via bus system):PROFIBUS DP
INTERBUS S
DeviceNet
D Number of programs:
- Maximum of 256 programs; symbolic spot addressing possible.
Because of the great number of programs, in most cases it is pos-
sible to assign a program to each weld spot.
D Programming of times (depends on integrated power supply unit):
- AC technology: in line cycles
- MF technology: in milliseconds
D Universally adaptable welding schedule:
- 3 programmable weld times (1. WLD: preheating weld time; 2.
WLD: weld time; 3. WLD: postheating weld time).
The welding times can be operated either together in one regula-
tion mode (standard operation) or in different regulation modes
(mixed operation).
- The 1.WLD and 3.WLD can be turned off.
- Programmable impulse mode for 2. WLD
- Programmable slope mode (current rise/decay time) for 2. WLD
D Welding operation modes:
- Spot welding (e.g. in connection with robots)
- Repeat mode (e.g. in connection with manual guns)
- Roll seams
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and Controls

Overview

D Half cycle operation

D Regulation modes:
- PHA (Phase angle)
- KSR (Constant Current Regulation)
Mixed operation for individual welding times is possible.
D Current monitoring:
- Reference currents are programmable independently from the
regulation command values
- Tolerance band in percent, asymmetrically programmable
- Monitoring in standard and mixed mode possible
D Automatic spot repetition in case of low current
D Time monitoring
D Electrode Management:
- Stepper function for current (%I stepper)
- Electrode tipdressing including initial dressing
- Stepper function for force (stepping of electrode force)
- Prewarning table with graphic representation of electrode wear
D Proportional valve control:
- Output signal is high after program selection
- Analog and digital pressure control
- Feedback possible
- Electrode force programming in kN for all welding programs
- Force scaling for adaptation to the valve characteristic curve
D Force profile:
- up to 10 different electrode forces can be programmed during the
execution of a program
D External weld time termination on half-wave
D Freely programmable output:
Up to 3 turn-on/-off times can be programmed during the sequence of
a program. Serves e.g. to control a back-pressure valve or for weld
spot-synchronous preparation of components that are subject to wel-
ding.

D Scaling programs:
- for current (adjustment of the welding device with regard to an ex-
ternal reference ammeter)
- for force (adjustment of the electrode force with regard to an exter-
nal reference dynamometer)
D Protocol function (ISO 9000):
- Error Protocol
- Weld Fault Protocol
- Data Change Protocol
- Weld Current Protocol
D Integrated diagnostic memory
2-4 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Overview

D Fault allocation:
- Events are programmable either as errors or warnings.
D Status display of I/O signals in online mode
D %I correction:
- for selected programs
- for all programs
- for selected electrode pairs
D General overview of system for:
- Start inhibit
- Weld on internal
- Time monitoring
- Current monitoring
- 2. WLD in PHA/KSR
- Program-related electrode number
D Upload/Auto-Upload (Data backup)
D Restore (Data restoration)
D Copy of welding programs
D Exchange of timer (data backup and restoration of entire module, inc-
luding counter content and actual values)
D Start simulation:
- Program selection and start of schedule can be initialized via GUI
D Available languages:
- German
- English
- NA English
- Spanish
- French
- Swedish
- Portuguese
- Italian
- Hungarian
D Online and offline programming possible
D Prepared for upgrade with an optional quality module or for extension
with an optional ultrasonic control board (USR).
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and Controls

Overview

2.3 Programming and Operation

All necessary parameters will be stored in the timer’s internal battery-
buffered RAM.

Operation, programming, and diagnosis are handled via the connected

PC. The PC can be either connected via
D the timer’s V24 interface (X1) or via
D an optional fieldbus interface (e.g. PROFIBUS).
While the V24 connection allows for access to a single timer only (e.g.
programming on location), the fieldbus interface allows for the contem-
porary connection of more than one timer.

Prerequisites for programming and operation via PC:

D Operating systems Windows95/98, NT4, or W2000
D Software BOS-5000 (”BedienOberfläche Schweißen” = GUI Wel-
ding)
D V24 connecting cable or in case of fieldbus interface corresponding
installation.

. For detailed information about BOS-5000, please refer to the

BOS-5000 manual.

. With regard to time programming, PSI and PST differ from each
other:
PSI: spacing in 1 ms
PST: in line cycles
(at 50 Hz: 1 line cycle corresponds to 20 ms)
(at 60 Hz: 1 line cycle corresponds to 16.6 ms)

The timer can be programmed ”online” as well as ”offline”.

D offline:
An active connection to the timer is not necessary.
Diagnosis and visualization are not possible.
The programming is handled and saved on the PC and can be trans-
ferred to the timer at a later point in time.
D online:
An active connection to the timer is necessary.
Diagnosis and visualization are possible.
The programming is handled via PC. Each parameter will be read out
and, after acknowledgement, written back to the timer. This way, mo-
dified and acknowledged parameters will be effective with the sy-
stem’s next program start at the latest.
2-6 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Overview

2.4 Hardware Installation

The timer module is fastened to the right side of the global housing.
In addition to the standard display and operating elements and termi-
nals, it contains
D the corresponding I/O module for the timer’s connection to the higher
level PLC or the robot (is installed ex works and requires the corres-
ponding timer firmware)
D a slot for the optional fieldbus module for programming/operation/dia-
gnosis of all timers connected to the fieldbus
D a slot for an optional quality module or for extension with an optional
ultrasonic control board (USR).

PSx 6000

Slot for optional quality module

or ultrasonic control board USR

type-specific I/O module

A
D
D
R
V24 interface for connecting a PC with
Power supply unit BOS-5000 software
(programming, logging, diagnosis, and
error display for the connected timer)

Slot for fieldbus module for connecting

more than one timer to a central PC with
BOS-5000 software
(programming, logging, diagnosis, and
error display for all timers connected to
the fieldbus)

Battery for buffering the timer’s internal

RAM

. The dimensions of the global housing and the functional units for
cooling depend on the size of the integrated power supply unit and
can be slightly different than the above illustrated example.

L For installation and mounting, please refer to the corresponding manu-

als of the power supply unit in use (see page LEERER MERKER).

CAUTION
Malfunctions and damages are possible!
Incorrect installation, connection, or operation can provoke unex-
pected or erroneous reactions of the device, which may lead to
dangerous situations in the welding station.
Please comply with all instructions in the manuals.
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 2-7
and Controls

Overview

2.4.1 Timer front (without I/O module)

LED LOGIC; green. Is lit when the 24 VDC (logic

supply voltage) is pending.
LED; red. Is lit, when:
with PSI: DC link voltage > 60 V
with PST: Mains voltage ok

LED READY; green. Is lit when there is no error in the timer.

The device is ready to weld.
LED WELDTIME; yellow. Is lit when the power supply unit is
triggered. Welding current flows.
LED BATTERY ERROR; red. Is lit when the battery must

Optional quality module or ultrasonic control board USR

type-specific I/O module. Refer to page 2-9
be exchanged.

RESET button. Brings the timer back into the

READY status after detection (and elimination)
of an error.
DIP-switch for setting the address at which the central PC can reach the
timer via the fieldbus.
Important only when using fieldbus modules.
A
Boot LED; red. Is lit when the timer D
is in “boot” mode. D
R
”Boot” button for activating the ”boot” mode. Is required for a firmware exchange
in connection with the ”WinBlow” software. Welding processes are not possible
while booting. Exit booting: Turn 24V logic voltage on/off.

V24 connection to the programming device

(for programming on location).

24 VDC output for the internal power supply unit

24 VDC input to logic voltage supply
Terminals to 24 VDC voltage distribution
24 VDC output for supplying the fan in timers with ventilation systems X4

24 VDC output for supplying external consumers

X5

Not used X8

Output for influencing the electrode force (controlling a proportional control X2

valve)
Fieldbus module

Input for (force) feedback.

Not used X9

Measuring input for constant current regulation (KSR) X3

Battery for buffering the internal RAM.

2-8 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Overview

. For Technical data of the timer, please refer to chapter 4.1 on page
4-1.

CAUTION
Immediately upon pushing the ”boot” button, welding processes
become impossible! The timer interrupts the program sequence,
switches all signal outputs to 0 V and goes into ”boot” mode (for
firmware exchange). The button shall
- never be pressed during operation and
- be pressed only by authorized personnel.
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 2-9
and Controls

Overview

2.4.2 Front of the I/O module ”DEV-NET”

- Diagnostic messages of the module (according to DeviceNet specification)

- NA: 6 DIP switches for setting the node address (Mac ID)
- DR: 2 DIP switches for setting the baud rate
(each according to DeviceNet specification)

- Bus connection
Connection scheme - please refer to chapter 5.3.3, page 5-15 X13
For information on signal exchange via DeviceNet,
please refer to chapter 5.3.3 on page 5-15

- Signal inputs I0 to I7 (24 VDC), with indicator LED

X12
For signal assignment, please refer to chapter 5.3.3 on page 5-15

- Signal outputs O0 to O7 (24 VDC), with indicator LED

X11
For signal assignment, please refer to chapter 5.3.3 on page 5-15

- Voltage supply of the I/O modules (24 VDC)

Terminal 1 and 3 connected internally
X10
Terminal 2 and 4 connected internally
For connection variations, please refer to chapter 5.3.1 on page 5-13

. For technical data of the I/O module, please refer to chapter 4.2 on
page 4-2.
2-10 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Overview

Notes:
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 3-1
and Controls

Timer functions

3 Timer functions

3.1 Main components of a welding station

Welding stations that are equipped with PS 6000 generally consist of the
following main components:
D Weld timer with integrated power supply unit (in AC or MF technology;
AC: thyristor power supply unit; MF: medium-frequency inverter)
D suitable weld transformer with current sensor and
D pneumatically or electrically driven gun, electrodes included.

In addition, an upstream control that controls the entire process regar-

ding the work piece and monitors its safety is necessary. This can be pro-
vided by e.g.
D a programmable logic controller (PLC)
D a robot control
D a manual control (e.g. for manual welding guns) or
D a combination of the above.

Start PROP
Gun
I O
Progr. No.
PLC or (WLD) Trans-
PS 6000 Electrodes
robot former

DRM
O I
WC
Current sensor
I: Input
O: Output Actual current value
PROP: Proportional control valve
DRM: Pressure feedback
WC: Weld complete contact
WLD: Weld time

Main components of a welding station

The weld timer ensures the controlled flow of the actual welding process.
In order to do so, it must control and regulate a great number of functions
and physical variables. Main tasks are e.g.
D the communication with a higher-level PLC or robot control via I/O si-
gnals
D triggering a proportional control valve or a servomotor in order to in-
fluence the electrode force
3-2 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Timer functions

D making sure that the different times are scheduled correctly (e.g.
squeeze, current, hold time etc.)
D controlling the power supply unit to produce a correct welding current
D indicating either a correct or erroneous weld at the end of the welding
program.

. The possibility to activate the solenoid valve (in order to close the
gun) does not exist for this type of timer.

Time
Current I
Transformer
Start

Primary Force F Current

circuit

+ + +
- - -
1.SQZ
Secondary circuit + WLD HLD
SQZ

SQZ: Squeeze time (for explanations please refer to chapter 3.3.4, page 3-8 ff)
WLD: Weld time
HLD: Hold time (for explanations please refer to chapter 3.3.4)

Physical variables for affecting the weld

3.2 Welding Operation Modes

In order to execute a welding process, the timer can be operated via PLC
/ robot or controlled manually by an operator.
To do so, the PS 6000 provides several different welding operation mo-
des:
D Single spot mode
D Seam mode.

3.2.1 Single Spot

Is suitable for operation in connection with robots, welding machines,
automatic welders and manual guns; for spot, projection, and butt welds.
A “high” level at the START input (see also page 6-2) starts the welding
process (welding program) exactly 1x - starting with the 1.SQZ.
At the end of the program, the timer outputs the WELD COMPLETE
(WC) output signal, as long as no welding error has been detected.
For a new welding process, the start signal has to be toggled off/on.
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 3-3
and Controls

Timer functions

Start

WC

Producing a spot weld Producing another spot

weld

Welding operation mode single spot, signal schedule

3.2.2 Seam mode

Suitable for roll seam stations.
With this technique, you pass over the welded parts with rolling electro-
des and the parts are connected by individual spot welds.
As in single spot mode, the weld timer reacts to the start signal and starts
the welding process.
The weld time (2.WLD) and a possibly programmed cool time (2.CT) will
be repeated, as long as the high level at the START input is pending.
If the start signal changes to low level, the timer interrupts the flowing
current impulse and starts the hold time (HLD).

. If you want to terminate the current time not abruptly but by a cur-
rent ramp (current reduction, please refer to page 3-7), turn the
pressure feedback off (refer to page 5-7) while the start signal is
still high and the slope has been parameterized accordingly.
If the start signal is still high, a possibly programmed 3.CT and a
3.WLD will be performed before the hold time starts.

Seam mode is divided in stitch and seal welds:

Stitch weld:Successive weld times are separated from each other by
sufficiently rated cool times, so that successive spot welds
neither touch each other nor overlap.
Seal weld: The cool time is so short that successive spot welds overlap.

Stitch weld Seal weld Seal weld

ÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
2.CT 2.WLD
CT very small or 0

Seam mode
3-4 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Timer functions

3.3 Program
There are 256 different welding programs (program no. 0 - 255) availa-
ble. First, select the program via the program selection inputs (refer to
page 6-4), then start the welding process via high level at the START
input (see also page 6-2).

Each welding program contains all parameters necessary for the exact
definition of a weld. Basic parameters are e.g.
D Currents that are to be effective in different current blocks (refer to
chapter 3.3.1 ff)
D Times that are supposed to run consecutively (please refer to chapter
3.3.4, page 3-8 ff)
D Electrode force (for further explanations, please refer to page 5-7).

3.3.1 Programmable Current Blocks

However, the process may require to produce the heat necessary for a
single spot weld in consecutive current blocks. Therefore, you can ex-
ecute a spot weld using up to three current blocks (1. WLD, 2. WLD, 3.
WLD). With regard to its time and current, each block can be program-
med separately.

. Programming the currents depends on the active regulation mode

(refer to page 3-11):
PHA (Phase angle): in scale values
KSR (Constant Current Regulation): in kA

Between the blocks, cool times can be programmed (1.CT, 3.CT). If you
set a cool time = 0, the two corresponding blocks lie seamlessly next to
each other.

Start of program schedule End of program schedule

+ + +
+ + + + + +
- - - - - -
- - -
1.SQZ 1. 3.
+ 1. WLD CT 2. WLD CT 3. WLD HLD
SQZ 1. %I 2. %I 3. %I

1st current block 2nd current block 3rd current block

(preheating time) (postheating time)
SQZ: Squeeze time (for explanations please refer to chapter 3.3.4, page 3-8 ff).
WLD: Weld time
HLD: Hold time (for explanations please refer to chapter 3.3.4)
%I: Current

Available current blocks

1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 3-5
and Controls

Timer functions

1.WLD (1st weld time / preheating time):

With this current block, you can preheat the metal with a smaller current
(1.%I) prior to the actual welding process (in the 2nd current block), in or-
der to reduce the risk of e.g. welding splashes.
If you do not want to use the 1.WLD, simply set 1.WLD = 0.

2.WLD (2nd weld time / 2nd current block):

With this current block, you actually weld a spot with the command cur-
rent (2.%I).
D The 2nd weld time must always be programmed.
D Within the 2.WLD, the functions:
- ”Impulse mode” (refer to page 3-6) and
- ”Slope” (refer to page 3-7) are available.

3.WLD (3rd weld time / postheating time):

With this current block, you can heat the metal with a smaller current
(3.%I) after the actual welding process (2nd current block).
This compensates e.g. for too rapid cooling of the spot welds caused by
the electrode’s cooling. It improves the structure of the welded part and
serves to relieve weld stresses.
If you do not want to use the 3.WLD, simply set 3.WLD = 0.
3-6 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Timer functions

3.3.2 Impulse Mode

In addition to the possibility to distribute the heat necessary for one sin-
gle spot weld on 3 successive current blocks (refer to page 3-4), you
also have the impulse mode at your disposal.
Within the 2nd current block, the heat necessary for welding a spot can
be distributed on up to 9 successive impulses which reduce the risk of
welding splashes as well.
Between the impulses, you can program a 2.CT.
If you set the 2.CT = 0, all impulses lie seamlessly next to each other.
You can set the impulse mode via parameter ”Impulse”.
This parameter determines how often the 2.WLD will be repeated taking
into consideration a programmed 2.CT.

2nd current block

20 ms = 1 cycle
2.WLD
Example: Impulse mode OFF
IMP = 1
2.WLD = 60 ms
2.CT (not relevant, because 1 impulse only)
2nd current block

Example: 2 impulses 2.WLD 2.WLD

2.CT
IMP = 2
2.WLD = 60 ms
2.CT = 40 ms

2nd current block

Example: 3 impulses
2.WLD 2.WLD 2.WLD
IMP = 3 2.CT 2.CT
2.WLD = 60 ms
2.CT = 40 ms

Examples of programming the impulse mode

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and Controls

Timer functions

3.3.3 Slope (Current Ramp)

If the Slope function is activated, the timer independently produces a li-
near current increase (upslope) or decrease (downslope) for the 2nd
current block within a programmable time span. The Slope function re-
duces the switch-on current peak and thus the stress on the welding sta-
tion.
For programming, use
D current upslope time (UST) to determine the time span in which the
momentary current shall be increased from ”starting current” to the
command current of the 2.WLD (2.%I), or
D current downslope time (DST) to determine the time span in which
the command current of the 2.WLD (2.%I) shall be reduced to the ”fi-
nal current”.

Please note:
D Current upslope and downslope times are always part of the 2nd cur-
rent block.
The current upslope time starts with the beginning of the 2nd current
block.
The current downslope time ends with the end of the 2nd current
block.
D Current upslope and downslope times are not influenced by an acti-
vated impulse mode or a possibly programmed 2.CT. I.e. they ignore
a possible 2.CT and proceed.
D If the sum of UST and DST is larger than the 2nd current block, the
command current in the 2nd block (2.%I) will never be reached! Fault
messages as e.g. ”current too low” appear.
D Please use, in connection with the slope, the fade-out time (refer to
page 3-18).

Example: 3 impulses including 2nd current block

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

20 ms = 1 cycle

Example: Slope in connection with impulse mode

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and Controls

Timer functions

3.3.4 Programmable Times

The schedule of a welding program depends on the use of different pro-
grammable time spans. Each time span serves a certain purpose within
the program schedule.

. With regard to time programming, PSI and PST differ from each
other:
PSI: spacing in 1 ms
PST: in line cycles (at 50 Hz: 1 line cycle corresponds to 20 ms
at 60 Hz: 1 line cycle corresponds to 16.6 ms)

Welding program execution without impulse mode in the 2nd current block:

1st current block 2nd current block 3rd current block

Start

2.WLD
1.SQZ SQZ 1.WLD 1. 3. 3.WLD HLD
CT CT
UST DST

Time

Current

Time

Welding program execution with impulse mode in the 2nd current block (example here: impulses = 3):

1st current block 2nd current block 3rd current block

Start

2. 2.
2.WLD 2.WLD 2.WLD
1.SQZ SQZ 1.WLD 1. CT CT 3. 3.WLD HLD
CT CT
UST DST

Time

Current

Time

Example of a time diagram with all programmable time spans

1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 3-9
and Controls

Timer functions

1.SQZ (1st squeeze time):

During the 1.SQZ, the welding gun must be closed completely. No cur-
rent flows in this time segment.
In all operating modes (single spot and seam mode), the 1.SQZ always
starts immediately after the start signal.

SQZ (squeeze time):

The squeeze time is used to build up the working force of the electrodes.
No current flows in this time segment.
The welding gun must be closed when the SQZ begins (see 1.SQZ).
The programmed squeeze time (SQZ) starts under the following condi-
tions only:
D High level at input X2/4 (if 0 V at X2/2)
(for required voltage, please refer to chapter 4.1 on page 4-1)

If this condition is missing, the welding program will be selected and star-
ted (and a possibly programmed 1. SQZ will begin), but the further pro-
cess will be delayed until this one condition is met (also refer to chapter
5.2.5 on page 5-7).

. The SQZ must always be higher than 0.

Shortest possible SQZ with PST: 1 cycle
with PSI: 16 ms.

. Within the SQZ, the timer checks, by measuring the ohmic resi-
stance, if the connected measurement circuit is faultless or not.
In case of an error (refer to page 5-11), the timer interrupts the wel-
ding program and deletes the output signal ”Control ready”.

. At the end of the SQZ, the timer checks the discrete input signal
”Welding circuit feedback” (I0). If the signal is missing inspite of
the discrete output ”Welding circuit enable” (O0) being set, the
error message ”Welding circuit 1 not closed” is generated.

1.WLD (1st weld time; preheating time)

Refer to page 3-5.

1.CT (1st cool time)

Separates the first from the second current block if the programmed va-
lue is higher than 0. Serves to relieve stress from the welded part.
Refer to page 3-4.

. The 1.CT can only be programmed if the 1.WLD is larger than 0.

3-10 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Timer functions

2.WLD (2nd weld time)

Refer to page 3-5.

2.CT (2nd cool time)

Separates the impulses from each other during impulse mode if the pro-
grammed value is higher than 0. Serves to relieve stress from the welded
part.
Refer to page 3-6.

. The 2.CT can only be programmed if the impulse mode is activated

(parameter ”impulses” > 1).

UST (Upslope time / Current upslope time)

Refer to page 3-7.

DST (Downslope time / Current downslope time)

Refer to page 3-7.

3.WLD (3rd weld time; postheating time)

Refer to page 3-5.

3.CT (3rd Cool time)

Separates the second from the third current block if the programmed va-
lue is higher than 0. Serves to relieve stress from the welded part.
Refer to page 3-4.

. The 3.CT can only be programmed if the 3.WLD is larger than 0.

HLD (Hold time)

Is used, in order to fix the welded part during cooling. Current has stop-
ped flowing in this time segment.
At the end of the HLD, the welding gun opens up. If there hasn’t been
detected any welding fault, the output signal WELD COMPLETE (WC)
will be output (refer to page 6-14).
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 3-11
and Controls

Timer functions

3.4 Regulation Modes

The weld timer provides the following regulation modes:
D Phase angle (PHA) and
D Constant Current Regulation (KSR ).

The allocation between program and regulation mode is very flexible:

Thus, two different regulation possibilities are available:
D Standard operation:
A regulation mode can be assigned to every welding program. The
set regulation mode is valid for all weld times of the program.
D Mixed operation:
Different regulation modes can be assigned to the program’s weld ti-
mes.

. Regulation and monitoring are separate functions! This is why the

current command values are separately parameterizable for regu-
lation and monitoring.
Please refer to chapter 3.6.1, page 3-15 ff.

3.4.1 Phase Angle (PHA)

Special case.
The operation mode PHA doesn’t provide for the regulation of an actual
variable (e.g. current), but triggers exclusively the power supply unit. In
the PST, this causes a triggering of the thyristors during the sinusoidal
half-wave (el. firing angle: 130 degrees to 30 degrees; the larger the fi-
ring angle, the less current flows in the secondary circuit); in the PSI, you
can thus influence the pulse width.

Features PHA:
D Currents are programmed in scale values (%I).
Programmable range: 0.0 to 100.0 scale values.
Programming resolution: 0.01 scale values
D No regulation.
D The resulting current in the secondary circuit depends on the elec-
trode/welded part contact resistance and the secondary voltage.
D A current sensor for measuring the actual current is not necessary.

. Current and time monitoring can be enabled in PHA mode.

Current monitoring though requires a current sensor (toroid).
3-12 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Timer functions

Mains

Weld transformer Electrodes

Programming:
Command current
value in %I (scale values)

Power supply unit

Current sensor
without current monito- only for dis- Actual current value (only necessary for
ring play purpo- current monitoring)
ses alternatively

with current monito-

Measured value Actual current value
ring
conditioning

Actual value display

Actual kA value
Mean phase angle
in %I (scale values)

Current monitoring

-Status
- Tolerance band -Faults
programmable refe-
rence current
(in kA)

Principle of the unregulated PHA operation

3.4.2 Constant Current Regulation (KSR)

Standard case (e.g. with robot guns).
In KSR mode, current regulation is activated. The actual current is mea-
sured and continuously compared to the programmed command cur-
rent. A series-connected controller processes the difference between
the command and the actual value and controls the phase angle/the
pulse width in the power supply unit in order to reach the command cur-
rent.
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and Controls

Timer functions

Features KSR:
D Currents are programmed in kilo Ampere (kA).
Programmable range: 0.5 to 250 kA
(can be limited by parameterization and the power supply unit in use).
Programming resolution: 10 A.
D The current in the secondary circuit is regulated.
D Eliminates the influence of the electric resistance on the weld process
in the secondary circuit (e.g. electrode/welded part contact resi-
stance).
D A current sensor for measuring the actual current is absolutely neces-
sary (please refer to page 5-10).

Programming: Mains
Command current value in kA
Weld transformer Electrodes
-
Controller

Power supply unit

Current sensor

Measured value Actual current value

conditioning

Actual value display

Actual kA value
Mean phase angle
in %I (scale values)

Current monitoring

-Status
- Tolerance band -Faults
programmable
reference current
(in kA)

Principle of the KSR regulation mode

3-14 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Timer functions

3.5 Current Prewarning and Limitation

3.5.1 Current Prewarning

Via the ”Current prewarning” parameter it is possible to indicate,
D from which scale value on the message ”Phase Angle Prewarning
has been reached” will be displayed.

This way, in KSR regulation mode, the timer can indicate e.g. an immi-
nent current limitation, caused by e.g. cable losses in the secondary cir-
cuit.

. The parameter value must be smaller than the current limitation va-
lue.

3.5.2 Current Limitation

. At first, parameterize the current prewarning.

Via the ”current limitation” parameter, you determine the minimum

phase angle (electric degree)
D in KSR mode by the controller’s command value and
D in PHA mode by programming.
To do so, please program the highest permissible scale value.

If the current limitation function reacts, the timer sends the message
”maximum phase angle”.

. The input value for the current limitation is absolute!

Therefore, the ”%I correction” function (see page 3-34) and the
”stepper” function (see page 3-27) might lead to an activation of
the current limitation.

. The parameter value must be higher than the current prewarning

value.
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 3-15
and Controls

Timer functions

3.6 Monitoring
The timer can monitor welding processes with regard to the following va-
riables:
D Current (please refer to chapter 3.6.1) and
D Time (please refer to chapter 3.6.2, page 3-20 ff).

Both monitor modes can be switched on and off separately.

Activated monitorings check the relevant actual value in comparison to
the programmed reference values and tolerance bands.
Since the variables current and time affect the heat within the spot, cor-
rectly set reference values and activated monitorings are essential mea-
sures and prerequisites for quality assurance.

. The reference values used for monitoring can be programmed in-

dependently from the regulation parameters.
A modification of the command values for regulation (closed-loop
control) does not affect the monitoring parameters!
Corresponding access rights allow the operator to set new refe-
rence values manually or accept a previously measured actual va-
lue as a new reference value.

3.6.1 Current Monitoring

. A current sensor is absolutely necessary for measuring the actual

current (please refer to page 5-10).

Tolerance range
Current monitoring compares the actual current that has been measured
by means of the r.m.s. value with the ”tolerance band”.
It depends on the programmed tolerance band whether the timer identi-
fies the measured actual current as ”good” or not. The following values
are decisive for the definition of the tolerance band:
D Reference current in kA
D Positive tolerance in % of the reference current
(Permissible upper tolerance band).
Actual values above the upper tolerance band lead to the message
”Current too high...”.
D Negative tolerance in % of the reference current
(Permissible lower tolerance band).
Actual values below the lower tolerance band lead to the message
”Current too low...” or ”No current...”.
3-16 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Timer functions

ÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇ
Current too high...
Permissible upper tole-
rance band (in %)

Tolerance Reference current in kA

band
Current ok

ÇÇÇÇÇÇÇÇÇ Permissible lower tole-

ÇÇÇÇÇÇÇÇÇ
Current too low.../no current... rance band (in %)

Principle: Tolerance band

Conditional permissible tolerance band

In addition to a ”good/bad” statement, it is often desirable to be informed
about the trend of the actual current values in time. In this regard, slow
but continuously increasing actual current values in the lower segment
of the tolerance band are especially interesting: Slowly developing er-
rors in the system (e.g. slowly increasing cable resistance within the
measuring circuit prior to a cable break) can lead to such effects. It is also
possible that not perfectly set reference current values are the cause for
actual current values in the lower segment of the tolerance band.

Therefore, the following additional parameters are at your disposal in

connection with the tolerance band:
D Conditional permissible tolerance band (in % of the reference cur-
rent) and
D ”Repeat factor”.
The parameter ”conditional permissible tolerance band” determines the
upper limit of the conditional permissible tolerance range. The lower limit
is defined via the parameter ”permissible lower tolerance band”.
The ”repeat factor” determines, how many consecutive spot welds may
lie in the conditional permissible tolerance range.
If this value is exceeded, the timer sends the message ”Current too low
for a series of welds”.

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
Current too high...
Permissible upper tole-
rance band (in %)

Reference current in kA
with regard to one
single measure-
ment:
Current ok Conditional permissible to-
Conditional per- lerance band (in %)

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
missible tole-
Permissible lower tole-
rance band

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
rance band (in %)
Current too low.../no current...

Message ”Current too low for a

Performed spot welds series of welds”

Example: Principle of the Conditional Tolerance Band with Repeat Factor = 4

1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 3-17
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Timer functions

. Messages can be defined either as a ”welding fault” or as a ”war-

ning”. An event that has been defined as a ”warning” does not lead
to a blocking of the timer. A ”welding fault” though always requires
a ”Fault reset” (see page 6-6) in order to start the next welding pro-
cess.

Current monitoring modes

Since there are 3 programmable independent current blocks (refer to
page 3-4), current monitoring should be flexible and easy to handle.
Therefore, the two different monitoring modes ”Standard” and ”Mix” are
available:

D Standard operation:
The entire current profile (1st, 2nd, and 3rd current block, cool times
included) is part of the r.m.s. value measurement.
It will be represented by one actual value and monitored by one tole-
rance band only.
Because of this simple, but most of the time sufficient monitoring
mode, the quantity of data to be processed remains small, but possi-
ble cool times and different currents within the individual blocks
change the measurement result.
In this case, the reference current should be measured via sample
welds. If you use the 2.WLD only and no impulse mode, you can enter
the command current programmed for the regulation as the reference
current.
Tolerance band
Reference
current

1st * *
block 3rd block

1.WLD 1.CT 2nd block 3.CT 3.WLD

*: 2.CT
Measuring time

Principle of the monitoring mode ”Standard”

D Mixed operation:
The r.m.s. value will be measured separately for each current block
and monitored by the current blocks’ own tolerance bands (for 1st,
2nd, and 3rd current block). Programmed cool times are not taken into
consideration when calculating the actual value for each current
block.
This leads to a better transparency for the single current blocks, but
the quantity of data to be processed is larger.
In mixed operation, you can always use the command currents pro-
grammed for regulation as the reference currents.
3-18 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Timer functions

Reference current
Refe-
rence Refe-
current rence
1st current
block 3rd block

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

: Tolerance band Measuring time 2 = t1 + t2 + t3

Principle of the monitoring mode ”Mix”

Fade-out time and trail current

The above descriptions of the current’s temporal schedule are ideal ca-
ses (rectangular form). In reality though, the current recovers and de-
cays at the beginning and the end of a weld time. These effects have an
influence on the r.m.s. value measurement.
With the functions ”Fade-out time” and ”Trail current”, you can affect the
measurement specifically.

D Fade-out time:
Indicates, for how long after the start of a weld time, measured current
values are not to be taken into consideration for the calculation of the
r.m.s. value. This way, if set correctly, you can fade out the entire
transient recovery process.
Use of fade-out time:
- in connection with the ”Slope” function (refer to page 3-7):
please program the same value for the fade-out time as for the cur-
rent upslope time (UST);
- when welding thick sheets and when the use of a deeply immers-
ing welding gun (gun reaches far into the material) is necessary;
- in connection with current scaling:
Measuring instruments for the reference welding current are pro-
vided with a ”fade-out function” as well (e.g. Miyatchi: ”First Cycle”;
indication from which cycle of the weld time on measured values
shall be taken into consideration).
For current scaling, make sure that the measurement instrument
in use is set to the timer’s currently parameterized fade-out time.

D Trail current:
Indicates if the decaying process after the end of the weld time shall
be taken into consideration for the calculation of the r.m.s. value (trail
current ON).
In connection with fade-out times higher than ”0”, this may result in
the determination of too low r.m.s. currents when calculating the mea-
sured value, even though the absolute command current in steady
state has been reached.
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 3-19
and Controls

Timer functions

Current

Time

Fade- Trail cur-

out time rent

Weld time

Fade-out time and trail current

The programmed fade-out time always starts

D at the beginning of a current block
D at the beginning of an impulse.

An activated trail current always starts

D at the end of a current block
D at the end of an impulse.

2nd block

1st
block 3rd block

Fade-out time:
Trail current:

Starting points of the fade-out time and the trail current

. The programmed fade-out time is identical for all weld times and for
all welding programs!
Therefore, please make sure, that the fade-out time is always smal-
ler than the smallest programmed weld time.

. An activated trail current is valid for all weld times and all welding
programs.

. If for your application the only quality criteria is the heat introduced
into the spot weld (heat: Q 9 i2 x t x R), please program the fade-out
time with the value ”0” and switch ON the trail current.
3-20 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Timer functions

3.6.2 Time Monitoring

Time monitoring is separately adaptable to each program and compares
the actual time necessary for the complete current profile to a program-
med reference time.
As actual time we understand the time span from the beginning of the
first current block till the end of the last current block, cool times included.
This way, you can avoid the execution of too big weld time changes in the
individual welding programs.
The following values are decisive for programming the time monitoring
function:
D Time monitoring ON/OFF
D Reference time
D Permissible time deviation from the programmed reference time.
Actual times above the permissible time deviation lead to the mes-
sage ”Weld time too long...”.
Actual times below the permissible time deviation lead to the mes-
sage ”Weld time too short...”.

Permissible time deviation

1st * *
block 3rd block

1.WLD 1.CT 2nd block 3.CT 3.WLD

*: 2.CT
Reference time

Principle: Time monitoring

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Timer functions

3.6.3 Monitor Stepper

. A current sensor is absolutely necessary for measuring the actual

current (please refer to page 5-10).

It serves when executing the electrode maintenance functions

D ”Stepper” (refer to page 3-27) and
D ”Electrode tipdressing” (refer to page 3-27)
for monitoring the programmed %I stepper.
This way, you can avoid the execution of too big changes in the individual
stepper or tipdressing curves.
With an activated stepper, the timer changes the programmed command
current in dependence of the electrode wear.
The ”Monitor Stepper” gives you the possibility to program, separately
for each singular stepper or tipdressing curve, stepper values in percent
which then will be taken into consideration as reference values for the
monitoring process.

3.7 Interlock
In the welding operation mode ”single spot”, the timer goes into ”Inter-
lock” upon the end of the SQZ. While in ”Interlock”, the 1., 2., and 3.WLD
and the HLD are processed even after the input signal ”Start” has been
reset.

. ”Interlock” can be interrupted only by opening the stop circuit (see

page 5-14).

. In the welding operation mode ”seam mode”, there is no ”Inter-

lock”. If the input signal ”Start” is reset during a weld time, the timer
terminates the cycle that has just begun and continues with the
hold time.

For more information regarding ”Interlock”, please refer to input signal

START on page 6-2.
3-22 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Timer functions

3.8 Measuring Circuit Test

This function checks the measuring circuit for interruptions and short cir-
cuits during the squeeze time (see page 5-11). This way, errors in the
cables/current sensor can be detected in time.
If an error is detected, the weld timer interrupts the current welding pro-
gram before entering the first programmed weld time and generates a
corresponding message (”measuring circuit open” or ”short circuit in
measuring circuit”).

To activate the function, switch parameter ”Measuring circuit test” to

”On”.

Conditions:
D The parameter ”monitoring stopped” is switched off and
D the function ”current monitoring” (refer to page 3-15) is activated.

. Messages can be defined either as a ”fault” or as a ”warning”. An

event that has been defined as a ”warning” does not lead to a blok-
king of the timer. A ”fault” though always requires a ”Fault reset”
(see page 6-6) in order to start the next welding process.

CAUTION
Welding current might be too high!
Both messages must always be defined as a ”fault”.
Otherwise the controller receives no or erroneous information ab-
out the actual value. This might result in the controller triggering
the power supply unit fully.
After 40 ms at the latest, the welding schedule will be interrupted
with the message ”weld time termination/no current” (”no cur-
rent”: refers to the measured actual value).
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Timer functions

3.9 Limitation of the 1st Half Cycle (for PST only)

The activation of the first current half cycle can be limited in order to pro-
tect the weld transformer and the thyristor power supply unit.

Example: A command value of 55 scale units means that

D in welds with smaller command currents (0 to 55 scale units), the 1st
half cycle is not affected
D with higher command currents (> 55 scale units), the 1st half cycle is
limited to 55 scale values.

For programming you have 2 parameters at your disposal:

D ”Limit 1. half cycle”:
Parameter affecting the entire module.
Only the first half cycle of a weld is limited.
D ”1. Half-cycle after cool time”:
Can be set separately for each welding program.
The first half cycle of each weld time or each impulse is limited if pre-
viously a cool time has been programmed > 0.
3-24 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Timer functions

3.10 Automatic Spot Repetition

This function serves to reduce necessary user intervention in the case of
occasional ”current too low...” or ”no current...” welding faults.
Conditions:
D Current monitoring is activated and
D the function ”monitoring stopped” is switched off.

The function ”Automatic spot repetition” can be switched on and off se-
parately for each welding program via the parameter ”Spot Repeat”.
If the automatic spot repetition is activated, the timer is able to repeat -
starting with the SQZ - an erroneous welding process automatically
once, in case of a ”current too low...” or ”no current...” message. In this
case, the gun remains closed after the erroneous process and program-
med squeeze time, weld times, and hold times are repeated.
If the repetition leads to a correct weld, the welding station continues its
normal process afterwards. If during repetition, another error is detec-
ted, a corresponding message will be displayed (”Current too low...”, ”no
current...”).

If automatic spot repetition is activated, bad fittings or not perfectly lying

electrodes might lead in extreme cases to a repetition of each single spot
weld. I.e.: the clock time might increase very fast and maybe even unno-
ticed.
Therefore, the timer provides the parameter ”Max. repetition” (highest
permissible amount of spot repetitions in sequence).
An internal counter will always be reset to 0 if a welding process has
been successful straight away. Otherwise, if the value falls below the
”permissible lower tolerance band” and the automatic spot repetition is
activated, the counter will be incremented.
Automatic spot repetition will only take place if the internal counter value
is smaller/equals the ”max. repetition” parameter. If this is not the case,
the timer generates the message ”Current too low for a series of welds”.

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
Current too high...

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
Permissible upper tole-
rance band (in %)

Current ok Reference current in kA

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ Permissible lower tole-

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
rance band (in %)

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
: Welds that have
been activated Current too low.../no current...
by automatic
spot repetition. Message ”Current too low
Welds for a series of welds”

Example: Principle of the automatic spot repetition with ”max. repetition” = 4

1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 3-25
and Controls

Timer functions

. Messages can be defined either as a ”fault” or as a ”warning”. An

event that has been defined as a ”warning” does not lead to a blok-
king of the timer. A ”fault” though always requires a ”Fault reset”
(see page 6-6) in order to start the next welding process.

3.11 Electrode Maintenance

During their life, electrodes are subject to a process-related wear (see
chapter 3.11.1) which can be noticed by e.g. an enlargement of the elec-
trode’s contact point.

Wear

Enlargement of the contact point caused by electrode wear

To compensate for this effect, the timer provides two different procedu-
res:
D ”Automatic stepper” (refer to page 3-27) and
D “Electrode tipdressing” (refer to page 3-27).

Both procedures can be activated either separately or combined.

3.11.1 Wear Factor and Wear per Welded Part

The wear of the electrodes depends on different factors, like e.g. pro-
grammed current, thickness and material of the welded part.
As long as you perform welds of only one type of material with the same
thickness and the same current during the life of an electrode, it can be
easily predicted, after how many welds the electrode is worn and must
be exchanged. The electrode wear can be displayed by means of a ”spot
counter”. The spot counter will be incremented by ”1” after each perfor-
med welding process.
If the parts that are welded during an electrode life consist of different
materials or different gauges, the wear per spot weld is not constant. In
this case, a spot counter is not sufficient anymore.
3-26 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Timer functions

Therefore, the wear of an electrode in the timer is monitored via a ”wear

counter”.
To do so, the timer increases the wear counter by the ”wear factor” after
each welding process. The wear counter cannot only be incremented by
”1” (as for the spot counter), but by any value.
Since you can enter the right wear factor for the weld in each program, a
correct measurement of the electrode wear is guaranteed.

Wear per part

Via the parameter ”Wear/Part” you can enter the electrode wear that is
caused by the welding process of one single piece. With this variable, the
timer can calculate how many pieces can be welded with the electrode
until the end of stepper (maximum electrode life). The amount of the re-
maining parts will be displayed in the ”Prewarning table” (see page
3-28).

Example:
A piece needs 6 welds.
Each spot weld (P1 to P6) is produced by a separate welding program
(Prog1 to Prog6).
For the upper spots (P1 to P3), 2 sheets must be welded, for the lower 3
spots (P4 to P6) 3 sheets.
The electrode wear for the spot welds P4 to P6 is higher (thicker mate-
rial). Therefore, the program-specific wear factor in Prog1 to Prog3 must
be programmed with ”1”, while the wear factor in Prog4 to Prog6 is ”1.5”.
The wear per piece is therefore 7.5.

. The wear factors in this example have only exemplary meaning. In

reality the wear factors for the materials and gauges in use will be
calculated in advance.

Wear counter:
0 1 2 3
(New electrodes)

P1. P2. P3.

WF=1 WF=1 WF=1

P6. P5. P4.

WF=1.5 WF=1.5 WF=1.5

WF: Wear factor 7.5 6 4.5

Example: Calculation of the wear

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Timer functions

3.11.2 %I Stepper (Stepper)

The stepper function keeps the current density in the spot weld constant
while during the electrode’s life, the spot weld becomes larger and larger.
To do so, you can define separate stepper curves for up to 10 different
electrode types. A stepper curve determines the percentage with which
the programmed command current should be increased automatically in
dependence of the current electrode wear.

Increase of current in %
(in relation to the programmed current) Highest permissible
wear
100

Stepper curve

Wear
0

Principle: %I stepper

. The resulting current modifications can be monitored by the func-

tion ”Monitor Stepper” (refer to page 3-21).

3.11.3 Electrode Tipdressing

With electrode tipdressing you can periodically restore the desired con-
tact area during the electrode’s life.
Therefore, after a certain wear, the electrodes must be treated in a tip-
dressing station for electrodes.
The timer uses the output signal ”tipdress request” (see page 6-17) to
request electrode tipdressing.

The additional possibility to define up to 10 different tipdressing curves

offers a perfect adaptability to different types of electrodes. A tipdressing
curve determines the percentage with which the programmed command
current should be increased automatically in dependence of the current
electrode wear.
. The resulting current modifications can be monitored by the func-
tion ”Monitor Stepper” (refer to page 3-21).

. The initial dressing function can be activated via parameter ”tip-

dressing of new electrodes”.
If initial dressing is activated, the timer requests immediate tip-
dressing if an electrode has been exchanged (refer to “Initial dres-
sing request”, page 6-13).
With freshly inserted electrodes this serves e.g.
- to create a defined weld spot diameter
- to create a defined contact angle
- to eliminate a protective sheet.
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Timer functions

3.11.4 Prewarning and End of Stepper

When the highest tolerable wear has been reached, new electrodes
must be inserted.
Here, the output signals
D ”Prewarning” (see page 6-18) and
D ”End of stepper” (see page 6-18)
are at your disposal. They shall only be used if the electrode mainte-
nance functions are activated (parameter ”Stepper”: ON).

3.11.5 Prewarning Table

The prewarning table offers you an overview with fast access to all im-
portant information and operations regarding electrodes with an activa-
ted electrode maintenance function:
D Weld timers, to which the individual electrodes have been assigned.
D Current wear (in percent, numerical, and graphical).
The graphic illustration is color coded. This way, upcoming prewar-
nings, tipdress requests, or the end of stepper can be easily recogni-
zed.
D Remaining parts that can still be welded with the relative electrode.
D Reset of one or more wear counters after the cap has been exchan-
ged.

3.12 Electrode Force

The indication which force the electrodes shall use to press the welded
parts together (in kilonewton: kN) is part of any welding program.
Therefore, the timer generates - with an internal characteristic curve -
for each programmed force value a corresponding output signal that can
be used as an actuating variable for the electrode’s force.

In order to output the force actuating variable,

D an analog signal is at your disposal at X2. For more information,
please refer to page 5-7.

The internal characteristic curve can be created either

D automatically by force scaling (please refer to chapter 3.13.1, page
3-30 ff).
or
D manually with the parameters ”conversion factor” and ”zero adjust”.
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Timer functions

”Conversion factor” (in kN/Volt):

With this factor, the timer calculates the output value of the actuating va-
riable for the force. See illustration.
”Zero adjust” (in kN):
Moves the zero crossing of the characteristic curve. This way the cha-
racteristic curve can be adapted to the working zero of the actuator sy-
stem in use. See illustration.

Programmed
force in kN

”max. force”

+
Zero
adjust

-
0 Actuating varia-
ble for force
”Max. force”: the parameter limits the hig- Highest actuating va-
hest possible programming of the electrode riable for force to be
force within the welding program. output
(dependent on hard-
ware: at X2 e.g. 10V)

Progr. force value (in kN) + zero adjust (in kN)

Actuating variable for force =
Conversion factor (in kN/Volt)

Characteristic curve for output of force value

. In order to make the programmed force work on the electrodes, it is

necessary to set the characteristic curve properly!

. During force scaling, the timer automatically calculates the neces-

sary values for the parameters ”conversion factor” and ”zero ad-
just”. After that, the parameters may not be altered manually!

In addition to the possibility to program an electrode force that is con-

stant for the entire welding process, the timer also offers the following
functions:
D Force profile:
It is possible to program 10 different force values for each welding
program. These force values can then be activated at certain times
within the welding process.
D Force Stepper:
Depending on the selected stepper or tipdress curve, you can deter-
mine the percentage with which the programmed basic force value
should be increased in dependence of the current electrode wear.
3-30 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Timer functions

3.13 Scaling

. Always scale the force first, then the current!

3.13.1 Force Scaling

With the function ”force scaling”, you adjust all components of the wel-
ding station that are part of the force build-up to their reference dynamo-
meter (e.g. force transducer). This bears the following advantages:
D Presetting the gun force in kilonewton (kN)
D Exact reproducibility of logged force values (ISO 9000)
D Force values of all scaled stations can be compared to each other and
transferred to other stations
D Comparable documentation.

. Basically, the timer also works without force scaling. But you can
only benefit from the above mentioned advantages after a force
scaling procedure.

CAUTION
Gun damages possible!
If you don’t use force scaling, the timer cannot make a correct con-
nection between the programmed force and the actuating variable
for force that is to be output (necessary for controlling the force
of the gun).
Therefore, the force that actually works on the gun can deviate im-
mensely from the programmed force.
The consequences might be erroneous welds and even damages
to the gun.
If you don’t use the force scaling function, it is absolutely neces-
sary to calculate empirically, after each gun exchange, the basic
force value for each required electrode force - starting with the va-
lue ”0”.

Prerequisites for force scaling:

D Proportional control valve, servo gun, or other suitable equipment
that can convert the timer’s actuating variable for force into a mecha-
nical force at the gun.
D External reference dynamometer with appropriate measuring range.
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and Controls

Timer functions

For force scaling, preset 2 different force actuating values in % (in rela-
tion to the highest value that can be output), use the reference dynamo-
meter to measure the resulting forces between the electrodes, and enter
the measured forces (in kN) into the timer.
The timer then calculates internally all data necessary for the adjust-
ment.

When executing the force scaling function, please pay special attention
to the following:

L For the two actuating values used for force scaling, the following is appli-
cable:
If possible, the higher value shall generate the maximum force used for
welding (upper end of the force working range).
Both values should differ from each other by at least 20%. The force re-
quired for electrode tipdressing is not to be assigned to the normal wor-
king range (because most of the times it is lower).
If you do not know which value is to be entered for force scaling, use
small values to execute sample scalings in order to see which forces will
be generated at the gun. This way, you make sure not to overstress or
damage the gun when force scaling. Then, slowly increase the preset
value while executing further force scalings until the higher preset value
generates the maximum force that you can use for welding.

L Please use for all comparable stations the same reference dynamome-
ter.

L Execute for each gun in the welding station and after each gun exchange
a scaling procedure.

L Verify an executed scaling by comparing the basic force values pro-

grammed in test welding programs with the actual values at the gun.
Make sure that the test programs run without current and that people
are safe during the measurements (possible danger caused by robot
movements).

L Execute a new scaling if a component actively participating in force ge-

neration (weld timer, proportional control valve, gun...) has been ex-
changed.

. Force scaling changes the parameter ”Conversion factor” and

”Zero adjust” (in electrode setup, also refer to page 3-28). There-
fore, after a force scaling procedure, the parameters may not be
manually altered!
3-32 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Timer functions

3.13.2 Current Scaling

The function ”Current scaling” serves to adapt the timer’s entire measu-
ring and control loop to your reference welding current measuring instru-
ment. This bears the following advantages:
D Reproducible, presettable currents with a maximum error below
+/-2%
(in relation to the current value of the reference welding current mea-
suring instrument)
D Exact reproducibility of logged current values (ISO 9000)
D Currents of all scaled stations can be compared better to each other
and transferred to other stations
D Comparable documentation.

. The timer also works without current scaling.

But you can only benefit from the above mentioned advantages af-
ter a current scaling procedure.

Prerequisites for current scaling:

D A current sensor connected to X3 (see page 5-10).
D External reference welding current measuring instrument with cur-
rent sensor.

. Before executing a current scaling always execute a force scaling

procedure (see page 3-30).

For current scaling, preset 2 different currents in scale values, then use
the reference welding current measuring instrument to measure the re-
sulting currents in the secondary circuit, and enter the measured current
values into the timer.
The timer then calculates internally all data necessary for the adjust-
ment.

When executing the current scaling function, please pay special atten-
tion to the following:

L Make sure that the current sensor of the reference welding current mea-
suring instrument is installed correctly in the secondary circuit. This
means:
- always install it in the same place
- install it vertically with regard to the current carrying conductor
- the sensor cable faces away form the current carrying conductor.

L For the two currents (in scale values) used for current scaling, the follo-
wing is applicable:
If possible, the higher value should lie at the upper end of the normal wor-
king range of your weld station.
Both values should differ from each other by at least 20 scale values.
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 3-33
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Timer functions

L Please use for all comparable stations the same reference welding cur-
rent measuring instrument.

L Set your reference welding current measuring instrument to the right

type of current (”AC” for PST, ”DC” for PSI) and set the appropriate mea-
suring range.

L Programmed fade-out times and an activated trail current are also effec-
tive during current scaling!
Therefore, prior to the scaling procedure, please check if the correspon-
ding functions are available and correctly set in your measuring instru-
ment.

L Always scale without a welded part and with closed electrodes.

L Execute for each gun in the welding station and after each gun exchange
a scaling procedure.

L Verify an executed scaling by doing a test weld comparing the current

shown in the timer with the current shown in the reference welding cur-
rent measuring instrument.

L Execute a new scaling if a component actively participating in the control

loop (weld timer, transformer, sensor...) has been exchanged.
3-34 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Timer functions

3.14 Corrections
The timer’s correction functions allow
D changes of current and
D changes of force (electrode force).

This way you can quickly execute process-related adjustments and

adaptations of the welding process without changing the originally pro-
grammed data. The corrections function as an addition to the program-
med basic values.

You can activate both types of correction

D for a certain electrode/gun (= Corr. (E)) and
D for individual programs or individual program sectors (= Corr. (P)).

. When the current correction is changed, the reference current that

is to be monitored will also be internally adjusted.

. The correction values can be limited in the basic settings. This limit
can be set within the range of +/-20%.

3.15 Weld Transformer Selection (PSI only)

In order for the PSI’s power supply unit to function correctly, the timer
must ”know” certain technical data about the weld transformer in use.
Therefore, the proper setting of certain parameters in the ”Weld Trans-
former Selection” is necessary:

When using PSG weld transformers:

D ”Type”:
Model of the PSG transformer according to name plate (e.g.
”PSG 3100.00”) and
D ”Number”:
Number of parallel transformers.

With this data, the PSI knows the type of the diodes, the diode selection,
and the highest permissible current for the welding station.

When using other weld transformers:

D ”Type”:
Please switch to ”Other transform.”.
D ”Number”:
Number of parallel transformers.
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Timer functions

D ”Transformer secondary current”:

Maximum secondary current of the transformer. The maximum wel-
ding current is limited to this value.
D ”Transformation ratio”:
Transformation ratio primary/secondary. This parameter is neces-
sary for converting primary and secondary current if for current mea-
suring you use the current sensors integrated in the primary circuit
(primary current regulation; used e.g. with transformers without inte-
grated KSR sensor).
D ”Number of diodes”:
Number of diodes connected in parallel in the secondary circuit.
D ”Type of diodes”:
Type of diodes used in the weld transformer.

Diode monitoring:
The parameter ”diode monitoring” is used to switch the monitoring func-
tion of the weld transformer in the secondary circuit on and off.

CAUTION
Destruction of the power supply unit and/or the weld transformer
is possible!
If diode monitoring is switched off, the PSI ceases to monitor the
diodes in the weld transformer. Under a high load this can lead to
major damages to the welding station.
Therefore, always turn diode monitoring on!
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Timer functions

Notes:
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 4-1
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Technical data

4 Technical data

4.1 Integrated weld timer

Degree of protection IP 20
Operating voltage +24 VDC ; +20 %, -15 %
with max. +/-5 % ripple
Rated current at 24 V PSI: approx. 1.5 A
(without I/O module and without PST: approx. 1.0 A
additional consumers at X5)
Starting current PSI: approx. 2.0 A for 10 ms
(without I/O module and without PST: approx. 1.5 A for 10 ms
additional consumers at X5)
Operating temperature 0 ... +55 °C
Temp. for storage/transportation -25"... +70°C
Air pressure 0 to 2000 m above sea level
Humidity condensation not permissible.
Climatic category 3K3 to EN60721-3-3
Number of programs max. 256;
the programs can be referenced via
the spot assignment
Programming on location V24/RS232 interface, isolated.
X1 connection: 9-pin D-Sub
Fieldbus for programming PROFIBUS-FMS or
(option) INTERBUS-PMS or
Ethernet
Operating software (firmware) Stored in Flash-Memory;
can be loaded via ”WinBlow” soft-
ware package (optional)
Program memory buffered RAM memory
Backup battery Lithium battery Type AA 3.6 V
to buffer RAM data and internal
clock with MAINS OFF.
Battery life approx. 2 years.
Pressure control for analog output (at X2):
proportional valve 0 to +10 V, max. 20 mA or
0 to 20 mA or
4 to 20 mA (at max. 500 ohms).
Input feedback (at X2):
logic 1: +16 V ... +30 V, 20 mA
logic 0: -1 V ... +4 V
Electrodes max. 32 (no. 0 to no. 31)
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Technical data

4.2 I/O Module ”DEV-NET”

Function:
Connection of the timer’s I/O to the higher-level PLC or the robot
D via DeviceNet with bus copper cable (serial I/Os) and
D via discrete 24 V signals at X11 and X12 (parallel I/Os).

Operating voltage (at X10) +24 VDC +20 %, -15 %

with max. +/-5 % ripple
Current input max. 2 A
depending on the wiring of the signal
in-/outputs
Power loss 0.5 VA per active input
2.4 VA per active output
Signal input field via DeviceNet 4 byte, max. 32 signals (0 to 31)
Signal output field via DeviceNet 4 byte, max. 32 signals (0 to 31)
Signal inputs (X12) logic 1: +16 V ... +30 V, 20 mA
logic 0: -1 V ... +4 V
Signal outputs (X11) +24 V, max. 0.1 A,
short circuit-proof
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Electrical connection

5 Electrical connection

5.1 Suppression of RF noise

Interferences (RF noise) are caused by transient peaks and can be
spread into the timer either directly or by coupling via connecting lines.
Therefore, interference suppression measures are necessary.

L Eliminate interferences already at their source. If this is not possible, in-

stall the interference suppression devices as close to the interference
source as possible.
L Make sure that all components that contain inductivities or switch ele-
ments are properly cleared.
L Install interference suppression devices always in such a way that they
cannot break since machines are often subject to strong vibrations.

DIODE RC ELEMENT

+ ∼
GND MP

Diode, suitable for small DC relays RC element for AC relays and

AC motors

DIODE AND ZENER DIODE RC ELEMENT

+
GND

DI-ZD attenuation element for large DC RC element for spark quenching of

contactors and defined drop-out times inductive loads

Examples of interference (noise) suppression

. The following table is only an example. The dimensions of the ne-

cessary modules depend on the actual load ratios.

Resistor Capacitor Diode

24 VDC - - 1 N 5060/ZL 12
48 VDC - - 1 N 5060/ZL 22
110 VAC 220 ohms / 1 W 0.5 mF 400/600 V
220 VAC 220 ohms / 5 W 0.1 mF 500 V
440 VAC 220 ohms / 5 W 0.1 mF 1000 V
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Electrical connection

5.2 Integrated weld timer

. For technical data, please refer to chapter 4.1, on page 4-1.

5.2.1 Output of the Internal 24 VDC Voltage Source (X4)

Connection: at X4; plug-in terminal, spacing 3.5 mm, 14-pin,
max. 1.5 mm2.
Mating connector included in shipment.
Cable length: (From the voltage source to the consumer)
max. 10 m with 0.75 mm2
max. 75 m with 1.5 mm2
Type of cable: unshielded, VDE 0281, 0812 (e.g.: Ölflex)
At X4, a 24 VDC supply voltage that the power supply unit derives from
the mains voltage is at your disposal.

. The supply through the internal 24 VDC voltage source and there-
fore the functionality of all devices fed from this source is guaran-
teed only if mains voltage is applied at the mains input of the power
supply unit!

Timer
X4 max. 2.5 A

+ 24 VDC 5 May be used, e.g., for

power supply of timer lo-
gics and of I/O module
0V 8

Internally generated 24 VDC power supply

L Please consider the following facts when using the internal 24 VDC vol-
tage source:
D max. current load: 2.5 A
D When supplying the timer logics:
If you switch off the mains voltage at the mains input of the power sup-
ply unit, you automatically switch off the timer as well. In this state,
- neither programming, diagnosis, or visualization via the timer
- nor communication between timer and PLC/robot is possible.
D When supplying the I/O module:
If you switch off the mains voltage at the mains input of the power sup-
ply unit, you automatically switch off the I/O module as well. In this
state,
- communication between timer and PLC/robot is not possible any-
more.
. If the above describe facts are not compatible with your applica-
tion, the 24 VDC supply of timer or I/O module must be provided by
external power supply units.
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Electrical connection

5.2.2 Supply of the Timer Logics (X4)

Connection: at X4; plug-in terminal, spacing 3.5 mm, 14-pin,
max. 1.5 mm.
Mating connector included in shipment.
Cable length: (From the voltage source to the consumer)
max. 10 m with 0.75 mm2
max. 75 m with 1.5 mm2
Type of cable: unshielded, VDE 0281, 0812
(e.g.: Ölflex)
The timer logics must be supplied with 24 VDC.

Timer
X4

10 24VDC
int. logics
Supply of the internal timer
11 0V logics

Logics supply input of the timer

The remaining wiring of X4 determines which voltage source supplies

the timer. You can select
D either the internal voltage source (refer to page 5-2) or
D an external power supply unit.
To do so, you only have to set/remove some jumpers at X4.

. For more information about the interconnections of X4, please re-

fer to chapter 5.2.4 on page 5-4 ff.

While a supply through the internal voltage source is preferred in standa-

lone installations (e.g. suspended welding station; additional 24 VDC
power supply units are not necessary), a supply via external power sup-
ply units is mainly used in networked timers (timer can be programmed
even if the welding network has been switched off e.g. via the line PC).

L If you use external voltage sources, please make sure that they are spe-
cified as ”safely separated” according to the Low-Voltage Directive
(72/23/EEC, 93/68/EEC and 93/44/EEC)!
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Electrical connection

5.2.3 Supply of External Devices (X5)

Connection: at X5; plug-in terminal, spacing 3.5 mm, 2-pin,
max. 1.5 mm2.
Mating connector included in shipment.
Cable length: Depends on the wiring at X4. See description
below.
Type of cable: unshielded, VDE 0281, 0812 (e.g.: Ölflex)
X5 is at your disposal for the 24 VDC supply of an external device (e.g.
force sensor).
The maximum current load/cable length at X5 depends on the voltage
source in use and the entire length of the cable between source and ex-
ternal consumer. The maximum current load at X5 must not exceed
0.5 A.

Timer
X4

10 24VDC Supply of
Int. logics - the internal timer logics and
11 0V
- X5
External
X5 consumer
max.
0.5 A 1 24VDC

2 0V

Connection of external devices to X5

L Make sure not to exceed the limit values specified for current load
(source, connections) and cable lengths!

. The remaining wiring of X4 determines which voltage source sup-

plies X5.
You can use either the internal voltage source (see page 5-2) or an
external power supply unit. To do so, you only have to set/remove
some jumpers at X4.
For more information about the interconnections of X4, please re-
fer to chapter 5.2.4 on page 5-4 ff.

5.2.4 24 VDC Voltage Distribution (X4)

Connection: at X4; plug-in terminal, spacing 3.5 mm, 14-pin,
max. 1.5 mm2.
Mating connector included in shipment.
Cable length: (From the voltage source to the consumer)
max. 10 m with 0.75 mm2
max. 75 m with 1.5 mm2
Type of cable: unshielded, VDE 0281, 0812 (e.g.: Ölflex)
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and Controls

Electrical connection

The internal circuit of X4 facilitates the wiring of the 24 VDC supply bran-
ches for the timer and the I/O module substantially. By plugging or remo-
ving certain jumpers, you can realize different supply variations without
altering the remaining wirings in the switch cabinet.
To do so, connect the relevant voltage source to X4/6 (24 VDC) and X4/7
(0 V).

Below you find descriptions of some possibilities. On the next page, you
find the corresponding illustrations representing the appropriate wiring.
Which kind of wiring is suitable for you, depends on the requirements of
your application.

1. Timer and I/O module are fed by an internal 24 VDC voltage source.
Application: Used preferably in standalone installations.
Advantage: Separate power supply units are not necessary.
Disadvantage:24 VDC will only be generated if the mains voltage is
present at the power supply’s mains input.
2. The I/O module is fed by an internal 24 VDC voltage source, the timer
is fed by an external power supply unit.
Application: Used in networked installations.
Advantage: Programming, diagnosis, and visualization are still
possible even after the mains voltage at the power
supply unit’s mains input has been switched off.
Electrical isolation between timer and I/O module with
discrete in-/outputs (parallel I/O) is possible.
Disadvantage:If you switch off the mains voltage at the mains input of
the power supply unit, I/O communication between
timer and PLC/robot is not possible anymore.
3. Timer and I/O module are both supplied by a mutual external 24V
power supply unit.
Application: Used preferably in networked installations.
Advantage: I/O communication between timer and PLC/robot,
programming, diagnosis, and visualization are still
possible even after the mains voltage at the power
supply unit’s mains input has been switched off.
Disadvantage:Electrical isolation between timer and I/O module with
discrete in-/outputs (parallel I/O) is not possible.
4. Timer and I/O module are both supplied by separate external 24V
power supply units.
Application: Used in networked installations.
Advantage: I/O communication between timer and PLC/robot,
programming, diagnosis, and visualization are still
possible even after the mains voltage at the power
supply unit’s mains input has been switched off.
Electrical isolation between timer and I/O module with
discrete in-/outputs (parallel I/O) is possible.
Disadvantage:2 external power supply units are necessary.
5-6 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Electrical connection

Version 1: Version 2:

Timer Timer

X4 X4
1 to I/O module 1 to I/O module
(see page (see page
2 5-13) 2 5-13)
3 Stop circuit 3 Stop circuit
(see page (see page
4 4
5-14) 5-14)
24VDC 24VDC
5 5
Inter- Inter-
nal 6 nal 6
vol- 7 vol- 7
tage tage
source 8 source 8
0V 0V
9 9
24VDC 10 24VDC 10 24VDC
Internal Internal
logics 11 logics 11 0V
0V 0V
12 12 External
p.s.u.

p.s.u. = power supply unit

Version 3: Version 4:

Timer Timer

X4 X4
1 to I/O module 1 to I/O module
(see page (see page
2 5-13) 2 5-13)
3 Stop circuit 3 Stop circuit
(see page (see page
4 4
5-14) 5-14)
24VDC 24VDC
5 5
Inter- Inter-
nal 6 24VDC nal 6 24VDC
vol- 7 vol- 7
tage 0V tage 0V
source 8 External source 8 External
0V p.s.u. 0V p.s.u.
9 9
24VDC 10 24VDC 10 24VDC
Internal Internal
logics 11 logics 11 0V
0V 0V
12 12 External
p.s.u.

Examples for wiring

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and Controls

Electrical connection

5.2.5 Pressure Control and Feedback (X2)

Connection: at X2; plug-in terminal, spacing 3.5 mm, 5-pin,
max. 1.5 mm2.
Mating connector included in shipment.
Cable length: max. 50 m with 0.5 mm2
max. 100 m with 0.75 mm2
Type of cable: shielded
(e.g.: NFL 13, Metrofunk; LiYCY)

An analog output signal that can be used for controlling a proportional

control valve is at your disposal at X2. The type of the output signal can
be alternatively programmed as
D a voltage signal (0 to +10 V, max. 20 mA),
D a current signal 0 to 20 mA or
D a current signal 4 to 20 mA.

The proportional control valve converts the pending signal into a pres-
sure which will be applied to the gun cylinder. According to the mecha-
nics of the gun, this will result in the force available at the electrodes (see
also page 3-28).

. The output signal at X2 will be output immediately after the selec-

tion of a welding program and not only upon its start!

In order to signal to the timer that the gun is closed or that the command
force has been reached, you use
D the input terminal 4 at X2.

The programmed squeeze time (SQZ) starts under the following condi-
tion only:
D High level at input X2/4 (in relation to 0V at X2/2)
(for required voltage, please refer to chapter 4.1, on page 4-1).

If this condition is missing, the welding program will be selected and star-
ted (and a possibly programmed 1. SQZ will begin), but the further pro-
cesses (schedule) will be delayed until this one condition is met.
After a waiting period of 5 seconds, the schedule will be interrupted with
the message ”No welding pressure”.

Which sensors and input signals are used for feedback depends on the
application. The entire pressure control and feedback e.g. can also be
handled via PLC program (if proportional control valve and feedback are
not connected to the timer itself but to the PLC or the robot).
In addition, applications without feedback or proportional control valve
are possible as well.
The following illustrations represent several connection possibilities.
5-8 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Electrical connection

L Make sure that in installations without feedback signal, the welded part
has been perfectly pressed together before the weld time starts!
In order to do so, you have to program sufficiently long squeeze times.
Insufficient squeeze times lead to a large amount of welding splashes!
This might lead to damage to the electrodes and work pieces.

Proportional control valve

Valve supply
+24VDC D
0V
D
X2 P
Pres-
1 0 to 10 VDC; 20 mA sure
Pressure control signal
GND for terminal 1 and 4 2 0V has
D D
been
3 reached
Feedback 4
Shield 5 D D

Connection of a proportional control valve with feedback

Valve supply Proportional control valve

+24VDC
X2
0V
Pressure control signal 1 D
GND for terminal 1 and 4 2 D D
3
Feedback 4
D
Shield 5 D D

X4

+ 24 VDC 5
Device-internal
voltage source 8
0V

Connection of a proportional control valve without feedback

. The connection ”without feedback” is applicable if

- you don’t use the feedback function or
- if the feedback signal is connected to the PLC/robot.
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and Controls

Electrical connection

X2
Pressure control signal 1
GND for terminal 1 and 4 2
3
Feedback 4
Shield 5

X4

+24 VDC 5
Device-internal
voltage source
0V 8

Wiring without proportional control valve

. The connection ”wiring without proportional control valve” is ap-

plicable if
- you don’t use a proportional control valve or
- the proportional control valve and the feedback signal are con-
nected to the PLC/robot.

L If pressure control and feedback are completely handled by the PLC pro-
gram, the PLC/robot must make sure that the programmed weld time will
be started only if the gun/electrodes are in proper condition.
To do so, two solutions are possible:
1. The PLC informs the weld timer via input X2/4.
With this solution, the welding program will be started, but the SQZ
starts running only when a “high” level is available at the input mentio-
ned.

Proportional control valve

X2
Pressure control signal 1
GND for terminal 1 and 4 2
Pressure control Feedback
3

Feedback 4
5 0V (signal GND)
Shield

PLC / robot

Signaling of the state ”gun is ready

for weld” via +24 VDC

Wiring for timer types with pressure feedback via input X2/4

2. The PLC starts the welding program only if the proper condition of the
gun/electrodes can be guaranteed.
With this solution, always program the lowest SQZ in all welding pro-
grams (PST: 1 line cycle; PSI: 16 ms).
5-10 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Electrical connection

5.2.6 KSR Sensor (X3)

Connection: at X3; plug-in terminal, spacing 3.5 mm, 8-pin,
max. 1.5 mm2.
Mating connector included in shipment.
Cable length: max. 100 m (with recommended type of cable)
Type of cable: shielded, core cross section min. 0.75 mm2,
(e.g.: 2 x 2 x 0.75 mm2 LiYCY,
Bosch order no.: 1070 913 494)

The timers are provided with an integrated Constant Current Regulation

(KSR). The timer controls the current flow in the secondary circuit so that
the programmed command current can actually be reached.
This way, it is possible to compensate process- and handling-related
fluctuations of the contact resistance between electrode - workpiece -
electrode.

A sensor which indicates the current flow in the primary and secondary
circuit of the welding transformer is required for the regulation.
A current sensor installed in the secondary circuit can be connected via
the toroid input (X3; terminal 1 and 2).

. PSI devices have an additional integrated current sensor for the

welding transformer’s primary circuit. This way, by using the soft-
ware (BOS), you can switch between secondary and primary mea-
surement.
In ideal circumstances, the welding current is picked off at the se-
condary circuit of the welding transformer.
In special cases though (e.g. in case of very long weld times or for
temporary bridging in case of a failure of the sensors in the secon-
dary circuit) you can still switch to primary measurement if neces-
sary.

X3
Toroid input 1
Toroid input 2
Shield 3 D
4
5

Shield connection only at X3 terminal 3! Secondary circuit

to the power supply unit

Connection of the KSR sensor on the secondary side

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and Controls

Electrical connection

In order to ensure the proper operation of the sensor, please comply with
the following:
L Install the sensor in such a way that it is safe from damage caused by the
work piece and from welding splashes.
Choose places with the highest possible distance to the busbars or high
current cables. This reduces the influence of externally originating ma-
gnetic induction. Please comply with the above mentioned cable speci-
fications.
Never use magnetizable metal parts for fastening, but preferably copper
or brass.

L Make sure that the current-carrying conductor is lead straight and centri-
cally through the sensor. The voltage induced in the sensor (and there-
fore the measuring variable) has reached its maximum when the
conductor runs vertically to the spanned sensor plane.

L If the sensor is used in movable equipment (e.g. robots), certain parts of

the cables are subject to very strong mechanical stress (e.g. trailing
chain).
In such cases, please use appropriate cables and set the connecting li-
nes in such a way that in case of an error, they can be exchanged quickly
and easily.

L Connect the cable shield only at the side where the timer is located!

L Adjust the timer’s entire control loop regularly in order to avoid measu-
ring faults (current scaling). For this purpose, an external reference wel-
ding current measuring instrument is required.

During the SQZ, the timer checks, by measuring the ohmic resistance, if
the connected measurement circuit is faultless or not. This way, pro-
blems in the area sensor - cable - plug can be detected.
The following test criteria apply:
Measured ohmic resistance Result
< 7 ohms short circuit of measuring circuit
12 to 950 ohms measuring circuit ok
> 1100 ohms measuring circuit open

. Measuring values in between lead to an ambiguously assessable

result.

In case of an error, the timer interrupts the welding process and deletes
the output signal ”Ready”.
5-12 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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Electrical connection

5.2.7 Fan Connection (X4)

Connection: at X4; plug-in terminal, spacing 3.5 mm, 14-pin,
max. 1.5 mm2.
Mating connector included in shipment.
Cable length: max. 10 m with 0.75 mm2
max. 75 m with 1.5 mm2
Type of cable: unshielded, VDE 0281, 0812 (e.g.: Ölflex)
. Not all timers can provide a temperature-controlled 24 VDC connec-
tion of an external forced ventilation (max. 2 A). See wiring diagram
of the corresponding timer.
Forced ventilation modules are used in several Bosch ’Schweis-
skoffer’ types.

X4 Ventilation
module
1
+24 VDC 13 +24 VDC
14 PE
0V
2
0V

to PE bar

Connection of an external Bosch ventilation module

5.2.8 Programming Device (X1)

Connection: at X1; D-sub, 9-pin, at the cable via socket
Cable length: max. 20 m (with recommended type of cable)
Type of cable: shielded, core cross section min. 0.2 mm2,
Capacity max. 2.5 nF
(e.g.: 3 x 2 x 0.2 mm2 LifYCY, Metrofunk)
For connecting the programming device (PC, Laptop), please use the
RS232 interface X1.

X1 PC (COM1 or COM2)
1
RX 2 2 RX
TX 3 3 TX
4
4
GND 5 5 GND
6
7
8
9
Connector Connector

Connect shield to large area of metal shell of the plug-in connection

Transmission rate: 19200 bits/s

Parameters: 8E1 (8 data bits, even parity, 1 stop bit)
Transmission: PS5000 block protocol with CRC16
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 5-13
and Controls

Electrical connection

5.3 I/O Module ”DEV-NET”

Communication between timer and higher-level PLC or robot is primarily
handled via DeviceNet (copper cable).
In addition, there are discrete 24 VDC signals available, which can be
used via PLC, robot or control panel.
Therefore, the I/O module provides
D 8 inputs (24 VDC, at X12)
D 8 outputs (24 VDC, at X11)
D 4 byte input field (DeviceNet connection)
D 4 byte output field (DeviceNet connection).

5.3.1 Power Supply (X10)

Connection: at X10; plug-in terminal, spacing 3.5 mm, 4-pin,
max. 1.5 mm2.
Mating connector included in shipment.
Cable length: (From the voltage source to the consumer)
max. 10 m with 0.75 mm2
max. 75 m with 1.5 mm2
Type of cable: unshielded, VDE 0281, 0812
(e.g.: Ölflex)

. For further technical data, please refer to chapter 4.2 on page 4-2.

Two types of connection are possible:

1. Connection of the I/O module supply to X4 of the timer or
2. direct connection of the I/O module supply to a separate 24 VDC
power supply unit.

. If you connect the I/O module to the timer’s X4 (1st type of connec-
tion), you can use either the internal voltage supply (see page 5-2)
or an external power supply unit. To do so, you only have to set/re-
move some jumpers at X4.
For more information about the interconnections of X4, please re-
fer to chapter 5.2.4 on page 5-4 ff.

L Make sure to use only such external voltage sources that are specified
as ”safely separated” according to the Low-Voltage Directive
(72/23/EEC, 93/68/EEC and 93/44/EEC)!

L If an electrical isolation between I/O and timer is necessary, the timer and
the I/O module must be operated via separate 24 VDC voltage supply
units!
5-14 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Electrical connection

L Please make sure that the correct function of the stop circuit (see il-
lustrations below) is guaranteed in every connection type!
In dangerous situations at the welding station or in case of intended
switch-off of the weld timer, the in- and outputs of the I/O module are to
be switched to low level. To do so, an external monitoring device must
open the floating contact which then interrupts the power supply at X10.
In case of an open stop circuit, the timer sends the following message:
”Stop circuit open / no 24 V”. This message is automatically reset, i.e. it
disappears automatically when the stop circuit is closed.

I/O module Timer

X10 X4

24VDC 1 1

0V 2 2 0V

24VDC 3 3

0V 4 4 24VDC
Floating contact
internally jumpered: Load: 24 VDC,
Terminal 1 and 3 max. 3 A
Terminal 2 and 4
Stop circuit

Connection of the I/O module supply to X4 of the timer

I/O module Stop circuit

24 VDC power
supply unit
Floating contact
X10 Load: 24 VDC,
max. 3 A
24VDC 1 24VDC

0V 2 0V

24VDC 3

0V 4

internally jumpered:
Terminal 1 and 3
Terminal 2 and 4

Direct connection of the I/O module supply to a separated 24 VDC power

supply unit.

L Use terminal 3 at X10 as a 24 V source for triggering the inputs at X12.

Use terminal 4 at X10 as a 0 V reference potential at X11.

L Because of the internal jumper at X10, the incoming supply voltage can
be transferred to further devices.
Make sure, though, not to exceed the limit values specified for current
load (voltage source, connections) and cable lengths!
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 5-15
and Controls

Electrical connection

5.3.2 DeviceNet Connection

In order to integrate the timer in a DeviceNet bus system, please use
X13.

Cable length: according to DeviceNet specification

Type of cable: copper, shielded, according to DeviceNet speci-
fication

previous following
Weld timer
DevNet node DevNet node

...

1
2
3 X13
4
5
last node with termi-
nator according to
DeviceNet specifica-
tion

Example: DeviceNet connection of the last 3 weld timers at the bus

. For more information on which I/O signals are exchanged between

the weld timer and the DevNet host, please refer to chapter 5.3.3.

Setting the DeviceNet address:

via NA switch. Address (MAC ID) according to DeviceNet specification.

Setting the DeviceNet baud rate:

via DR switch, according to DeviceNet specification.

5.3.3 Signal outputs and inputs

Connection X11, X12: Plug-in terminal, spacing 3.5 mm, max. 1.5
mm2.
Mating connector included in shipment.
Cable length: max. 100 m at 0.5 mm2
Type of cable: Unshielded, VDE 0281, 0812
(e.g.: Ölflex)
5-16 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Electrical connection

. For further technical data, please refer to chapter 4.2, on page 4-2.
For information regarding the functionality of all signals, please re-
fer to chapter 6.

from PLC/robot/control panel

to PLC/robot/control panel

Input field (control word)

Width: 4 byte.
Input signals are assigned to the individual bits (bit
0 to bit 31).
For assignment, please refer to the following page.
serial with
DeviceNet
via X13
Output field (status word)
Width: 4 byte.
Output signals are assigned to the individual bits
(bit 0 to bit 31).
For assignment, please refer to the following page.

Description
X12 refer to page
I0 Welding circuit feedback 6-4
I1 Not used
I2 Not used
I3 Not used
I4 Not used
I5 Not used
I6 Not used
I7 Not used

X11
O0 Welding circuit enable 6-19
O1 Not used
O2 Not used
O3 Not used
O4 Not used
O5 Not used
O6 Not used
O7 Not used

X10
+24V Supply input 5-13
0V Supply input 5-13
+24V Signal voltage output for passive switch elements 5-13
0V Reference potential for outputs at X11 5-13

Assignment of all signal in- and outputs

1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 5-17
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Electrical connection

Input field Output field

Bit Signal name Description Bit Signal name Description

Refer to page Refer to page
0 START 6-2 0 WELD COMPLETE (WC) 6-14
1 TIPS HAVE BEEN DRESSED 6-9 1 TIP DRESS REQUEST 6-17
2 WELDING CIRCUIT RELEASE 6-3 2 PREWARNING 6-18
3 ELECTRODES HAVE BEEN REPLACED 6-11 3 END OF STEPPER 6-18
4 RESET FAULT 6-6 4 CONTROL READY 6-16
5 RESET FAULT WITH WC 6-7 5 WELDING FAULT 6-17
6 RESET FAULT WITH SPOT REPEAT 6-8 6 WITHOUT MONITORING 6-19
7 WELD ON EXTERNAL 6-5 7 WELD / NO WELD 6-17
8 SPOT SELECTION 01 6-4 8 INITIAL DRESSING REQUEST 6-13
9 SPOT SELECTION 02 6-4 9 NEW ELECTRODE 6-19
10 SPOT SELECTION 04 6-4 10 Not used
11 SPOT SELECTION 08 6-4 11 Not used
12 SPOT SELECTION 16 6-4 12 Not used
13 SPOT SELECTION 32 6-4 13 Not used
14 SPOT SELECTION 64 6-4 14 PRESSURE FEEDBACK 6-13
15 SPOT SELECTION 128 6-4 15 Not used
16 SPOT SELECTION 256 6-4 16 STATUS 01 6-20
17 SPOT SELECTION 512 6-4 17 STATUS 02 6-20
18 SPOT SELECTION 1024 6-4 18 STATUS 04 6-20
19 SPOT SELECTION 2048 6-4 19 STATUS 08 6-20
20 SPOT SELECTION 4096 6-4 20 STATUS 16 6-20
21 SPOT SELECTION 8192 6-4 21 STATUS 32 6-20
22 SPOT SELECTION 16384 6-4 22 STATUS 64 6-20
23 SPOT SELECTION 32768 6-4 23 STATUS 128 6-20
24 SPOT SELECTION 65536 6-4 24 STATUS 256 6-20
25 SPOT SELECTION 131072 6-4 25 STATUS 512 6-20
26 SPOT SELECTION 262144 6-4 26 STATUS 1024 6-20
27 SPOT SELECTION 524288 6-4 27 STATUS 2048 6-20
28 SPOT SELECTION 1048576 6-4 28 STATUS 4096 6-20
29 SPOT SELECTION 2097152 6-4 29 STATUS 8192 6-20
30 SPOT SELECTION 4194304 6-4 30 STATUS 16384 6-20
31 SPOT SELECTION 8388608 6-4 31 STATUS 32768 6-20

Assignment of the signal in- and output field for DeviceNet connection
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Electrical connection

Notes:
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 6-1
and Controls

I/O Signal Descriptions

6 I/O Signal Descriptions

This chapter contains the descriptions of all I/O signals regarding their
importance for the timer. Signal names are always put in quotation
marks (”Signal name”).

. For information regarding the assignment of all in-/output signals

of the ”DEV-NET” I/O module, please refer to chapter 5.3.3 from
page 5-15 ff.

6.1 Input Signals

6.1.1 Alphabetical Overview

Signal name Page

ELECTRODES HAVE BEEN REPLACED 6-11

RESET FAULT 6-6

RESET FAULT WITH SPOT REPEAT 6-8

RESET FAULT WITH WC 6-7

SPOT/PROGRAM SELECTION 6-4

START 6-2

TIPS HAVE BEEN DRESSED 6-9

WELDING CIRCUIT FEEDBACK 6-4

WELDING CIRCUIT RELEASE 6-3

WELD ON EXTERNAL 6-5

6-2 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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I/O Signal Descriptions

6.1.2 Start
A positive edge at the input triggers the acceptance of the currently se-
lected welding program (for more information regarding program selec-
tion, see page 6-4 ff) if the timer is in ”Ready” (see page 6-16).
Schedule:
1. The welding program starts.
If programmed, the 1.SQZ starts running.
2. SQZ starts.
Until the end of the SQZ, it is possible to interrupt the welding process
by resetting ”Start”.

. The start of the SQZ depends on the pressure feedback. For more
information, please refer to page 5-7.

. Within the SQZ, the timer checks, by measuring the ohmic resi-
stance, whether the connected measurement circuit is faultless or
not.
In case of an error (refer to page 5-11), the timer interrupts the wel-
ding program and deletes the output signal ”Control ready”.

3. If ”Start” continues to be high after the end of the SQZ, Interlock starts
in single mode. While in Interlock, the 1., 2., and 3.WLD run even after
resetting ”Start”.
After resetting ”Start” in seam mode, only a current cycle that has al-
ready begun will be finished.

. ”Interlock” can be interrupted only by opening the stop circuit (see

page 5-14).

. Whether the weld times are executed with or without welding cur-
rent depends on the input signal ”Weld on external” (refer to page
6-5).

4. HLD runs.
5. The output ”Weld complete” (refer to page 6-14) acknowledges the
weld schedule.
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I/O Signal Descriptions

Start

1.SQZ SQZ 1.WLD 1.CT 2.WLD 3.CT 3.WLD HLD t

Start Interlock

Interlock in single mode

Start

1.SQZ SQZ 1.WLD 1.CT n x 2.WLD HLD t

Reset of ”Start” during 2.WLD in seam mode

6.1.3 Welding Circuit Release

The input signal will always be set except during an electrode exchange.
If ”welding circuit release” is missing during a program start with Weld/No
Weld turned on, the timer generates the error message: ”No welding cir-
cuit release”.

. ”Welding circuit release” is the prerequisite for the output signal

”Welding circuit enable” (refer to page 6-19).
6-4 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
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I/O Signal Descriptions

6.1.4 Welding Circuit Feedback

Input for the feedback contact of the welding circuit contactor. Needs to
be triggered with high level while the contactor is closed.
The timer checks the input ”Welding circuit feedback”
D at the end of the SQZ.
If the output signal ”Welding circuit enable” is set and ”Welding circuit
feedback” is missing, the error message ”Welding circuit 1 not closed”
will be output.
D after opening the welding circuit contactor.
If ”welding circuit feedback” is still set after 100 ms after the contactor
has been opened, the error message ”Welding circuit 1 not opened”
will be output.

6.1.5 Spot Selection, Program Selection

A maximum of 24 input signals (spot selection ”x”) is at your disposal for
selecting the desired welding program (program no. 0 to 255) or the desi-
red spot weld (spot no. 256 to 8388608).
To do so, the binary coded program/spot number will be applied to the
inputs. The illustration below contains examples.

. The spots 0 to 255 are linked and fixed to the corresponding pro-
grams 0 to 255, but spot numbers higher than 255 can be assigned
freely to the programs 0 to 255 via spot selection.
When you select a spot then you always select the corresponding
program as well.

. The binary coded spot/program number must be transferred to the

timer via DeviceNet in one single bus cycle.
Otherwise the data transferred in the corresponding bus cycle will
be interpreted as separate spot/program numbers and selected
one after the other.

. Immediately after selection of a welding program, the timer outputs

the command force of the electrodes programmed there.

. In case of a positive edge of the input signals

D ”Tips have been dressed” (refer to page 6-9) or
D ”Electrodes have been replaced” (refer to page 6-11)
the pending bit pattern will be temporarily interpreted as the num-
ber of an electrode! For method of operation, please refer to the in-
dicated cross references.

. The function ”Start simulation” within the user interface (BOS) al-
ways refers to program numbers!
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: High level of the corresponding signal

Value
Input signal (dec)
Spot selection 01 1
Spot selection 02 2
Spot selection 04 4 ...
Spot selection 08 8
Spot selection 16 16
: :
Spot selection 8388608 8388608

...
00
01
02
03
04
05
06
07
08
09
10

12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
11
Selected spot number:

Binary coded selection of a spot (of an electrode) via input signals ”Spot selection x”

6.1.6 Weld On External

Sometimes it is necessary to execute a welding program without weld
current (e.g. within the scope of a clock time optimization at the welding
line or for other settings/tests).

Therefore, an external device (robot, PLC, keylock switch at the control

panel) can determine via this input signal
1. whether the timer should execute all welding programs without cur-
rent as a rule or
2. whether the timer itself, based on the parameterization, has an in-
fluence on this decision (with or without current).

Regarding point 1.:

If ”Weld on external” is not set, all welding programs in the timer - inde-
pendent from the rest of the timer’s parameterization - will be executed
without current. The power supply unit will not be triggered in this case.

Regarding point 2.:

If ”Weld on external” is set, the reaction depends on the following para-
meters:
D Weld on internal (globally affects all programs in the timer) and
D program-related weld (is part of each welding program and is effec-
tive in the corresponding program only).

The execution of a welding program with current is possible only if

D ”Weld On External” is set and
D Weld internal and
D the program-related weld (firing) has been switched on.

This corresponds to an AND operation of all 3 mentioned conditions.

. For feedback of this AND operation to an external device, please

use the output signal ”Weld / No weld” (see page 6-17).
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6.1.7 Reset Fault

If an error occurs, the timer goes into ”Block”.
In this state,
D it is not possible to start a welding process
D the LED READY at the timer’s front goes off (see page 2-7)
D and the output signal ”Control Ready” will be reset (refer to page
6-16).

. Error and status messages are listed in the ”Error list

PS5000/PS6000” (No.: 1070 087 001).

While the timer automatically deletes ”self-resetting” errors after the

cause of the error has been eliminated, ”not self-resetting” errors require
a ”reset fault” after the elimination.
This operation can be executed either via
D Software (BOS),
D the reset button at the timer’s front (see page 2-7) or
D a positive edge of the ”Reset fault” input signal.

L Please note that after ”Reset fault”, the timer only restores the ”Ready”
state. In ”Ready” the following is applicable:

D it is possible to start a new welding process

D the LED READY at the timer’s front is lit
D and the output signal ”Control ready” is set.

. The timer does not execute any other actions!

If the error occurs during a welding process, the gun might still be
closed and the robot e.g. remains on the current welding position.

Via the input signals ”Reset fault with WC” (see page 6-7) and ”Reset
fault with spot repeat” (see page 6-8), other operations can be initiated
in addition to ”Reset fault”. Please refer to the indicated cross referen-
ces.
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I/O Signal Descriptions

6.1.8 Reset Fault with WC

. For basic information, please refer to page 6-6!

A positive signal edge leads to

1. Reset fault” and subsequently
2. to the setting of the signal ”Weld complete” if the input signal ”Start” is
still pending.

DANGER
Dangerous machine movements possible!
The signal ”Weld complete” initiates the robot’s positioning to the next
weld spot.
Therefore, make sure to avoid dangerous situations at the welding sta-
tion caused by ”Reset fault with WC”!

. ”Reset fault with WC” can also be initiated via the GUI (BOS).

”Reset Fault with WC” is used

D in connection with robots and
D in connection with errors except ”Current too low” and ”Current too
low for a series of welds”.

. In connection with errors except ”Current too low” and ”Current

too low for a series of welds”, please note the signal ”Reset fault
with spot repeat”. Refer to page 6-8.

If an error occurs while a part is being welded, the robot usually remains
at the welding position with the gun closed.
Via ”Reset Fault with WC”, it is now possible
D to continue the process at the next spot weld.

CAUTION
The current spot weld is erroneous!
Please check the part!
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6.1.9 Reset Fault with Spot Repeat

. For basic information, please refer to page 6-6!

A positive signal edge leads to

1. ”Reset fault” and subsequent
2. repetition of the welding program schedule provided that the input si-
gnal ”Start” is still pending.
If the repetition is completed without another error, the signal ”Weld
complete” will be set.

DANGER
Dangerous machine movements possible!
The signal ”Weld complete” initiates the robot’s positioning to the
next weld spot.
Therefore, make sure to avoid dangerous situations at the welding
station caused by ”Reset fault with spot repeat”!

. ”Reset fault with spot repeat” can also be initiated via the GUI
(BOS).

”Reset Fault with spot repeat” is used

D in connection with robots and
D in connection with the errors ”Current too low” and ”Current too low for
a series of welds”.

. In connection with other errors, please note the signal ”Reset fault
with WC”. Refer to page 6-7.

If the error ”Current too low” or ”Current too low for a series of welds” oc-
curs while a part is being welded, the robot usually remains at the wel-
ding position with the gun closed. Via ”Reset Fault with spot repeat”, it is
now possible
D to repeat the current, erroneous spot weld.

If, after that, another error occurs, please use ”Reset fault with WC”.
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I/O Signal Descriptions

6.1.10 Acknowledgment ”Tips have been dressed”

The timer informs the robot via the output signal ”Tipdress Request” (see
page 6-17) that a tipdress procedure must be executed ”soon” (see
page 3-27).

. The time for outputting the signal ”Tipdress Request” is paramete-

rizable (BOS).

If the robot recognizes the ”Tipdress Request”, it must move the relevant
electrode to the tipdress station - at the latest after its maximum wear
has been reached. Dependent on the setting of the parameter ”Stop at
end of stepper” (BOS), the timer goes into ”block”, sends the message
”tipdressing necessary”, and waits for the acknowledgment ”Tips have
been dressed”.

. The programming of the robot determines when the robot recogni-

zes the ”Tipdress Request”. The relevant robot inputs are often
scanned only before welding of a new part and not after each spot.
This behavior requires the following:
D The time between the output of the signal ”Tipdress Request”
and the maximum wear must be sufficiently set. Only this way it
can be guaranteed that the part can be completely welded before
reaching the maximum wear.

The robot tells the timer that the electrode dressing procedure is finished
by sending the message ”Tips have been dressed”.

. Since a timer can control and handle more than one electrode, the
robot must not only send the message ”Tips have been dressed”
but also the number of the recently dressed electrode. At its spot
selection inputs (see page 6-4), the timer expects the binary co-
ded electrode number contemporarily with the signal ”Tips have
been dressed”.

As long as a new electrode tipdressing process is still possible at this

point, the timer reacts to a positive signal edge at the ”Tips have been
dressed” acknowledgement as follows:
1. The bit pattern pending at the spot selection inputs (see page 6-4)
will be interpreted as a binary coded electrode number.
2. The tipdress counter of the recognized electrode number will be in-
cremented.
3. The wear counter of the recognized electrode number will be reset to
0.
4. The output signal ”Tipdress Request” (refer to page 6-17) will be re-
set.

. A transferral of electrode number ”0” mutually triggers the actions

2. and 3. for all electrodes!
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Example. The following settings are used:

%I Stepper: On
Stepper: active (if Stepper final current > basic current)
Tipdressing: On (if max. tipdressing steps > 0. Here: max. tipdressing steps = 3)
Tipdress Curve: active (if tipdressing final current > basic current)
Wear factor: 1.0
Wear start section (offset): 0
Wear stepper section: 100
Max. wear: 100 (= wear stepper section - offset)
Tipdress request: 10 (= 10 before max. wear)
Prewarning: 30 (= 30 before max. wear)

Current End of Stepper

(%)
1st tipdressing 2nd tipdressing 3rd tipdressing

Stepper final current

Tipdress final current

Basic current
90 90 90 70 Current wear
0 0 0 100

”Tipdress request”

Acknowledgement Time
”Tips have been dressed”

Time

Example: Electrode tipdressing process

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I/O Signal Descriptions

6.1.11 Acknowledgment “Electrodes have been replaced”

First, the timer informs the robot via the output signal ”Prewarning” (see
page 6-18) that an electrode must be exchanged ”soon”.

. Prior to the end of stepper (see page 6-18), the time for outputting
the signal ”Prewarning” is parameterizable (BOS) as wear. If ”elec-
trode tipdressing” is activated, the timer outputs ”Prewarning”
only when no further tipdressing procedure is allowed.
It depends on the parameterization of the timer whether further
welds are still possible after exceeding the end of stepper.
If the robot recognizes the ”Prewarning”, in ideal circumstances, it mo-
ves the gun to the gun maintenance position in order to exchange the
electrodes.

. The programming of the robot determines when the robot recogni-

zes the ”Prewarning”. Normally, the relevant robot inputs are scan-
ned only before welding of a new part and not after each spot.
This behavior requires the following:
D The time between the output of the signal ”Prewarning” and the
end of stepper must be sufficiently set.
D The function ”Stop at end of stepper” is switched off.
Only this way, it can be guaranteed that the part can be completely
welded.

The timer must be informed about the executed electrode exchange ei-
ther via ”Electrodes have been replaced” or via GUI (BOS).

. Since a timer can control and handle more than one electrode, the
robot must not only send the acknowledgement ”Electrodes have
been replaced” but also the number of the recently exchanged
electrode.
At its program selection inputs, the timer expects contemporarily
with the signal ”Electrodes have been replaced” the binary coded
electrode number.

The timer must be informed about the executed electrode exchange ei-
ther via ”Electrodes have been replaced” or via GUI (BOS).

. Since a timer can control and handle more than one electrode, the
robot must not only send the acknowledgement ”Electrodes have
been replaced” but also the number of the recently exchanged
electrode.
At its spot/program selection inputs, the timer expects the binary
coded electrode number contemporarily with the signal ”Electro-
des have been replaced”.

The timer reacts to a positive signal edge at the ”Electrodes have been
replaced” acknowledgement as follows:
1. The bit pattern pending at the spot/program selection inputs (see
page 6-4) will be interpreted as a binary coded electrode number.
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2. The tipdress counter of the recognized electrode number will be re-

set.
3. The wear counter of the recognized electrode number will be reset to
0.
4. The output signal ”Prewarning” or ”End of stepper” will be reset.
5. When ”Tipdressing of new electrodes” is activated (initial dressing;
please refer to page 3-27), the output ”Initial dressing request” (see
page 6-13) will be activated.

. A transferral of electrode number ”0” mutually triggers the actions

2. and 3. for all electrodes!

Example. The following settings are used:

%I Stepper: On
Stepper: active (if Stepper final current > basic current)
Tipdressing: On (if max. tipdressing steps > 0. Here: max. tipdressing steps = 3)
Tipdress Curve: active (if tipdressing final current > basic current)
Wear factor: 1.0
Wear start section (offset): 0
Wear stepper section: 100
Max. wear: 100 (= wear stepper section - offset)
Tipdress request: 10 (= 10 before max. wear)
Prewarning: 30 (= 30 before max. wear)
Stop at End of Stepper: Off

Current End of Stepper

(%)
1st tipdressing 2nd tipdressing 3rd tipdressing

Stepper final current

Tipdress final current

Basic current
70 0 Current wear
100

”Prewarning”

Time
”End of Stepper”

Acknowledgement Time
”Electrodes have been replaced”

Time

Example: Electrode replacement

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I/O Signal Descriptions

6.2 Output Signals

6.2.1 Alphabetical Overview

Signal name Page

CONTROL READY 6-16

END OF STEPPER 6-18

INITIAL DRESSING REQUEST 6-13

NEW ELECTRODE 6-19

PRESSURE FEEDBACK 6-13

PREWARNING 6-18

STATUS 6-20

TIPDRESS REQUEST 6-17

WELD COMPLETE (WC) 6-14

WELD/NO WELD 6-17

WELDING CIRCUIT ENABLE 6-19

WELDING FAULT 6-17

WITHOUT MONITORING 6-19

6.2.2 Pressure Feedback

Indicates if high level is pending at the pressure input (X2/4; please refer
to chapter 5.2.5 on page 5-7).

6.2.3 Initial Dressing Request

Informs the PLC/robot that the active electrode requires initial dressing.
If the function ”tipdressing of new electrodes” (BOS) is activated, the si-
gnal will be set after the relevant electrode has been exchanged.
”Tips have been dressed” (refer to page 6-9) resets ”Initial dressing re-
quest”.
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6.2.4 Weld complete (WC)

The output signal ”Weld complete” informs the connected peripherals
(PLC/robot) about the termination of the welding process.
This way, the next step of the working process can be initiated. The lo-
gics for generating a WC is activated in the following cases:
1. in case of single spot welding (e.g. in connection with robots) after
each spot
2. in case of seam mode (e.g. roll seam welds) at the end of the seam
3. upon ”set WC” (possible only via BOS)
4. upon ”Reset Fault with WC” (see page 6-7).

. How long the WC remains set, depends on the input signal ”Start”.
See ”WC period”.

The 1. and 2. case give you the possibility to adjust the WC to your appli-
cation via parameterization (BOS).
D Automatic output of the WC only after a proper weld, or even after an
erroneous weld.
D Time at which the WC should be set (see ”WC starting time”).

WC period
Normally, the timer resets the signal ”Weld complete” automatically if it
recognizes a negative edge at the input ”Start”.
Nevertheless, there are situations possible in which the ”Start” signal is
reset prior to setting the WC. Here, a triggering on the negative edge of
”Start” is not possible. Therefore, when setting the WC, the timer checks
whether ”Start” is still pending and reacts as follows:
”Start” is set: WC will be reset only after a negative edge of
”Start”
Start” is not set: WC will be reset after the parameterized WC pe-
riod (GUI (BOS); default: 20 ms) has expired.
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I/O Signal Descriptions

”Start” is not pending anymore:

Start Progr. WC period runs.

t
WC

t
WLD HLD Progr. period

”Start” is still pending:

Neg. edge resets WC.

Start

t
WC

t
WLD HLD

WC period depends on signal ”Start”

. The programmed WC period also runs during start simulation

(BOS)!

WC starting period
The time, at which ”Weld complete” shall be output, is - in relation to the
end of the HLD - parameterizable within the following limits:
D with PSI: +/-1000 ms
D with PST: +/-50 cycles.
Restriction: The earliest possible output of the WC is possible after 20
ms or 1 cycle after the start of the HLD.

Default setting: End of HLD minus 20 ms or 1 cycle (see ”example”).

This way, the starting time of the WC can be anticipated and moved into
the HLD time as well as delayed.

Neg. value Pos. value

WC
t
WLD HLD

Moving of WC starting time

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Example: ”Fast robot communication”

If ”Weld complete” is used as a command for positioning the robot to the
next spot, you can compensate constant response times (caused by si-
gnal processing in the robot, drive, or PLC area) by anticipating the star-
ting time of the WC. This will lead to shorter clock times.

CAUTION
Damage to the installation caused by positioning movements with
a closed gun are possible!
Therefore, make sure that the electrodes are already open when
the robots’ drives start!

6.2.5 Control Ready

The output signal indicates that the timer is ready to weld.
In this state,
D you can start a new welding schedule (see page 6-2)
D the LED READY at the timer’s front is lit (see page 2-7).

If an error occurs, the timer goes into ”Block”.

In this state,
D it is not possible to start a welding process
D the LED READY at the timer’s front goes off
D the output signal ”Control ready” is reset.

. Error and status messages are listed in the ”Error list

PS5000/PS6000” (No.: 1070 087 001).

In order to restore the ”Ready”-state of the timer after an error, you have
the following possibilities at your disposal:
1. Push the reset button at the timer’s front (see page 2-7) or
2. a positive edge at the ”Reset fault” input signal (refer to page 6-6) or
3. a positive edge at the ”Reset fault with WC” input signal
(refer to page 6-7) or
4. a positive edge at the ”Reset fault with spot repeat” input signal (refer
to page 6-8) or
5. operation via software (”Reset fault”, ”Reset fault with WC”, and ”Re-
set fault with spot repeat” are also possible via BOS).
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I/O Signal Descriptions

6.2.6 Welding Fault

If an error occurs during welding,
D the timer sets the output ”Welding Fault” and
D deletes the output signal ”Control Ready” (refer to page 6-16).

Further welding processes can only be started, when all pending errors
are eliminated and acknowledged (reset). Please refer to ”Reset fault”
on page 6-6 ff.

. Error and status messages are listed in the ”Error list

PS5000/PS6000” (No.: 1070 087 001).

. It depends on the parameterization of the timer (BOS; fault alloca-

tion) whether an event is interpreted as an error or a warning.

6.2.7 Weld/No Weld

Via the output signal ”Weld/No weld” you can check whether the cur-
rently selected welding program is executed
D with current (output is set) or
D without current (output is not set).

During a welding program you can work with current only if

D ”Weld on External” (see page 6-5) is set and
D Weld internal (parameterizable via BOS) and
D program-related weld (parameterizable via BOS) have been swit-
ched on.

I.e. that ”Weld/No weld” is the result of an AND operation of all 3 mentio-
ned conditions.

6.2.8 Tipdress Request

Informs the PLC/robot that the active electrode must be tipdressed as
soon as possible.
If further electrode tipdressing is still allowed at this point, the signal will
be set when a parameterizable wear value is reached.
The acknowledgement ”Tips have been dressed” resets ”Tipdress re-
quest”.

. For more information, refer to ”Tips have been dressed” on page

6-9 ff.
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6.2.9 Prewarning
Will be set, when a parameterizable wear value is reached. The output
signal informs the PLC/robot that the active electrode will reach the end
of stepper soon and that the electrode must therefore be replaced.
The output signal will be
D set with Start if the active electrode is in Prewarning
D updated at the end of the weld time
D reset via ”Electrodes have been replaced”.

. For more information, refer to ”Electrodes have been replaced” on

page 6-11 ff.

6.2.10 End of Stepper

Will be set, when a parameterizable wear value is reached. The output
signal informs the PLC/robot that the active electrode has reached the
end of stepper.

. It depends on the parameterization of the timer whether or not furt-

her welds are still possible after exceeding the end of stepper (pa-
rameter ”stop at end of stepper”).

The output signal will be

D set with Start if the active electrode has reached the end of stepper
D updated at the end of the weld time
D reset via ”Electrodes have been replaced”.

. For more information, refer to ”Electrodes have been replaced” on

page 6-11 ff.
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I/O Signal Descriptions

6.2.11 Without Monitoring

Via the output signal ”Without monitoring” you can check whether the
currently selected welding program is executed
D without current monitoring (output is set) or
D with current monitoring (output is not set).

CAUTION
Faulty welds are possible!
If current monitoring is switched off, actual current values that lie
outside the permissible tolerance bands do not lead to a welding
fault!
Therefore, make sure that all weldings that might be executed ”wi-
thout monitoring” are checked sufficiently!

During the process of a welding program, current monitoring is active

only in the following cases (”Without monitoring” is not set):
D the timer-related Monitoring stopped (effective for all programs) is
switched off
D the program-related current monitoring is active for all weld times.

6.2.12 New Electrode

The output will be set if the welding program selected via spot selection
has been assigned to an electrode with count ”0”.

6.2.13 Welding Circuit Enable

Is output at the beginning of a welding process if
D ”Welding circuit release” (see page 6-3) is set and
D Weld/No Weld is turned on.

”Welding circuit release” is reset if

D “Welding circuit release” changes to low level,
D an error occurs, or if
D within 60 seconds, no new start signal has been recognized.
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I/O Signal Descriptions

6.2.14 Status
The timer transmits its current binary coded status via the 16 ”status x”
outputs with DeviceNet.

Value : High level of the corresponding signal

Output signal (dec)
Status 01 1
Status 02 2
Status 04 4
Status 08 8
Status 16 16
Status 32 32
Status 64 64
Status 128 128
Status 256 256
Status 512 512 ...
Status 1024 1024
Status 2048 2048
Status 4096 4096
Status 8192 8192
Status 16384 16384
Status 32768 32768
00
01
02
03
04
05
06
07
08
09
10

12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Current timer status:
11

65534
65535
Binary coded output of current timer status

Currently, the following messages are defined:

Code
Description
(dec)
00 OK
80 Stop circuit open / no +24 V
81 Current passed without command
84 Battery error
85 Memory deleted ==RAM checksum error
86 Data Restore active
87 No welding program == invalid parameter
88 Hardware error
89 I/O bus error (only in timers with serial I/O bus)
93 Synchronization error
94 Sequence inhibited
98 Command value too large
99 Welding process error
100 Supply voltage error
107 No enable for weld circuit
120 Welding circuit 1 not closed
122 Welding circuit 1 not opened
124 No welding pressure
160 Heat-sink temperature too high
165 Hardware error driver module
166 24 V supply voltage error
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Maintenance

7 Maintenance

7.1 Battery
In order to buffer the RAM (contains the entire parameterization with all
welding programs) and the internal clock, an integrated battery is provi-
ded.
Type of battery: Lithium
Size: AA
Voltage: 3.6 V
Order No.: 1070 914446

When the remaining battery capacity becomes critical, the timer genera-
tes an error message or warning (parameterizable). The LED BATTERY
FAULT at the timer’s front is lit (see page 2-7).
If the event has been defined as an error message, a welding process is
not possible in this state.

L Include battery replacement in the regular maintenance schedule of the

installation! Replacement: at least every 2 years.

CAUTION
Damage caused by improper handling of electronic components!
Therefore, batteries must be replaced by authorized technical per-
sonnel only!

CAUTION
Data loss!
Without a pending supply voltage and after removal of the battery,
data back-up is guaranteed for up to 24 hours only.
Therefore, always have at your disposal a new battery and insert
it immediately upon removal of the old one.

Battery replacement The battery may be exchanged while the timer is running.

1. Turn the battery cover on the timer’s front (see page 2-7) to the left
and remove the old battery.
2. Insert the new battery correctly. For correct polarity, please refer to
the illustration on the front of the timer.
3. Now, close the battery compartment with the battery cover.
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Maintenance

7.2 Firmware
The timer will be shipped with the latest firmware installed. Via the pro-
gramming device (BOS), the version of the firmware can be displayed.
In rare cases, it may be necessary to update the firmware.

CAUTION
Damage caused by improper handling.
Firmware updates may therefore be carried out upon our instruc-
tion and by authorized technical personnel only!

For a firmware update, you need

D a pointed object for operating the ”boot” button (for position, refer to
page 2-7),
D a PC with ”WinBlow” software,
D a suitable connecting cable (timer <-> PC, for wiring, refer to page
5-12) and
D a data carrier (floppy disk, CD) with the corresponding firmware.

L Proceed as follows:
1. Connect one of the PC’s V24 interfaces (COM1 or COM2) to the ti-
mer’s X1.
2. Start the ”WinBlow” software. Select the desired language and the
V24 interface.
3. Insert the data carrier containing the firmware into your PC. Select the
path and file name of the firmware. Firmware files carry the extension
”.hex”.
4. Click on ”Backup - Load Firmware - Restore”.
You are prompted to set the bootstrap mode on the unit.
. Further welding processes are not possible anymore!
If you want to exit the bootstrap mode at this point, you have to in-
terrupt the timer’s 24 VDC power supply (see page 5-3).

5. Push the recessed ”boot” button on the front of the timer. This way, the
unit is switched from operating to bootstrap mode. This condition is
indicated by the ”Boot” LED above the button.
. After having initiated the next step, do not interrupt the power sup-
ply until the complete firmware has been loaded!

6. Confirm at the PC that the bootstrap mode has been activated. The
firmware is now being loaded. A bar indicates the current status of the
process.
7. Wait until the PC signals the end of the transmission.
8. Interrupt the timer’s 24 VDC power supply for at least 5 seconds (re-
move X4). Then reinstall X4.
The timer is booted with the new firmware.
9. Check the firmware version via the programming device (BOS).
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 8-1
and Controls

Status and Error Messages

8 Status and Error Messages

If timer-relevant events occur during operation, you are informed by the

timer.

Primarily you can differ between

D faults and
D warnings.

In case of faults
D it is not possible to start a welding process (schedule)
D the LED READY at the timer’s front goes off (see page 2-7)
D the serial output signals ”Status” (refer to page 6-20) show important
higher level causes for errors
D the output signal ”Control Ready” will be reset (refer to page 6-16).

In case of warnings
D other welding processes can still be executed.

. It depends on the parameterization of the timer (BOS; fault alloca-

tion) whether an event is interpreted as a fault or a warning.

Faults as well as warnings can be ”self-resetting”.

”Self-resetting” means that the timer automatically deletes such events
after elimination of the error’s or warning’s cause. They do not require a
manual ”Reset fault”.
Examples for self-resetting faults:
- Stop circuit open / no 24 V
- Power voltage off / too low
- Synchronization / mains voltage error.

The timer uses code numbers to signal faults and warnings. Only in the
programming device or in the line PC, the code numbers are substituted
by text. This saves memory resources in the timer and reduces the time
necessary for communication.

. Error and status messages are listed in the ”Error list

PS5000/PS6000” (No.: 1070 087 001).
8-2 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Status and Error Messages

Notes:
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 9-1
and Controls

CE Declaration of Conformity

9 CE Declaration of Conformity
9-2 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

CE Declaration of Conformity
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG 10-1
and Controls

Timer Diagrams

10 Timer Diagrams

The following pages contain some examples of timer diagrams.

 Timer Diagrams

Timer Diagrams

10-2
*1: Delay of pressure feedback

Bosch Rexroth AG Electric Drives

Start
Program selection

ÉÉ ÉÉ
*1
Pressure feedback
Weld on external ÉÉ ÉÉ

and Controls
Analog pressure output ÉÉ É
Weld Complete WC
(Start/Period programmable before end of HLD)
ÉÉ

1. Squeeze time
Squeeze time
1. Weld time

PSx 6xxx.624
1. Cool time
2. Weld time
3. Cool time

1070 087 027 / 02

3. Weld time
Hold time

Example for normal schedule, single spot

 Timer Diagrams

1070 087 027 / 02 PSx 6xxx.624

Start
Program selection

Pressure feedback
Weld on external

Analog pressure output ÉÉ É

Weld Complete WC
(Start/Period programmable before end of HLD)
É
É

1. Squeeze time

and Controls
Electric Drives Bosch Rexroth AG
Squeeze time
1. Weld time
1. Cool time
2. Weld time
3. Cool time
3. Weld time
Hold time

Example for normal schedule, seam mode

10-3
 Timer Diagrams

10-4
*1 Delay of pressure feedback
*2 Synchronous start of the squeeze time
Start

Bosch Rexroth AG Electric Drives

Program selection

asynchronous
*1
Pressure feedback
Weld on external

and Controls
Analog pressure output É
É É
É
Weld Complete WC
(Start/Period programmable before end of HLD)
ÉÉ

1. Squeeze time
Squeeze time
*2
1. Weld time

PSx 6xxx.624
1. Cool time
2. Weld time
3. Cool time
3. Weld time

1070 087 027 / 02

Hold time

Example for delay of pressure feedback during 1. SQZ

1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG A-1
and Controls

Appendix

A Appendix

A.1 Abbreviations

%I General abbreviation for current, can be PSG Transformer-rectifier unit for the PSI in-
measured in kA or in SKT (scale values) verter series
AC Alternating Current RA (RO) Relay output

CT Cool time, time between the current im- Repeat mode. Mode for manually operated
REPEAT
pulses/blocks (1., 2., 3.CT) systems only

DC Direct Current SKT (scale Measure of the electric phase angle

values)
DST Downslope time. Time in which the %I de-
creases until the end of the 2.WLD. Slope Current ramp, current increases/decreases
from an initial to a final current value
EMC Electromagnetic compatibility
Solenoid Solenoid valve, controls the cylinders for
ESD Electrostatic discharge, abbreviation for all closing the electrodes
terms that concern electrostatic discharges,
SING Single spot mode. For automatic and
e.g. ESD protection, ESD hazard, ESD- manual welding machines
sensitive components
SQZ Squeeze time. Time that runs before the
ext. External, e.g. in connection with a +24V weld time. The electrodes squeeze the
voltage for signal transducers (switches) parts to be welded together.
and actuators (valves) outside the timer.
Stepper Current stepping for compensation of elec-
GUI Graphical user interface trode wear
HLD Hold time, time after the last weld time, in Temp. Temperature
which the welded part can cool down.
UST Up-slope time. Time in which the %I in-
HSA Main Switch Trip creases from the beginning of the 2.WLD.
IMP Number of impulses that form the 2.WLD VWZ Preheating time, also referred to as 1.WLD
kA Kilo-Ampere WC Weld complete. Signal is output when the
spot has been welded
Constant current regulation. Keeps the cur-
KSR
rent in the welding circuit constant. Weld / No Ignition, firing pulses for triggering the
weld power unit are switched on and off
Constant voltage regulation. Balances line
KUR
fluctuations. WI Mains load limitation control (Welder inter-
lock), monitors and influences the mains
LT Power supply unit (thyristor or inverter)
load
MC Monitoring contact, e.g. for monitoring the
pressure inside the cylinder that closes the WLD Weld time. The following types of WLD ex-
electrodes or monitoring of the electrode ist: 1.WLD (preheating weld time); 2.WLD
position, e.g. ”gun closed” (main weld time); 3.WLD (postheating weld
time)
NBS see WI Time and current (%I) of all 3 weld times
can be programmed separately.
NWZ Post-heating time, also referred to as Programming of impulses and slope is only
3.WLD possible in the 2.WLD
OFF Off time, time between two spot welds in WT Weld timer, also referred to as timer, or re-
which the solenoid valve is not triggered. sistance weld timer
Relevant for Repeat mode only.
PE Protective Earth
PG Programming device / welding computer
PHA Phase angle (shift)
PLC Programmable Logic Controller
A-2 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Appendix

A.2 Index

Symbols Diode monitoring, 3-35

%I Stepper, 3-27 DST (current downslope time), 3-7

Numbers E
1. Half cycle, 3-23 Electrical connection, 1-9
Electrode force, 3-28
A Electrode life (Stepper), 6-18
Acknowledgment ”Electrodes have been replaced”, Electrode maintenance, 3-25
6-11 Electrode tipdressing, 3-27
Acknowledgment ”Tips have been dressed”, 6-9 Electrodes have been replaced, 6-11
Air pressure, 4-1 EMC, 5-1
Assembly, 1-6 EMERGENCY-STOP facilities, 1-9
Automatic spot repetition, 3-24 End of Stepper, 3-28, 6-18
Errors, 8-1
B ESD, A-1
Backup battery, 4-1 Electrostatic discharge, 1-12
Battery, 4-1 grounding, 1-12
Battery replacement, 7-1 workplace, 1-12
ESD-sensitive components, 1-12
C Ethernet, 4-1
Cables, 1-9
CE mark, 1-13, 9-1 F
Code numbers, 8-1 Fade-out time, 3-18
Communication, 5-13 Failure of the sensor, 5-10
Condensation, 4-1 Fan connection, 5-12
Conditional permissible tolerance band, 3-16 Faults, 8-1
Connection, 5-1 Features, 2-2
Constant current regulation, 3-12, 5-10 Fieldbus module, 2-6
Control ready, 6-16 Firmware, 7-2
Cooling, 2-2 Firmware update, 7-2
Cooling water, 1-8 Force, 3-28
Chlorides, 1-8 Force profile, 3-29
Degree of hardness, 1-8 Force scaling, 3-30
Insoluble substances, 1-8 Force Stepper, 3-29
Nitrates, 1-8
pH value, 1-8 G
Sulfates, 1-8 Grounding bracelet, 1-12
Corrections, 3-34
CT (cool time), 3-9, 3-10 H
Current blocks, 3-4 Hardware, 2-6
Current downslope time (DST), 3-7 HLD (hold time), 3-10
Current input, 4-2 Humidity, 4-1
Current monitoring, 3-15
Current prewarning and limitation, 3-14 I
Current scaling, 3-32 I/O interface, 2-6
I/O Module ”DEV-NET”, 5-13
D I/O module supply, 5-13
Degree of protection, 4-1 Impulse mode, 3-6
DeviceNet Connection, 5-15 Initial dressing request, 6-13
Diagrams, 10-1 Input signals, 6-1
Dimensions, 2-2 Installation, 1-6
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG A-3
and Controls

Appendix

Intended use, 1-3 Proportional control valve, 5-7

INTERBUS-PMS, 4-1
Interlock, 3-21, 6-3 Q
Qualified personnel, 1-4
K Quality module, 2-6
KSR, 3-12
KSR sensor, 5-10 R
Rated current, 4-1
M RC element, 5-1
Main components of a welding station, 3-1 Regulation modes, 3-11
Mains connection, 2-2 Repair, 1-11
Maintenance, 1-11, 7-1 Repeat factor, 3-16
Measuring circuit test, 3-22 Reset fault, 6-6
Mixed operation Reset fault with spot repeat, 6-8
monitoring, 3-17 Reset fault with WC, 6-7
Regulation, 3-11 Retrofits, 1-11
Modifications, 1-2 Robots, 3-2
Modifications by the user, 1-11 Roll seam, 3-3
Modules sensitive to electrostatic discharge. Siehe RS232, 5-12
ESD-sensitive components
Monitor Stepper, 3-21 S
Monitoring, 3-15, 6-19 Safety instructions, 1-2
Monitoring modes, 3-17 Scaling, 3-30
Schedule diagrams, 10-1
N Seal weld, 3-3
New electrode, 6-19 Seam mode, 3-3
Secondary circuit, 5-10
O self-resetting, 8-1
offline, 2-5 Signal descriptions, 6-1
online, 2-5 Signal outputs and inputs, 5-15
Operating temperature, 4-1 Single spot, 3-2
Operating voltage, 4-1, 4-2 Slope, 3-7
Operation, 2-5 Spare parts, 1-12
Output signals, 6-13 Spot repetition, 3-24
Overview, 2-1 Spot selection, 6-4
SQZ (squeeze time), 3-9
P Standard operation
PE, A-1 monitoring, 3-17
PHA, 3-11 Regulation, 3-11
Phase angle, 3-11 Start, 6-2
Postheating time, 3-5 Starting current, 4-1
Power loss, 4-2 Status, 6-20
Power supply, 5-13 Stepper, 3-27
Preheating time, 3-5 Stepper monitoring, 3-21
Pressure control, 4-1, 5-7 Stitch weld, 3-3
Pressure feedback, 6-13 Storage, 4-1
Prewarning, 3-28, 6-18 Supply of External Devices, 5-4
Prewarning table, 3-28 Supply of timer logics, 5-3
Primary circuit, 5-10 Suppression of RF noise, 5-1
PROFIBUS-FMS, 4-1
Program selection, 6-4 T
Programming, 2-5 Test procedures, 1-11
Programming Device, 5-12 Time monitoring, 3-20
Programs, 4-1 Timer diagrams, 10-1
A-4 Bosch Rexroth AG Electric Drives PSx 6xxx.624 1070 087 027 / 02
and Controls

Appendix

Timer front, 2-7

Tipdress request, 6-17
Tipdressing, 3-27, 6-9
Tolerance range, 3-15
Toroid input, 5-10
Trail current, 3-18
Type code, 2-1

U
Ultrasonic control board, 2-4, 2-6
UST (current upslope time), 3-7

V
Voltage distribution, 5-4
Voltage source, 5-2

W
Warnings, 8-1
Wear factor, 3-25
Wear per welded part, 3-25
Weld, 6-17
Weld complete, 6-14
Weld On External, 6-5
Weld transformer selection (PSI only), 3-34
Weld/No Weld, 6-17
Welding circuit enable, 6-19
Welding circuit feedback, 6-4
Welding circuit release, 6-3
Welding current, 2-2
Welding fault, 6-17
Welding operation modes, 3-2
Welding splashes, 1-13
Without monitoring, 6-19
WLD (weld time), 3-5
Working safely, 1-13

X
X1, 5-12
X10, 5-13
X11, 5-15
X12, 5-15
X13, 5-15
X2, 5-7
X3, 5-10
X4, 5-2, 5-3, 5-4, 5-12
X5, 5-4
1070 087 027 / 02 PSx 6xxx.624 Electric Drives Bosch Rexroth AG A-5
and Controls

Appendix

Notes:
 Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 93 52-40-50 60
Fax +49 93 52-40-49 4 1
[email protected]
www.boschrexroth.com

Printed in Germany
1070087027 DOK-PS6000-E/A624*****-FK02-EN-P