Bosch Rexroth AG - PRC7000 and PRI7000 Training

Resistance welding
Training
Documentation

Weld Timer
PRC7000
and programming /
Maintenance Tool
PRI7000

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 Weld Timer PRC7000 and PRI7000

Contents Page 1
• Welding Equipment 7
• Comparison PRC7000 vs PSI6000 8
• Hardware PRC7000 9
• Diagnostic Module 12
• Hardware PRC7000 14
• ProfiNet I/O Module 23
• PRC7000 Interface overview - Review 25
• PRC7000 Welding Cabinet 26
• Resistance Welding Theory 28
• Resistances during welding 29
• Generating the %I via inverter (PSI) 31
• System requirements for Software PRI7000 34
• Check Before Installation of Software PRI7000 35
• Installation of User Interface Software PRI7000 36
• Getting started- MKT Tool 42
• MKT Tool- Adding Service 43
• MKT Tool- Adding Timers 44

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 Weld Timer PRC7000 and PRI7000

Contents Page 2
• MKT Tool- Setting Default Directories 45
• MKT Tool- Global Options 46
• PRI7000 Service 47
• Introduction to PRI7000 Version 1.6.1.0 48
• Operating Modes of PRC7000 49
• Start Screen PRI7000 53
• Icons used in PRI7000 54
• Programming Introduction 59
• Global Settings 60
• Gun Settings 62
• Tip Settings 64
• Tip dresser Settings 66
• Transformer Settings 68
• Stepper Curves 69
• Filling timer with Parameter manually 71
• Welding Job 72

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 Weld Timer PRC7000 and PRI7000

Contents Page 3
• Types of Weld Jobs 73
• Welding Job 74
• Programming a Weld Job 78
• Copy/Clone Weld Job 85
• Exercise 86
• Programming Spots 87
• Exercise 92
• Working with the training equipment 93
• Starting a WeldSpot simulation 94
• Diagnosis Introduction 95
• Diagnosis: Last welds 96
• Diagnosis: Histogram 97
• Diagnosis: Spot Overview 98
• Diagnosis: Logging 99
• Diagnosis: Spot/Spatter Overview 104
• Diagnosis: Web Interface I/O
108
• Diagnosis: Error Configuration 109

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 Weld Timer PRC7000 and PRI7000

Contents Page 4
• SetUp: Start Simulation 110
• Global Functions: Import 111
• Global Functions: Export 117
• Global Functions: Backup 119
• Global Functions: Restore 120
• Global Functions: Firmware Update 121
• Global Functions: Spot Transfer 122
• Global Functions: Timer Overview 125
• Global Functions: Timer Information 126
• Global Functions: Screen access level 127
• Prewarning: Tiplife 128
• Prewarning: Tip dresser life 130
• Prewarning: Gun life 131
• Prewarning: ActGlobalSpot 132
• Plant Layout 133
• Error Details 134

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 Weld Timer PRC7000 and PRI7000

Contents Page 5
• Creating New WeldSpots from Existing WeldSpots
138
• Using Filter in WeldJobs 139
• Activating UIR-Regulation 144
• Manual Gun Resistance Calibration 145
• Automatic Gun Resistance Calibration 146
• Activating UIR-Regulation 147
• STC Analysis 153
• Additional Information 173

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 Weld Timer PRC7000 - Hardware

Welding Equipment
Mains Input

PRC7 Machine Interface,

Rectification 000
PRC7000 I/O Bussystem

DC-Link
Weld Timer
Pressure / Force (0 -10VDC)
Inverter
1 kHz Current-Feedback primary 24 VDC Supply / Stop Circuit
VoltageFeedback
24 VDC PLC 16In- / 8Output

Voltage-Feedback

Current-Feedback
secondary
Welding Current-Feedback Welding
Gun VoltageFeedback Gun

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 Weld Timer PRC7000 - Hardware

Comparison PRC7000 vs PSI6000

 Multi Controler Timer  Approved welding system

 High Energy efficiency  One TriCore controler
 Upto 10000 weldjobs, absolutely  Standard 256 Programs
flexible in Programming and Monitoring  Flexible Hardware configuration
 Integrated PLC
 Only one Hardware per
Power level

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 Weld Timer PRC7000 - Hardware

Hardware PRC7000

 Power Unit PU  Control Unit CU

 
TriCore CPU: Multi - Core CPU System
responsible for:
Welding current ProfiNet I/O Robot Comm.
Time & Force
Ethernet IP connection

Connecting Plugs to PRI7000

 Display and LED’s

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 Weld Timer PRC7000 - Hardware

Hardware PRC7000
1. LED Indication and Display

Features:
 Three diagnosis LEDs are located at the
front side of the PRC7000 WeldTimer

CU “Status Control Unit” LED

LEDs STZ “Weld time” LED

CU

PU

STZ

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 Weld Timer PRC7000 - Hardware

Hardware PRC7000
1. LED Indication and Display

PU “Status Power Unit” LED

discharging

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 Weld Timer PRC7000 - Hardware PRC7000

Diagnostic Module
Functions:
 Display of the PRC7000 status
 Display and set of the network configuration
 Display and reset faults / warnings
 Display of timer Hardware/Firmware Versions

Exercise:
Please set the Timer IP-Address to
192.168.1.xx for XFE0 connection
According to the label on the simulator

Note: After changing the IP-Address,

you have to restart the timer to
activate the new setting !!

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 Weld Timer PRC7000 - Hardware PRC7000

Diagnostic Module
Effect of control keys
Esc Return to previous display / level.
 (Up) Move up within a menu.
 (Down) Move down within a menu.
Enter Acknowledge - or - call up the next display / level.
The  and  keys both have an autorepeat function. If these keys are pressed down for more
than one second, the autorepeat function is activated.

Automatic displays
Booting: the PRC7000 is currently booting
PRC7000: the PRC7000 is in "Ready" state (normal state)
<xxxxx>: a fault or warning is present.
<xxxxx> represents the fault or warning code.
The fault must be eliminated and reset in order to return the timer to "Ready" state.
 Hardware faults cannot be reset.
 Self-acknowledging faults are automatically reset by the system when the cause of the fault is no
longer present (e.g. line voltage off/on).
 For code numbers with explanations and possible remedies, refer to the PRI7000 online help,
Section “Messages”.

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 Weld Timer PRC7000 - Hardware

Hardware PRC7000
2. Connecting Plugs PU
TransformerPRC7 Mains
000
V U L3 L2 L1 PE

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 Weld Timer PRC7000 - Hardware

Hardware PRC7000

Plug XDS1

Plug XDS1 is the equivalent to Plug “X4” and Plug “X8” in PSI6000

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 Weld Timer PRC7000 - Hardware

Hardware PRC7000

Plug XGM1

Plug XGM1 is the equivalent to Plug “X3” in PSI6000

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 Weld Timer PRC7000 - Hardware

Hardware PRC7000

Plug XGM2

Plug XGM2 is the equivalent to Plug “X2” in PSI6000

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 Weld Timer PRC7000 - Hardware

Hardware PRC7000

Plug XGM3

Plug XGM3 is the equivalent to Plug “X9” in PSI6000

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 Weld Timer PRC7000 - Hardware

Hardware PRC7000

Plug XGM4

Plug XGM4 is new in the PRC7000 timers

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 Weld Timer PRC7000 - Hardware

Hardware PRC7000 XFE0 Ethernet port 0, user interface

Features:
• Connector XFE0 is a standard RJ45 socket

3. Connecting Plugs CU Robot • Gigabit Ethernet

• 1000Base-T, 100BASE-TX, 10BASE-T Standard
• Green LED: link - Yellow LED: activity

XFU0 USB port 0

Features:
• Connector XFU0 is a standard type A USB socket
Laptop via • USB 2.0 standard (Host)
• Type A socket
Ethernet (or USB) • Max. current consumption of device 500mA
(USB not yet implemented)
XFS1 WIC (Weld Interface Controller) port 1
XFE0, XFU0, Features:
• Connector XFS1 is a standard RJ45 socket, port 1
according to WIC
Extension for (Weld Interface Controller) standard
• 100BASE-TX, WIC-standard
more I/Os or • Green LED: link - Yellow LED: activity
further options XFS2 WIC (Weld Interface Controller) port 2
XFS1, XFS2 Features:
• Connector XFS2 is a standard RJ45 socket, port 2
according to WIC
(Weld Interface Controller) standard
• 100BASE-TX, WIC-standard
• Green LED: link - Yellow LED: activity

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 Weld Timer PRC7000 - Hardware

Hardware PRC7000
Robot

Laptop HMS V 1.6

Note: Starting with Version

V1.5.0 communication to PC or
Laptop is also possible with
plug XFE1 or XFE2.
Robot
This is possible, if your HMS-
ProfiNet Board has a Firmware
Laptop HMS V 1.10 higher than V1.10 !!!
V1.10 is standard delivery status
Laptop
since Jan.2016

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 Weld Timer PRC7000 - Hardware

Hardware PRC7000
3. Connecting Plugs CU (2)

Features:
 16 discrete inputs (24VDC)
 8 discrete outputs (24VDC)
Function:
 Connection of discrete I/O signals.

XGD1, XGD2, XGD3

discrete
inputs/outputs

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 Weld Timer PRC7000 - Hardware PRC7000

ProfiNet I/O Module 1

2
Fastening screws

LED for network status (with respect to ProfiNet controller):

AnyBus module ProfiNet IO Off: no connection to ProfiNet controller

(2-port variant)
Green: connection to ProfiNet controller established

Green, flashing: connection to ProfiNet controller established,

ProfiNet controller is in stop mode

3, 5 LED for Link/Activity (port 1/port 2):

Off: no connection to network

Green: connection to network established

Green, flashing: data transfer active

4, 6 Ethernet port connectors with integrated switch

4: Port 1; 6: Port 2

7 LED for module status:

Off: module not initialized

Note: The HMS-ProfiNet Board in Green: module is working normally
PRC7000 looks very similar Green, flashing ounce: diagnostic event detected

to a ProfiNet Board in PSI6000, Green, flashing twice: triggered by SW tool for module identification in the network

but it is a different Hardware !! Red: module error that can possibly be corrected by rebooting the
timer
Never take a ProfiNet Board from
Red, flashing ounce: configuration error
PSI6000 to transfer into a Red, flashing twice: IP address not defined
PRC7000 !!! Red, flashing 3 times: station name not defined

Red, flashing 4 times: module error

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 Weld Timer PRC7000 Hardware PRC7000

ProfiNet I/O Module

The ProfiNet I/O Module is used for communication from the Robot or Plc to the weld timer.
The signals are type specific.(customer specific).
The configuration of this module is done by the Profinet-Master. (not part of PRI7000)

Features:

 Suitable for PRC7000 (slot XFE1)

 ProfiNet (RT classification, conformity class B)
 Fast Ethernet (100 Mbit/s), full-duplex mode
 Available as 2-port variant with integrated switch
 Simple IP configuration

Function:
 Connects the timer I/O to the higher-level PLC or the robot via ProfiNet and
 connects the timer to a programming terminal (PC with PRI7000) via Ethernet.

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 Weld Timer PRC7000 - Hardware PRC7000

PRC7000 Interface overview - Review

1 XFE1 Universal interface slot
Standard: Anybus CC
Alternative: ProfiNet
2 XGSD1 SD-card and XFU1 Micro-USB
3 XFE0 Ethernet

(2) 4 XFU0 USB0

5 XFS1 WIC
(10)
(1) 6 XFS2 WIC

(11) (3) 7 XGD1, XGD2, XGD3

(4) Discrete IO block (16 inputs / 8 outputs)
Expandable via WIC (welding interface controller)
(12) (5) 8 Diagnosis module; for error display; fault Reset
(9)
(13) (6) 9 LEDs CU, PU, STZ
10 XDS1 supply +24V, Stop circuit, HSA
(14) (8)
11 XGM1 Transformer interface
Secondary voltage, Secondary current, Transformer temperature
Process interface (7)
12 XGM2, Pressure interface
13 XGM3, Force interface
14 XGM4, Analog interface
The LEDs and the diagnosis module can only display
2x analog inputs, 2x analog outputs, 2x digital inputs
the status of the WT if the logic supply voltage is present!

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 Weld Timer PRC7000 - Hardware PRC7000

PRC7000 Welding Cabinet

Front / rear view

Cabinet Type: WSC 70 RC – 300.00

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 Weld Timer PRC7000 - Hardware PRC7000

PRC7000 Welding Cabinet

Cabinet Schematic: #1070093664

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 Weld Timer PRC7000 Weld Process

Resistance Welding Theory

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 Weld Timer PRC7000 Weld Process

Resistances during welding

 At the beginning of the weld, the contact

resistances are predominant.
This is where the heating up phase begins.
Contact resistances are influenced by:
Sheet surface (contamination, oxide),
deposit on the electrode surface, force, coating.

 With increasing temperature, the contact

resistances drop rapidly and material
resistances predominate.

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 Weld Timer PRC7000 Hardware

Generating the %I via inverter (PSI)

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 Weld Timer PRC7000 Hardware

Generating the %I via inverter (PSI)

25 µs 450 µs

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 Weld Timer PRC7000 Hardware

Generating the %I via inverter (PSI)

25 µs 450 µs

25 µs 450 µs

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 Weld Timer PRI7000 Software

PRI 7000

PRI7000 GUI
PRI7000 MKT Tool PRI7000 Service (Programming
Interface)

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 Weld Timer Software PRI7000

System requirements for Software PRI7000

Please check before you install the PRI7000 software, if your computer
has

1. Windows 7 64bit SP1 or higher

2. .net Framework 4.5.1 or higher (for details look at next page)
3. 4GB Ram or more
4. ca 500MB free disc volume for installation
5. 1920x1080 resolution for your Monitor

This is essential for correct operation of the program.

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 Weld Timer Software PRI7000

Check Before Installation of Software PRI7000

If you want to check for the Microsoft .Net Framework 4.5.1 or higher is installed on
your computer, please open the “Control Panel” on your PC, Select Uninstall or
Change a Program under “Programs and features”

You can install by going to http://www.microsoft.com/net

Only continue installation after this Package is installed on your computer.

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 Weld Timer Software PRI7000

Installation of User Interface Software PRI7000

The PRI7000 Program is available as a standard MSI Installation routine.
Current version is V 1.6.1.0 (April 2016)

Please start this file for standard installation on your Win7/10 PC.

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 Weld Timer Software PRI7000

Installation of User Interface Software PRI7000

Start the program PRI7000_1.6.1.0.msi or any higher version.

For easy use select “Default Path” for your first installation.

For further installations e.g. after

Installing a newer Version, you
may use the options:
• Migrate Versions
• Select shared Path
To use the collected data in the
former Version also in the new
Version.

For first installation, please use

Default settings.

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 Weld Timer Software PRI7000

Installation of User Interface Software PRI7000

Proceed through the following screens.

Please accept the License

Agreements and start installation

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 Weld Timer PRC7000 and PRI7000

If you want to maintain the default

Location for your files
Press “Next”
- And finally “Install”

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 Weld Timer Software PRI7000

Installation of User Interface Software PRI7000

Please wait a short while until you get
The Windows7 safety request.

After this the installation will start .

and finally end with the

screen below.
Press “Finish” to close the screen

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 Weld Timer Software PRI7000

Installation of User Interface Software PRI7000

Now these 3 Programs are installed on your computer, ready to use.

1. PRI7000 Service
Start this Program to start the data service

2. PRI7000 GUI
This is the graphic user interface for Programming
and servicing the Timer PRC7000

3. PRI7000 Master Konfig. Tool

Here you can configure the operation of the
PRI7000 User Interface

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 Weld Timer Software- MKT Tool

Getting started- MKT Tool

1. Start the Master Konfiguration Tool (MKT) program first.

2. Log in using the NWS-Login Domain

3. Select UserName: System

Password: System

Press Ok

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 Weld Timer Software- MKT Tool

MKT Tool- Adding

Service
4. Select the menu: “Service”

5. Enter your PC’s name in the

column “Service Name”.
You will find this name in the
Screen: Control panel \ System.

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 Weld Timer Software- MKT Tool

MKT Tool- Adding Timers

6. Select the menu: “Timers”.

7. Enter the Timer Name, Timer IP Address and your PC Name in Service List
(Please check the different labels on your timers and PCs)
8. Save your input.
9. Check for confirmation message in the base line (bottom left side)

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 Weld Timer Software- MKT Tool

MKT Tool- Setting Default

Directories New from Version 1.6

10. Select the menu: “Import / Export”.

11. In this screen, you can define, where

the different data sets shall be stored.

Once activated, all the information to get the

software running will be uploaded from the network
folder path given here

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 Weld Timer Software- MKT Tool

MKT Tool- Global Options New from Version 1.6

12. Select the menu: “Global Options”

If you want, change the feature
“ActiveDirectoryLogin” to “NO”. This
avoids unnecessary mouseklicks
during “LOG IN”. BMW setting is “Yes”

Option1: Timer -> PRI7000 (default),

Option2: PRI7000 -> Timer
Depending the option selected, the
timer name will be updated in Timer
and software (PRI7000)

You can set the autologoff time for

PRI7000

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 Weld Timer Software- PRI7000 Service

PRI7000 Service New in Version 1.6

13. Close the MKT Program and start the PRI7000 Service Program
14. check in this screen the Service Status and TimerStatus.

If the default port is not available, the port can be configured freely. The configuration is stored
(C:\Program files (x 86) \Bosch Rexroth AG\PRI
7000_1.5.1.0\CS\ServiceConfig\NWSService.Config) and used the next time, if the default port not
available.

15. Minimize the Service screen and Start the PRI7000 User Interface

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 Weld Timer Software PRI7000

Introduction to PRI7000 Version 1.7.2.0

In this section of the training you will learn about the different areas
and topics of the program PRI7000 in an introductory view.
The details about the different screens will follow in a later section.

We will now look into the:

• Main program areas as Programming, Diagnosis and Overview
• The use of the different icons
• Practice exercises to get familiarized with the program

Of special interest of the program are the use cases:

• Quick loading of many timers with startparameter
• Diagnosis and data examination

For testing and self experiencing please use the training

Simulators.

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 Weld Timer Software PRI7000

Operating Modes of PRC7000

Weldspots and Weldjobs, similar as the Programs in the PSI6000 systems can be
executed in different operating modes:

1. PHA – Mode: This is no longer used for welding activities, but for Service
activities.
Programming current with “Phase angle values” or “%I”, force and time.
No current feedback required.

2. CCR – Mode: This is typically used for welding activities – in detail –

Programming weld parameters current with “kA values”, force and time.
Current feedback required.

3. UIR – Mode: This is also used for welding activities in adaptive mode.
Programming weld parameters current with “Reference curves”, force and time.
Current and voltage feedback required.

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 Weld Timer Software PRI7000

Operating Modes of PRC7000

PHA – Mode:
Feedforward control. No feedback. No reaction of the system to any changes.

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 Weld Timer Software PRI7000

Operating Modes of PRC7000

CCR – Mode:
Closed loop control for current in ms. Reaction of the system to changes in current.
No reaction of the system to changes in the weldprocess.
Timer always welds with programmed Parameter for: Current, Time & Force.

No reaction of the system to changes in the weldprocess.

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 Weld Timer Software PRI7000

Operating Modes of PRC7000

UIR – Mode:
Closed loop control in ms against the reference curves.
Reaction of the system to changes in the weldprocess.
UIR Regulator becomes Master of the Current Regulator and modifies the current
during the weldtime and – if necessary – prolongates the weldtime.

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Start Screen PRI7000 Version 1.7.2.0

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Icons used in PRI7000 (1)

In the top line, you see the active PRI7000 Version 1 and your user level 2

2 3

For changing the user level

press into the area 2
and enter your Username and Password.

Here for training:

Select Username: System
Password: System
Press “Enter” to log in.

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 Weld Timer Software PRI7000

Icons used in PRI7000 (2) New in Version 1.6

In the top line, you also see these options:

1 2 3 4
2

1. Shortcut to selection of Query Builder Configuration

2. Help: Online HELP for PRI7000
About: Information about the version
and date of the PRI7000
2
3
3. Here you may change the language

4. Here you can “Logout” and change the user level to “Everyone”.
Level “Everyone” is watch only status.

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 Weld Timer Software PRI7000

Main Icons used in PRI7000 (3)

Main program areas in PRI7000
1. Programming
2. Diagnosis
1 2 3 3. SetUp
(for UIR-Regulation and STC Mode)

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 Weld Timer Software PRI7000

Status display
Icons used in PRI7000 (4)
5
4
5 Link to Prewarning
(Gun Life, Tip Dresser
1 2 3 Timer Tips Tip- Gun
Link to Life, Tip Life)
dresser
Error Table
Navigation in PRI7000
1 2 3
1. Here you may jump back to the previous page.
When you press this button the display changes to =>
2. Now you may go back to the next page again.
3. Here you can always get to the Start Screen.
4. This area is for Timer selection and communication status:
green: The selected timer is connected
yellow: The program is trying to connect to this timer
red: The selected timer is not connected
5. Here you see the status of the sub- components of this timer (gun, Tip Dresser, Tip)
green: ok red: Error grey: not defined

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 Weld Timer Software PRI7000

Shortcut Icons used in PRI7000 (5)

1 2 3 4 5 9 6 7 8

Shortcut Icons in PRI7000

(accessible from every page)

1. Parameter Import 4. Logging

Parameter Export Spot/Spatter overview
2. Backup Histogram
Restore Overview Spot
Auto Backup
3. Timer Overview 5. STC Recording
Timer Info STC Analysis
Spot reference 6. Firmware Update
Spot Transfer 7. Start Simulation
Prewarning 8. Screen Access level
Plant Layout 9. NEW Training Mode
Error details
Error Configuration

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Programming Introduction
In the area “Programming” you can edit
and enter all data you need
3
for your Welding process
• Global Parameter
1 • Weldjob 1
• Heat stepper
for your welding equipment
• Tips
2 • Guns
• Tipdresser
• Transformer 2

3 and for your weldspots.

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 Weld Timer PRC7000 and PRI7000

Global Settings

All parameters
similar to BOS6000

Current monitoring ON by default

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Global Settings New in Version 1.6

2
1

1. This parameter is active in Version >=1.6.

In the future, when all the spot information is saved in a central database, the robot will have the
capability to validate the information between the database and timer. If there is any difference in
info, the data from the database will be uploaded to the timer. This is achieved by setting the
“Enable dynamic data requests” parameter to ON.

As of now this setting is not implemented. This is done using the Profeb tool

2. The special help icon on top of every page directs to the help file corresponding to that page

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Gun Settings This is similar to the “Electrode” page on BOS6000

As default setting, there is a Dummy Gun for test defined:

Press the + Sign to add a new Gun and give a new number 1 and name 2

1
2

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Gun Settings Note: Do not forget to specify the

Transformer Type !!
Important parameter:
Gun Number: any identification No.
Gun Name : any identification Name
Gun Transformer count: how many transformers are
connected
Current measurement selection: Primary / secondary

Max. Current: specifies the max. current to be used

Max. Force: specifies the max. force to be used

Gun measuring range: defines the current measuring range

i.e. the max. current to be used w/o fault

Transformer selection: please select the transformer 6130.11 type

Voltage measurement: Switch on voltage measurement for all

weldjobs of this gun. (general measurement)

Check the different parameter using the online help!

Activate the parameter and press “F1”

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Tip Settings This is similar to the “Stepper” page on BOS6000

Important parameter:
Tip Number: identification No. linked to
gun No. (automatically set)
Stepper active: turn ON to activate prewarning
Warning Counts: Number, when end of tiplife is
generated (Tipchange request)
First Wear: Defines the end of Start phase
and beginning of Stepper phase
Tip Max Wear: Number, when a Tip error
is generated (Tipdress required)
Tip dress request: Number, when a Tip warning
is generated (Tipdress request)
Max Tip dress no.: max. No of Tipdress
Revolutions per tip dress operation: When using a
pneumatic tip dresser, you can set the revolutions
based on the cap diameter

Select tip dresser name: see next page!

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Tip Settings
For selecting a tip dresser use the dropdown menu.
If you have a tip dresser configured, this will open a list with active tip dressers.
Now you may select one of the active tipDresser 1 or use the link to the tipDresser parameter 2

1 2

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Tip dresser Settings (optional)

1 5

First step, this page is empty.

1. Press the + to add a new Tip dresser.
2. Open the Parameter settings.
3. Enter the following Parameter:
2
Tip Dresser No: 1
Tip dresser change warning: No. when Tip Dresser gives
a warning
Tip dresser end of life: max. No.of Tip Dresser operations 4
Tip Dresser name: any customer specific name
4. Press enter to save changes
5. For deleting a tip dresser, use the – sign.
You have to confirm deleting.

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Tip dresser Settings (optional)

Tip dresser Parameter:

If you need explanation for the individual parameter, please mark the
parameter input area and press the “F1” (help Button)

In the bottom line, you will see the input range for the marked parameter

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Transformer Settings

For BMW Spartanburg PSG6130.11 is the only Transformer Type used, so you don’t have to
specify any parameter.

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Stepper Curves (optional)

Stepper curves
There are 2 Stepper curves already predefined in the timers.
No.1 with exponential and No.2 with linear characteristic.

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Stepper Curves (optional)

If you want to create a new Stepper curve:
Press the + Sign to add a new Stepper Curve and give a new name

Create as many input lines you need by pressing the + sign and enter Values.

finally save the parameter.

check for white background
or the message “Success”.

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Filling timer with Parameter manually

Please follow the given sequence in programming:

1. Global Settings
2. Transformer Settings
3. Tip Dresser Settings
4. Stepper Curves
5. Gun Settings
6. Tip settings
7. Weld Job
8. Spot Reference

This means:
In gun settings, you need data from transformer settings.
In Tip settings, you need data from tip dresser settings and stepper curves.
In the spot reference, you need data from the gun and from the weld job.
So the above shown sequence avoids loops in entering data.

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Welding Job
A Weld Job is similar to a program number in BOS6000. In BOS6000 there was a limitation to
create only 256 different weld schedules per timer. The PRC7000 has the capability to create up to
10000 different weld jobs per timer

The main programming screen of a weld job is divided into 5 main parts:

1. The “Graph” showing the type of weld schedule programmed

2. “Weld Block Values” where the welding parameters (Time, Current, Force) corresponding to
each sequence block are entered. 50 different weld blocks can be programmed per weld job

3. “Monitoring Values” where the different monitoring parameters are configured for UIR
Regulation

4. “Sequence Values” where different sequence blocks are programmed. A Sequence Block can
be a “Pre Weld”, “Main Weld” or “Post Weld” and up to 10 different sequence blocks can be
added per weld job

5. “Weld Job Values” where the additional program/weld job specific parameters are configured

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Types of Weld Jobs

In the weldjobs, we have 2 different types:
1. Service activities with Type = 0 as:
Tipdress routines
calibration routines
Tipdress check etc.

2. Welding activities:
Type is not 0
and any name is possible.

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Welding Job
Programming a Weld Job:
Use the following steps to generate a weld job:
1. First step is to determine what kind of weld schedule is programmed. Depending on that it is
necessary to add the corresponding Pre, Main or Post weld Sequence blocks under
Sequence Values  Sequence General. To start easy only use 1 Main Sequence

2. Create the current profile entering parameter in the list for “Weldblock Values”
Check the visualisation on the screen.

3. Enter additional Parameter in the list for “Weldjob Values”.

4. Enter Monitoring Parameters under “Monitoring Values”.

Current monitoring is active automatically in all weldjobs. The tolerances are defined in the
global parameter

Let’s start with an easy example using one of the weld templates
There are 6 different weld templates for standard weld current profiles.

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Welding Job
For an easy exercise, please use “templates No.6”. Use the + sign to create a new weld job.

Please select this template No.6

with a double click.

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Welding Job
Now you see in the top of the screen the current profile:
You have one Main Sequence, using 9,0 kA for 100 ms

“Radial Menu”
to open or close it:
press the centre area.
Details next page!

Scroll down to get to the table to enter “Currents, time and Force”.

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Welding Job- Radial Menu

In this “Radial Menu” you have an “Inner” 1 (light blue colour)
and an “Outer” (dark blue colour) regions
2 1
Pressing on 1 you can quickly switch “Regulation” , “Monitoring”
ON or OFF for the selected weldjob, or for the full timer (Global)

Pressing on 2 you can quickly switch individually “Regulation” , “Monitoring” ON or OFF for all
spots using the selected weldjob.

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Programming a Weld Job

Weldblock Values:
1. Please scroll down, to get to the input area for weldparameter under “Weldblock Values”
section

2. Create a new input line using the right mouse button in the Area “Main1”

3. Enter the below given parameters corresponding to Welding Block number 2

These current values are taken from the template i.e. 9kA

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Programming a Weld Job

4. Save the new weldjob with any new name. (here I used “WeldJob1001) When the input is
saved, the background colour turns to white in the input table.

5. After successful save, the WeldJob looks as follows

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Programming a Weld Job

Graph:
Check the current profile in the graphic display:

“Radial Menu”

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Programming a Weld Job

Sequence Values:
Please scroll further down, to get to the input area for “Sequence Values Sequence General”:
1. Select the regulation Mode. KSR or PHA
2. Enter limits for UIR Regulation

1 2

3. Enter additional UIR Parameter in “Sequence ValuesSequence advanced”: (only if required)

3

4. You can also add an additional weld sequence by pressing right mouse button on “Main1”

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Programming a Weld Job

WeldJob Values:
Please scroll further down, to get to the input area for WeldJob Values:

x 0,1mm

Parameter for Heat/Force Stepper

Parameter for voltage sensor test UIR

Additional Parameter for UIR

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Programming a Weld Job

Here you see an analogy between BOS6000 and PRI7000 parameter

2 3 4

1 1 Parameter for Heat Stepper

2
3
4
Parameter for Force Stepper

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Programming a Weld Job

Monitoring Values:
Enter the Monitoring Values:
HINT:
Use the right mouse button in the area
Sequence Values\ Main1 and select:
“Add Monitoring Block” to create a monitoring
Block.

Now you can select any monitoring Value like: UIP, PSF, FQF, Resistance, Time or Voltage and
edit the reference value and tolerances.

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Copy/Clone Weld Job

After entering the first weld job, you can duplicate this one WeldJob into many WeldJobs (up to 10
at once) using
the “Copy” or “Clone” Option.
Copy: Copy data from one WeldJob into another
defined WeldJob.
Clone: creates duplicates of a WeldJob with the same
Name with appendix “Clone xyz”

Now you can modify the parameter in these Clones and finally
modify the names to get new WeldJobs.

In the bottom line you get a Copy/Clone Status message

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Exercise
Task 1:
Create 3 clones for the already existing WeldJob. Change the names of the cloned weldjobs

Task 2:
Enter the following Parameter for WeldJob1010, WeldJob1011 and WeldJob1012.

Please use the “Copy” or “Clone” feature.

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Programming Spots
A spot must be defined with Type-ID first, separator sign, Spot number and any
additional comment text. Type-ID and Spot number are sent from Robot to timer via
ProfiNet Interface.
In the Spot declaration, there are also these 2 different types:

1. Service activities with Type 0 and any Spotnumber

2. Welding activities with Type not 0; here Type = 1 and any Spotnumber.

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Programming Spots
BMW requirement for a Spot Name is: Type ID and Spotnumber (separated 2 Numberblocks)
These are sent from the robot to Timer for Spot selection through the ProfiNet Interface.

Possible spot names: 0_0 Typ=0 Spotnumber=0

1_1001 Typ=1 Spotnumber=1001
1,1001 Typ=1 Spotnumber=1001
Typ1_Spot1001 Typ=1 Spotnumber=1001
Any letters in the Spot Name are only comment for the users, the timer only needs the numbers!

Use the + sign to create new Spots for your Welds (this creates a system spot name)

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Programming Spots
New in Version 1.6

Open this green spot(new)

1. Select the used Gun
2. Set “Spot Inhibit” to “Off”
3. Specify the SpotName
4. Select the Timer Name
1
5. Set “weld on to ON” (with current)
6. Select the WeldJob
7. Req. error reset User level 7

2
You may leave the other 3
parameter predefined!
4

Save your input and check 5

That the background colour 6
Changes to white

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Programming Spots

On selecting a spot name from the spot reference overview, you will notice a comment
list on the right hand side corresponding to the spot you have selected. At the moment,
these spot comments cannot be entered manually but only through an XML file import

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Programming Spots
New in Version 1.6

1. Copy: Copy data from one

Spot to another existing 1
Spot. 2
2. Clone: creates duplicates of a Spot 3

with the same Name and an 4

extension number
3. Export: Only the spot information is exported to an XML file

4. Linked export: Every spot is associated with information corresponding to

weldjob, transformer, gun etc. All this info is present in this linked export file

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Exercise
Task 1:

Create 4 unique spot names (using either copy/clone feature) and assign them to four different
weld jobs. Follow the Type ID corresponding to a welding program

Task 2:

Create 2 unique spot names (using either copy/clone feature) and assign them to 2 different weld
jobs. Follow the Type ID corresponding to a service program

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Working with the training equipment

Weld Trainings Simulation with Touch Panel and weld timer simulator
For safe and easy to use training equipment, we have prepared several simulation units
for the new welding system PRC7000.

This equipment allows you to test all

operations with the hard- and software
with low voltage input (24V).

On the Touchscreen, we have prepared

all the output signals, which usually the
Robot sends to the timer.
Here in training, you will have to do enable
all the robot activities by yourself.

NOTE: There is a 230VAC

input plug at the left
side of the panel.
Take care !

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Starting a WeldSpot simulation

Trainings Simulation with Touch Panel
With this screen you can activate the Inputs to the timer on the left side of the screen in the big
areas and you get the Output signals shown in the small fields on the right side of the screen.
output active = any colour display
output inactive = Grey
6
Please follow the sequence:
1. Enter your Type ID 1
2. Enter your Spot Number
3. Press button “Spot selection TEST T” 3 2
4. Check for feedback signals: 4
“Data valid” & “Spot valid” getting green
5. Press sequence enable
6. Press “Start” 5
enable
7. Check for the output “Weld complete”

Now the WeldSpot should be done

and you should hear a “beeeep” sound,
similar to a real weld.

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Diagnosis Introduction
In Diagnosis there are the following options:

1. Last Welds: Display of the Weld Graphs and

individual Information for one weldspot

2. Histogram: Summary Information for many

weldspots on one screen

3. Overview Spot: Overview about the regulation

and monitoring conditions of the weldspots.

4. Logging: Display of the protocols of the timer

i.e: “Error Log”, “Weld protocol” and “Data Change

5. Spot / Spatter overview:

In this screen, you can easily identify spatters

6. Web Interface: Displays the status of Input- and

Output-signals at the timer interface
(no automatic refresh)

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Diagnosis: Last welds

In the area “Diagnosis” you can get
Information about your Welding process.

In the “Last welds Screen” you get details

about the last welds:

1. Numerical information
2. Graphical display
3. Status feedback about: 3
regulation mode
monitoring mode 1
Fault / no fault.
4. Using the “Previous Weld Button”
you may go back max. 20.000 2
welds in every timer.
5. Press the green “update” Button
to restart continuous display for every 5
new weld. 4

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Diagnosis: Histogram
In the “Histogram” you can visualise summary
Values and Graphs for many weldspots:
You can select:
• Weld spot names
1• STC Numbers (Sheet Thickness Combination
• Weld job names 1
2
Push the “update” 2 button to
activate new selection

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Diagnosis: Spot Overview

In the “Spot Overview” you see regulation and
monitoring status of your weld spots with:
1. Timer, Spot name and weldjob relation
2. Switch setting e.g. UIR regulation “ON”
with the option to change “ON” <=> “OFF”
3. The active regulation / monitoring status with red / green circles ( OFF / ON)
4. The parameter, which are monitored (red colour = no monitoring defined)

1 2 3 4

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Diagnosis: Logging
On the page “Logging” you see the different logs.
1. Please select Start, End Date and timer(s).
2. Select, which protocol you want to see.
3. Whenever you change a filter (1) press “Update”
to activate the new selection.
4. You can easily export the log files in .csv format and directly open the directory.
1 1 1

2 3 4

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Diagnosis: Logging
New in Version 1.6

Details for “Weld Protocol”

In the weld protocol you get a lot of information about
all your welds. This is a very big table of data.
1. Please select Start, End Date and timer(s)
2. Select the filter icon corresponding to each column to narrow
the selection based on a particular parameter
3. Query Builder Configuration (more details on next page)

1 1
3

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Diagnosis: Logging
New in Version 1.6 1

Details for “Weld Protocol”

“Query Builder”

1. Query Builder Configuration:

Using this, you can select the
columns you want to see under
the Weld Current Log

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Diagnosis: Logging
New in Version 1.6

2
Details for “Weld Protocol”
2. Query Builder: Parameters can be
filtered based on the queries written in
this section

Example:
Objective: I want to only look at and export values corresponding to “Gun_1”.
Result: In the “Query Builder” I select the “Field” as “Gun name”. Operator as “=“ and Value
as “Gun_1”. Once I click “Save”, the Weld Protocol only shows rows corresponding to
“Gun_1”

 Question: What is the difference between Query Builder and Filter option

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Diagnosis: Logging
New in Version 1.6
1

Details for “Data Change Log”

2
The data change log has been completely
redesigned in Version 1.6

1. Please select Start, End Date and

timer(s)
2. Select the filter icon corresponding
to each column to narrow the
selection based on a particular
parameter

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Diagnosis: Spot/Spatter Overview

In “Spot/Spatter Overview” you can identify the
Spatter rate of the weld within a defined period.
1. Please select Start, End Date and timer(s).
2. Select the listing criteria

3. In the base line, you can activate also Spots without spatters or switch pages.

2
1 1 1

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Diagnosis: Spot/Spatter Overview

New in Version 1.6

1. After Selecting “STC Teach Name” from the drop-down menu, the screen will be split as
shown below:

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Diagnosis: Spot/Spatter Overview

New in Version 1.6

After selecting a particular STC name on the left hand side, Weldjob name and spot column will be
added and expulsion % will be calculated for each weldjob and spot name corresponding to that
STC name

1. Expulsion info based on

STC Name 1
2
2. Expulsion info based on
Spot name and Weld Job
corresponding to the
selected STC Name

1
2

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Diagnosis: Spot/Spatter Overview

New in Version 1.6

Spot/Spatter overview screen gives information about the Q-stop error count

1. STC-related Q-stop error

count
1
2. Spot related Q-stop error
count

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Diagnosis: Web Interface I/O

In the “Web Interface” you see the situation on the
ProfiNet Interface of the timer at the time, this screen
was displayed. (no automatic refresh!!)
To refresh the status, press “F5” in order to see the updated
I/O signals
NOTE: The IP-address identifies the timer.

Summary information

bit information

Red 0 = inactive
Green 1 = active

Inputs Robot => timer Outputs timer => Robot

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Diagnosis: Error Configuration

New in Version 1.6

Users can configure, what message is an

error and the message is a warning.
There are messages
that are not
configurable.

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SetUp: Start Simulation

In the screen “Start Simulation ” you are able to start
a weld from within the PRI7000 program.
For training purpose this is quick and easy.
At real welding equipment, please be very careful and
observe all necessary safety requirements and customer instructions.

Here in training environment,

please:
1. Select any Spot name
2. Press “Start Simulation
Prepare spot” first.
3. Press “Start Simulation 1
with ignition”

Now the WeldSpot should

be done and you should 2 3
hear a “beeeep” – if there is
current programmed in the
selected spot.

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Global Functions: Import

You need to have a prepared .xml-file with all required data.
Here in training, please use the file: BMW_Timer_StartData.xml

It is recommended to view the .xml file in Notepad++ for better

visualization

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Global Functions: Import Redesigned in Version 1.6

1
2
3

1. Now you have the option to import one file only (File import).
2. Or – to import many data files from a folder on your laptop (Folder import).
3. Select the file that you want to import.
4. Select “Analysis file” option. The software will then compare the parameters
between the import file and the ones already existing in the timer.

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Global Functions: Import Redesigned in Version 1.6

5. After the analysis, a summary of the similarities 5

and differences between the import file and
timer are populated
6. Black color text implies that the parameter is
6
present in the import file but not in the timer
7. Orange color text indicates that the parameter
is present both in the timer and import file 7

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Global Functions: Import

Open the page: Import Folder Import
1
Prerequisites before you use Folder Import:

1. Create a folder on your computer with the 2

same name as your Service Name
2. This created folder should contain the import
files for all the timers (XML format)
3. Each of those import files should have the
correct corresponding timer information i.e. IP
Address and LinePC info

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Global Functions: Import

1
2 3

4
1. Select the folder import option
2. Select your computer
3. Select the subdirectory that you want to import.
4. Select the Import option. Now individually data for all timers are imported.
5. You will see the timer in the list and an “In Progress” display showing data is being imported to the
respective timers

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Global Functions: Import

Open the page: Import Folder Import

6. If all the data in the import files is correct, you will see “Job succeeded” corresponding to each
parameter section

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Saving Timer Information

The PRI7000 program offers two different options for Data Saving:
1. Backup and Restore:
Here you create one .zip-file, containing all information of a specific timer.
With “Restore”, you create an absolute identical timer (clone)

2. Data Export and Import:

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Global Functions: Export 1

1. Select the “Export” option either from the Global Functions or

using the short cut icon
2. Determine the location where the export file will be saved.
Click on a to change the location

3. Determine the parameters to be exported (selective import) or select “All Param

Groups” to select all the parameters
4. Select the timers for which the parameters have to be exported and click on
“Export” at the bottom right hand corner of the screen
a
2
3

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Global Functions: Export

5. The output of the “Export” function is an XML file that has all the information
regarding the timer as well as the parameters selected for export

NOTE: It is recommended to open all XML files in Notepad++

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Global Functions: Backup

Whenever you change or enter parameter, make sure to save your data:
A backup creates a .zip file with all relevant data of the timer.

1
4
3

1. Please select the timer(s), you want to create a backup file. 2

2. Press the button Ok.
3. The backup file is created and
stored in the specified
subdirectory.
4. Check the status bar.

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Global Functions: AUTO Backup

Whenever you change or enter parameter, make sure to save your data:
From time to time it is advisable to generate the backup automatically

2 3

5
4
6

1. Please select the timer(s), you want to create a autobackup file.

2. Please select the sequence (Day, Week, Month)
3. Please select the cycle and time for the backup
4. Save the settings .
5. The autobackup will saved at the set folder (MKT)
6. In the status bar the last/next cycle will be shown

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Global Functions: Restore Individual File

Unlike BOS6000 where you have to restart the software in order to perform a
Restore, PRC 7000 lets you restore from within the software itself

2 3 4 5
1
6

1. Please select the timer (timers), you want to restore.

2. Select this option if you want to restore the weld protocol data
3. Select this option if you want to restore the histogram data
4. Select this option if you want to restore the data corresponding to data change log
5. Select the restore file corresponding to the timer
6. Press the Ok button. Now the timer will restart

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Global Functions: Restore Common Restor

Unlike BOS6000 where you have to restart the software in order to perform a
Restore, PRC 7000 lets you restore from within the software itself

2 3 4
1

6
1. Please select the timer (timers), you want to restore.
2. Select this option if you want to restore the weld protocol data
3. Select this option if you want to restore the histogram data
4. Select this option if you want to restore the data corresponding to data change log
5. Select the restore file corresponding to the timer – all timer get the same data
6. Press the Ok button. Now the timer will restart

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Global Functions: Restore Folder Restor

Unlike BOS6000 where you have to restart the software in order to perform a
Restore, PRC 7000 lets you restore from within the software itself

2 3 4
1

6
5
1. Please select the timer (timers), you want to restore.
2. Select this option if you want to restore the weld protocol data
3. Select this option if you want to restore the histogram data
4. Select this option if you want to restore the data corresponding to data change log
5. Select the option “Folder Restore” The restore will identify the backup by IP Address and upload
to the corresponding timer

6. Press the Ok button. Now the timer will restart

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Global Functions: Firmware Update

All Firmware updates will be done from within the PRI7000.

The FW Update files have a .zip extension

1. Select the FW file

2. Select the timers to update
3. Click on “FW Load” and wait for the Status to turn Green
4. After 5 seconds of the Status turning Green, click on Trigger FW
Update. The timer will restart on successful load of the FW

3 4

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Global Functions: Spot Transfer

Spot Transfer: You can use this screen for moving spots within
the Production line.

1. This Option moves a spot from one timer to another timer selected under
Target timer 4
2. This Option creates a copy of a spot
3. You may use a “Filter Option” for easy use.
3 1 2
4

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Global Functions: Spot Transfer

The main advantage of Spot Transfer function is the ability to move spots
easily even when they are on different line PC’s

1. First determine the Spot(s) you want to move or copy to another line PC
by selecting the Check boxes next to the corresponding Spot names
2. Select the “Copy Spot” or “Move Spot” option depending on the requirement
3. Select the “Start transfer” option
4. After successful transfer, the status message will read “File moved to repo Success”
2 2

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Global Functions: Spot Transfer

5. At the bottom of the Spot Transfer screen, you will see the spots that you
selected in the previous step. There will be symbol next to these spots
6. A new folder “SpotTransferRepository” will be created in
C:\ProgramData\Bosch Rexroth AG\PRI 7000Data\UI
Copy the “SpotTransferRepository” folder to a flash disk and paste it on the
destination line PC under the same path shown
7. Open the Spot Transfer function on the destination line PC and you will see the
spots that are moved/copied at the bottom of the screen as shown in 5

8. The spots can now be copied/moved to the timer of your choice using the normal procedure

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Global Functions: Timer Overview

1. Timer Overview:
Here you can analyse the communication Status and IP-Addresses
of the listed Timers in the Master Config Tool.
2. Timers can be added or deleted using the + and – options. It has the same
result as doing it in the “MKT-Program”
3. “Set host name” option can be used to update the existing timer name

1
2

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Global Functions: Timer Information

Timer Information gives detailed Information about the
Firmware components inside the Timers
e.g. Firmware on the ProfiNet Module

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Global Functions: Screen access level

If you are logged in with System level, you can then determine the read
access and write access level for each and every parameter in the PRI7000
program.

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Prewarning: Tiplife

1. As in BOS6000, Tip Life shows information about the remaining parts, a coloured bar
indicating the wear and also the actual Wear and Dress counters
1

2. For tiplife you see the maximum parameter defined in Tip settings

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Prewarning: Tiplife

1. In order to modify the actual wear or dress counters, the value in the yellow column could
by modified

2. Click on to resume the modified Wear and/or Dress counters

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Prewarning: Tip dresser life

In “Prewarning\ Tip dresser life”, you see the list with the wear status of the
Tip Dresser Wear in % and colour display:

green: no message
yellow: Prewarning
red: end of lifetime

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Prewarning: Gun life

In “Prewarning\ gun life”, you see status of the different gun component counters.
(These are not used by BMW)

green: no message
yellow: Prewarning
red: end of lifetime

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Prewarning: ActGlobalSpot

1. AllSpotData section under ActGlobalSpot gives Q stop global information for all the spots

2. This section gives spot specific Q- stop information

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Plant Layout
In “Plant Layout”, you see the list with the status of the connected
1. Timers
2. Tips
3. Tip Dressers
4. and guns.

The colour code is

Explained at the
Bottom of the screen

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Error Details
In “Error Details”, you see the list with the active
Errors, Warnings or Status Messages.

1 Reference to error protocol: 1

If there is a weld fault, you get a link to the display of this particular Weldspot.

Here some hints from the

Online help.

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Error Details
To clear a fault message:
Resolve the problem first. Then
1. Select the fault
2. Select one of these Options
or activate the I/O Signal for “Fault reset with reweld” or “Fault reset with weld complete”

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Error Table
The Error table has the same functionality as the page before:
To clear a fault message:
Resolve the problem first. Then
1. Select the fault
2. Select one of these Options
or activate the I/O Signal for “Fault reset with reweld” or “Fault reset with weld complete”

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ADDITIONAL INFO

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Creating new weldspots from existing weldspots

Whenever you have add new weldspots, then you can duplicate an existing Weldspot into
many Weldspots using the “Copy” or “Clone” Option, very similar to the weldspots.
Press the right mouse button into the yellow highlighted area of the spot, you want to
duplicate.
Copy: Copy data from one Spot into other predefined spots.
Clone: creates duplicates of a Spot with the same SpotName with appendix of 4 digits.
Rename the clones by opening the spotparameter and changing the spotname.
Do not forget to save !!!

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Using Filter in WeldJobs

If you work with many weldjobs or weldspots in several timers, it is very helpful to use the Filter
Option:
WeldJobs:
1. Using no filter, you see many different WeldJobs
2. Entering #31 in the Filter Area, you only get Weldjobs with Type ID 31
Hint: # xx selects for any in between string xx in the weldjob names
% xx selects for the string xx at the end of the weldjob names

1 2

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Using Filter in WeldJobs (2)

If you have selected a Filter Option,
1. you may use the “UP” or “Down” Arrows to select one weldjob after the other to inspect the
graphic display of the weldcurrent.
2. In the graphic display you see command and real values, if this weldjob was done as last
weld. Red: thick line = command current, thin line = real current
thin Black line = Reference Curve, thin green line = real resistance

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Using Filter in WeldSpots

WeldSpots:
1. Using no filter, you see many different WeldSpots
2. The first line is the filter line
Entering Timer1 in the Filter Area, you only get WeldSpots of Timer1.
You can set filter on: Spot_Name, WeldJob,Timer and Gun

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Using Filter in WeldSpots (2)

3. You can also combine several filter.

3a 3b

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Using Filter in Error Log

You can set some filter for characteristic problems like description. For this drag and drop the
marked position 1

Now the new option give You a overview about the different type of error.

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 Weld Timer PRC7000 and PRI7000

ADAPTIVE REGULATION

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 Weld Timer Software PRI7000

Activating UIR-Regulation Preparations (1)

1. Check that the “Voltage Measuring” is in good condition. (Cable, Shield,
Position and signal shape)
2. The timer calculates the dynamic resistance every ms based on R= U/I.
3. So – depending on the position of the voltage measurement the timer always
calculates the total resistance of the equipment.
One part belongs to the weld-Process, the other part belongs to the weld-equipment ( = gun)

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 Weld Timer Software PRI7000

Activating UIR-Regulation Preparations (2)

Before we start, we want to measure the resistance, which belongs to the gun. There are 2
Options:
Manual procedure: (Initial Gun Resistance Calibration)

1. Change the Tips and perform an initial tip dress cycle.

2. Start the “Tipdress check Program.
BMW uses a service routine 0, 24x
(x represents the number of the gun)
3. Watch the green Resistance curve in the
Last weld screen. (Characteristic “dead curve”)

3
4. Check the gun parameter for the used gun.

5. Enter the measured actual resistance manually into:

Current gun resistance and test value gun resistance.

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 Weld Timer Software PRI7000

Activating UIR-Regulation Preparations (3)

Automatic procedure: (Initial Gun Resistance Calibration)
for BMW Timer
1. Change the Tips and perform an initial tip dress cycle.
2. Set the Timer-Input “Gun Resistance Calibration” at Robot
3. Open the gun parameter: (only to see, what happens)

4. Start the “Tipdress check Program.

5. Watch the green Resistance curve in the
Last weld screen. (Characteristic “dead curve”)
6. Check the gun parameter for the used gun.

If you use this automatic routine for the first time, the actual gun resistance is copied into both
Parameter; Current gun resistance and test value gun resistance.
If you use this automatic routine after gun change, the actual gun resistance is copied only into the
Parameter “Current gun resistance”

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 Weld Timer Software PRI7000

Activating UIR-Regulation (in General)

1. Select the weldjob, you want to set to UIR-Regulation
2. Use UI-Setup Screen and collect 10-20 weldcurves (resistance) for this weldjob with the same
set of Parameter.
3. Check these collected curves and refine by:
a.) Delete the curve manually Spatter or spots with bad quality
b.) Delete all expulsion curves The first 5-10 spots after tipdress and the last spots before
tipdress.
c.) Delete all curves for current Weldjob
d.) Delete all curves for current Weld Timer
4. Create an average Curve from the remaining curves.
5. Send this average curve to timer.

Finally activate global and spot 1

related regulation (and monitoring) 2

3
4
5

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 Weld Timer Software PRI7000

Activating UIR-Regulation (Exercise)

1. Select UI Setup
2. Start WeldJob32_1113 on the Simulator about 20 times, turning the potentiometer.
3. Select WeldJob32_1113 and Press the “Update” button

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 Weld Timer Software PRI7000

Activating UIR-Regulation (2)

1. Use the “up” and “Down” buttons to scroll through your collected curves. The
active curve is shown in red colour.
2. Delete curves with spatters.
3. Check the wear counter and delete curves with wear below 10 and above 90.
4. Check the current correction factor and delete curves above 3% (heat stepper)
5. Make an average of the
remaining curves
6. Send this as Reference
Sequence to Timer 1
2
3
4
5
6

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 Weld Timer Software PRI7000

Activating UIR-Regulation (3)

1. Now, there is a reference curve for UIR Regulation for WeldJob32_113.
You can see this in the bottom of the graph.
2. The UIR Status wheel displays: Global Regulation & Monitoring is “ON”.

2
3. If you click onto the text
“Regulation” or “Monitoring”
you can swith “ON” or “OFF” 1

4. Turn “Regulation” and Monitoring on Global and Spot related.

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 Weld Timer Software PRI7000

Activating UIR-Regulation (4)

1. Now, watch the last weld for WeldJob32_1113. In the status wheel you see: UIR regulation
and UIR-Monitoring was “ON”.
2. The green line for actual resistance is mostly the same as the reference resistance
=> There is no activity of the UIR Regulator visible in Current.
3. Now turn a little bit on
the Potentiometer: Now
you see a difference in
resistance and a response
1
in current.

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 Weld Timer PRC7000 and PRI7000

STC RECORDING

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 Weld Timer Software PRI7000

STC Recording in PRC7000

STC Test with the PRI 7000. For this is the Soft- and Firmware 1.7.2.0 required.
1. Design of running KSR-WeldJob (no Stepper active, Gun Resistance set, KSR-Regulation)
2. Set the STC Number

2
1

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 Weld Timer Software PRI7000

STC Recording in PRC7000

3. Open the STC Recording

and press the button “Start recording” 1

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 Weld Timer Software PRI7000

STC Recording in PRC7000

4. Start the welding – the first curve with the low current will be shown 1

5. Adjust the current values like in the BOS 6000 in 200A steps and save the new parameter

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 Weld Timer Software PRI7000

STC Recording in PRC7000

5. After the test the created curve will be showed

6. Select the new Setup curve (for commissioning)

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 Weld Timer Software PRI7000

STC Recording in PRC7000

7. In the folder STC the data will be saved

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 Weld Timer PRC7000 and PRI7000

STC ANALYSIS

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 Weld Timer PRC7000 and PRI7000

STC Analysis
STC Analysis is an option to optimise weld production quality, based on STC parameter sets
which are created and tested in a weldlab.
In the screen below, you see a bunch of current and resistance curves for STC_4711 (training data)
1. Select correct source or subdirectory
2. Select filter “STC names”
3. Select STC_4711.
2 3 1 4

It is possible to have different

Subdirectories (here groups) for
every STC number (name)

4. Open the parameter view

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 Weld Timer PRC7000 and PRI7000

STC Analysis (2)

Now you can see the dynamic resistance curves together with the weld parameter, which were used to
create the curves in a weld lab. There is also the gun resistance of the lab gun!!
1. Press “up” and
watch the display.

The curves have different

Coulors:
Red: all curves present
in this group
Black: selected curve
(here Nr.6)
Bold: This is the active
Reference curve for
STC 4711 in the timer.

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 Weld Timer PRC7000 and PRI7000

1
STC Analysis (3)
In this screen is a lot of information given:
1. Headline: Source of the data 2
2. 2nd line: active reference curve for STC_4711

In the bottom you have the following options

1. Delete the selected curve (here curve Nr.1)
2. Delete all curves
3. Set (selected curve) as Setup curve In the bottom you get following information
4. Set (selected curve) as group curve 1. Curve selected in the screen above
5. Write active curve into timer (here curve Nr.1)
6. Write setup curve into timer 2. Defined setup curve for STC_4711

1
2
1 2 3 4 5 6

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 Weld Timer PRC7000 and PRI7000

Exercise: STC Analysis

1. Create a new weldjob using the STC_4711.
2. This is programmed in the weldjob \ Sequence values.
3. Please make some welds in KSR Mode first. Watch the graphs in the screen “Last weld”
4. Go to STC Analysis and select one of the curves from STC_4711
5. Write this selected curve into timer.
6. Make some welds in KSR Mode again. Watch the graphs in the screen “Last weld”
7. What happened?

8. Activate UIR Regulation

9. Activate UIR Monitoring
10. Turn the Potentiometer to stimulate the
UIR regulation and watch the weldcurves.

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 Weld Timer PRC7000 and PRI7000

Screen Access level

The read and write level could be seted regarding to the access level – log on.
This information will be saved in the folder ProgramData …\UI\ScreenAccessLevels.xml

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 Weld Timer PRC7000 and PRI7000

Troubleshooting during commissioning

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 Weld Timer PRC7000 and PRI7000
Error protocol – in search of spots with for example Q-Stop issue

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 Weld Timer PRC7000 and PRI7000

Check of the histogram input – spatter reflected to the “bad fitting/gap”

The histogram show the

monitoring values as well as the
corresponding curve

In this case is probably the bad

fitting responsible for the spatter
and violation of limit (UIP). All the
rest of the spots are inside of the
tolerance.

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 Weld Timer PRC7000 - Hardware

Check of the histogram input – violation of limit reflected to gun resistance

The gun resistance increased –

because of shaft change

After the upload of the gun

resistance the monitoring values get
stabile

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 Bosch Rexroth AG - Training Center Erbach

The Drive & Control Company

22.02.2016
Bosch Rexroth AG
Electric Drives and Controls
DC-IA/SVI223
Berliner Strasse 25
D-64711 Erbach (Odenwald)
Tel. +49 (60 62) 78-600
Fax +49 (60 62) 78-833
[email protected]
www.boschrexroth.com/training

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