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BOS6000 & PSI6000 Weld Control

PSI6000 Inverter
Hardware and
BOS6000 Software
Training Package 2011
Klaus Klick
DCC/SVC15

Version 1.36.0

Electric Drives and Controls

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Contents Page 1
System overview
Welding Sequence
Hardware configuration
Timer standard configuration
Timer Name & I/O configuration
Software communication
Ethernet configuration
BOS 6000 Software
Programming page
Icons
Welding Sequence
Programming exercise
Copy Parameter
Copy Programs / Timer
Current Monitoring
Extended Welding Sequence / Pressure Profile
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2

Contents Page 2
Heat Stepper
Heat Stepper & Tip dressing
General set-up
Electrode set-up
Power Unit set-up
I/O Diagnosis
Simulate Start
Timer Information
Last Weld
Plant Layout
Log In / Compare
Protocols
Overview
Error Table
Pre-Warning F2
Correction
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3

Contents Page 3
Force Calibration
Current Calibration
Set Up Heat Stepper Curves
Set Up Tip Dresser Curves
Backup
Restore
Help Page F1
How to extract spatter data

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BOS6000 & PSI6000 Weld Control

System Overview

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Welding Equipment
Mains Input

Machine Interface,
I/O Bussystem

Rectification
DC-Link
Inverter
1 kHz

Pressure / Force (0 -10VDC)


Current-Feedback

24 VDC Supply /
Stop Circuit

Voltage-Feedback

Optional Voltage-Feedback

Current-Feedback
Welding
Gun

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Welding Gun

Overview PSI6000 Inverter and Transformer

Primary sensors
for KSR
Inverter output
500V 1000Hz to the
Gun
Secondary coil (KSR)
UIR Connections
Typical ouput 5-12v DC
4 120kA, 1000Hz
depending on
Transformer
Configuration.

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Welding Sequence

F = Force [kN]
I = Current [kA]
t = time [ms]
Gun close

open
Weld Current

SQZ
Squeeze time
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WLD
Weld time

HLD
Hold time

Resistance Welding Process

Basics

Electrode 1
Contact-resistance Electrode-Sheet1

Sheet 1

Material-resistance 1
Contact-resistance Sheet-Sheet

Sheet 2

Material-resistance 2
Contact-resistance Electrode-Sheet2

Electrode 2

Electrode-Force F [kN]

Current I
[kA]
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Q = R x I x t
9

BOS6000 & PSI6000 Weld Control

Hardware Familiarisation

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10

Bosch Rexroth Welding Control Panel Device


Familiarisation
typical setup

4.) Signal lamps


5.) Main Switch

7.) 2x PST6250.333L1
8.) 2x Main Switch
9.) Fuses

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11

Bosch Rexroth Welding Control Panel Device


Familiarisation
typical setup

Roboter bus system (here: optical Interbus)

Bosch Rexroth Welding Control (timer)

Main switch including FI

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12

Timer Standard Configuration

I/O Card slot


Adaptive control
slot
Field bus module
slot

Side View

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13

Understanding Weld Timer Type Codes

Welding controls
PSI6300.100L1

PSI6300.333L1
PSI6300.350L1
PSI6300.773L1

PSI63C0.357L1
PSI63S1.259L1

Transformers
PSG6130
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14

Timer Configuration PSI 6100.201L1


Profibus I/O
Serial Com
Parallel I/O
24 Volts internal /
external supply, see
next page.

External pressure
control to prop valve

Secondary current
feedback,
Transformer temp
feedback.

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Output to the
transformer

15

24volts Distribution

Internal links

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16

External Fan Operation

The fans are normally located at the rear of the panel, forcing air
to be driven across the fins of the heat sink.

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17

Proportional Valve Control and feedback

+24volt feedback, from the prop valve, tells the welding control
that the demanded pressure has been reached, this then allows
robot control to give the command to close the gun and allow the
weld schedule to commence.
If no prop valve is used, then +24volts and 0volts must be
supplied to pin 4 & 2 !!

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18

Transformer Feedback

Industry Standard is 150mV / kA. This


is adjusted automatically during a
calibration procedure to suit the
individual application

A normally closed contact in the


transformer, feeds back temperature
OK. If no feedback is available, then
these pins must be shorted.

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19

Software Communication

Wiring schedule for the Serial port


Software Communication is
normally via a specific
communications card, via
Interbus / Ethernetetc.
You can also connect directly
to individual timers via the
serial port, X1

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20

Ethernet Communication configuration


When connecting via an Ethernet link, please ensure
you have set the I.P address correctly on the
computer, otherwise no communication will be
possible.
This indicates that your computer has detected a local
area connection.
To access the IP setting, double click the icon, with
your mouse.
If you do not have this icon present, select the
option below

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21

Ethernet Communication Configuration


The General tab will
now become visible

A further
configuration screen
will appear

Ensure that the IP address you select does not


exactly match the IP address of the Timer, the
last digit should be different

Select Properties
Select Internet Protocol (TCP/IP) then OK
Select, Use the following IP Address then OK
Setting the IP Address

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Enter an IP Address and subnet mask then OK

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22

BOS6000

BOS6000 Software Familiarisation

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23

BOS6000 Username & Password

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24

Timer Reference

2. Add the timer name


3. Add any reference
comment
4. Select your
communication method.
V24, Ethernet.etc
5. If you are connecting
via Ethernet, then insert
the IP address here
6. Select Online or Offline
mode
7. Select protocol to
enable the UIR monitoring
8. Select the direction of
data flow, on initial
communication
1.To add a new or additional
timer, select the Add button
first, the Add/change Timer
box will then appear above

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9. When the information


has been installed, press
OK
10. Select continue button
25
to access the program

Timer Status

Monitor the Status and


Description window, if a red bar
appears and stays then there is
a problem with your
communication path, cable, or
the timer may be switched off.

Monitor the Status and Description


window, a yellow bar should
proceed a green bar.
This indicates that communication
path is operational, and the
database is being populated with
the timer information.
Please be patient, on the initial
start-up it can take several minutes
to gather all the data for the
database.

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All subsequent connections will only


take seconds to get on-line

26

Program Page
Programming
The spot number, program
and communication status is
found at the top of program
page, as well as the drop
down menus
The raised tab indicates the
page that is currently being
viewed
Nearly all functions/pages
can be quickly accessed via
the icons that are situated
at the top of the pages.
A single click will select the
required page, and another
single click will return you to
your previous screen.

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27

BOS6000 Icons
Error Table

Plant layout

Protocols

Compare

Pre-warning Table
Parameter Overview,
incorrect parameters
Login

Spot reference
Comments
Rights
Administration

Timer
reference
Overview
Spot reference
Table

Program Page
(Parameter data)

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Diagnosis
(i/o interface)

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Correction
Set-up

28

Sequence
The BOS6000 software
only shows tabs, which
are available.
e.g: PSQ-Tab is
only shown, if XQR PCB
is mounted in the timer.
The BOS6000 software
only shows parameter,
which are accessible.
e.g: COOL 2 time is
only shown, if the
number of impulses is
bigger than 1.

Monitoring parameters
are only shown, if
kA-monitoring is ON

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29

Program tabs
Programming

By selecting individual tabs within the


pages you can navigate around the
software at the click of a button

Dependent on the timer status, you can


see if the timer is online, or offline.
Blue is working offline
Green is working online

You can also see at a glance if the weld


has a pre-heat, a post heat, or even if
upslope or down slope.

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30

Sequence
Programming
The sequence screen allows
the user to see the
programmed weld
parameters at a glance

Timer

Program

Pressure

Weld time
Squeeze Weld
current

Hold

For PSI6000 inverters the


times are all programmed in
milliseconds.

PST6000 timers are


programmed in cycles
1 cycle = 20ms

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31

Sequence
To select a weld program:- to
access the required program,
simply select the program from
the up/down buttons, or type in
the actual program number. The
electrode number will update
when a program is selected.
To select a spot number:utilising the down arrow select
the required spot number, and
the program that is associated
with it will automatically appear
Inhibit Seq (P) (Inhibit this
program sequence)
This needs to be set to Off, if
not then the weld sequence will
be inhibited for this program only
Weld On/Off Int (P)
(Internal weld on/off)

Sequence:- There are 3 sequence options,


Single: 1 weld sequence per start signal
Repeat: 1 weld sequence repeated until the start signal is dropped
Seam: 1 weld permanently on till the start signal is dropped

This needs to be set to On, if


not then the weld will be turned
Off forElectric
this program
only and
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32

Programming exercise
Please enter the
following Weld programs

Step1: Prog1 2
Step2: Prog3 5

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33

Programming exercise

Copy1
If you select one
Parameter,

2) You may copy


this parameter
Using the right
mouse button

1) You see the input range of this parameter

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34

Programming exercise

Copy2

Using the Copy feature from the main menue, you have all Options
to copy any data from the weld timers.

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35

Sequence
Regulation:- Mix or
Standard

If Standard is selected then


weld 1 and weld 3 can only
be programmed in the same
mode as weld 2

If Mix is selected, weld 1 &


weld 3 can be programmed
in PHA (phase angle) or
KSR (constant current)
mode

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36

Sequence

*see illustration on the next sheet

Monitoring:
Mix or Standard
Standard mode: the actual
current is determined by the
complete weld cycle including
any cool times
Mix mode: the actual current
is determined by the individual
weld times

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37

Sequence

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38

Sequence
PHA: Phase Angle Regulation
Programmed in scale units %,the greater the %Ht, then
the greater %age of current flowing

Phase angle, fixed


value determined by
program

Half-cycle of
mains
voltage

31

130

- Electrical

degrees
0

180
120

High current

99

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0
Programmable range

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-15

- Scale units (%)

Low current

39

Principle of Unregulated Phase angle welding

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40

Principle of Constant current regulation

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41

Sequence

Electrode:
0 31 different electrodes
can be selected, dependent
on your firmware version

Reweld:
If this function is activated
and a low weld current
occurs with the start signal
still high, the control will
automatically attempt to
reweld the program, if the
weld is low again a weld fault
is output.
Note:- if there is no current,
then a reweld will not be
activated

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42

Sequence

Impulse:
This function indicates how
many times the weld 2, cool 2
function is repeated during one
weld sequence.

If the impulse function has a


figure greater than 1, then
the portion of the program
that is inside the green
shape is repeated however
many times is programmed

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43

Sequence

Current monitoring

Current monitoring:
When the monitoring is
activated (ON), the
reference current and all the
tolerance band parameters
become visible

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44

Sequence

Repeat factor, is the number


of consecutive welds allowed
in the conditional permissible
tolerance band;
if this occurs, the actual
figure is displayed here

1
2
3
4

2
3
4

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45

Sequence

Ref, kA is the
programmed reference
current
Act. Ref. kA is the
actual current
achieved
Average PHA is the
actual Phase angle
required to achieve the
required current

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46

Spot table
In the spot reference table a particular spot name is linked to a program number and a
timer.
This allows selection of spots by their individual name.
Important: The Spot reference table must be transferred into the timer to get active!!

3.)

1.)
2.)

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47

Spot table

4.)

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48

Sequence

If this Icon is coloured, then


when pressed, the
comments sheet for the
actual spot number that is
assigned to this program will
be displayed

The number of comment


fields can be altered in the
Config tool

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49

Extended Sequence

from this page the pressure


profile function can be activated.

When the profile is activated the


force can be programmed to a
specific value at any time during
the weld sequence.
The force can be altered up to 10
times during the weld process

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50

Heat Stepper

Heat increase %
in the lifetime of
electrode caps
Heat stepper:activation on/off
Wear factor:individual welds can be
given a greater or
lesser weighting,
dependent on the
actual wear to the tips

Max Wear:The number of welds over which the


heat is stepped (incremented)

Wear/comp:- The
number of welds taken
to complete
cycleby
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and
Controls

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Warn Wear:Number of welds


before the end
of the max-life,
that pre-warning
becomes active
(50)

51

Heat Stepper

Heat increase
% between tip
dresses

Max Wear:The number of welds over which the


heat is stepped (incremented)

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52

Heat Stepper and tip dressing


Please note:The Max life is
calculated by the
multiplying
(Max Wear x tip dress
steps) + Max Wear

Tip Dress Steps:The number of dress


steps (10)

i.e. (500 x 10) + 500 =


5500 welds

Dress-Request:- The
number of welds before
the max wear that the tip
dress request output is
activated

Heat increase
% between tip
dresses

Max Wear:Dress new Electrode:- The number of welds over which the
heat is stepped (incremented) (500)
The weld is
inhibited, until the gun
is dressed,
immediately
after the
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electrode
has

i.e. 5450 welds

53

General set-up

If activated the weld will be


inhibited when max life is
reached
The (S) indicates that the
function will be activated for
ALL programs
Max Weld Time, this is the
control of the max weld
time, for all programs

This parameter Inhibits the


current Monitoring on All
programs
Max Rewelds:- this the
number of consecutive
rewelds at one position

Mode Pressure Output:


There are several
options for pressure
output, 4-20mA, 020mA, 0-10V output to
the prop valve

Current measurement
selects the type of
monitoring, either
secondary or primary

A measuring loop check is a verification of the current sensor in the secondary circuit.
On : Measuring loop test active, sensor faults are detected.
.
Off : Measuring loop test not active, sensor faults are not detected.

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54

General set-up
The Fade out time parameter is used to suppress the natural
current rise at the beginning of the weld time for current
measurement
The Trail current parameter is used to activate or deactivate
measurement of the trail current after the last weld time.
On : The trail current is included in the measured result.
Off : The trail current is not included in the measured result.
Both settings in BOS6000 must match the settings of the
external current meter for comparative measurements.

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55

Electrode Set-Up

The %I Prewarning
parameter indicates the heat
value (in scale divisions SKT)
for which an imminent %I
limitation is to be detected for
the electrode displayed.
Upper currrent limit is the
maximum programmable set
limit of the current in the
individual electrode
Bosch sensors have been
adjusted to 150 mV / kA.
When using third-party
sensors, the appropriate
transmission ratio can be
programmed using the
Toroid sensitivity parameter

For details on the


measuring range,
see the next sheet

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56

Electrode Set-Up

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57

Electrode Set-Up
Transformer type. When a predefined transformer is selected,
this automatically selects the
transformer ratio, and the diode
type, If the transformer type is
unknown, then you must
program the diode type and
nominal current.
The Diode
supervision/monitoring
parameter may be used to
deactivate diode monitoring
(secondary diodes of the
welding transformer).
The computational emulation
of the welding diode
temperature determines
whether the junction
temperature is rising to more
than 150C, the switch off
temp can be programmed
from this parameter
Actual welding diode temp
Actual Mains supply Voltage

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58

Electrode Set-Up

For the calibration


procedures see next
few slides.

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59

Power Unit Set-up

Power unit type,


Medium frequency
Inverter 6000 series
Timer type:Software / Firmware
Version:-

Electric Drives and Controls

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60

Diagnosis User-Diagnostics I/O

Start signal;
this is a signal sent from
the robot, to initiate the
start of a weld sequence
depending on the
program- /spotselection.

Electric Drives and Controls

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61

Diagnosis User-Diagnostics I/O

Acknowledge tip dress;


after a Tip Dress request
is output from the timer, it
is acknowledged by a
response from the PLC
only when the robot is in
the tip dresser.
Typically there are
specific weld programs
associated with tip
dressing.

Electric Drives and Controls

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62

Diagnosis User-Diagnostics I/O


Ready Weld timer: the
status of the weld timer
is healthy and the timer
is ready to weld, this
signal stays Hi unless a
fault has occurred
Weld process error:
this signal only goes hi
when a weld fault has
occurred, it can be
reset via input 04, 05 or
06
Weld ON: this shows
the status of the
external and internal
weld on, if both are hi
then current can be
passed

Electric Drives and Controls

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63

Diagnosis Simulate start


Starting the weld from the
timer.
Press the Diagnostic
Button
Select Simulate Start
Select the Program you
wish to fire.

At the position
Start with Ignition
click once in the On tab
The timer will now execute
a weld

Electric Drives and Controls

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64

Diagnosis Timer information

Electric Drives and Controls

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65

Diagnosis Last Weld

This page gives


you all information
about the last
weld sequence.

Electric Drives and Controls

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66

Plant Layout

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67

Plant Layout

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68

Plant Layout

According to the status


chart on the previous
page, what is the
condition of the timers
on the right ?

1.

Error state pending,


i.e. control fault

2.

End of stepper

3.

Offline

Click on the Timer icon will


redirect you to the
timer information page

Electric Drives and Controls

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69

Login
If you want to log in, or change user,
select the change user icon, or press
F12. Select your username from the
drop down menu and enter your
password

Electric Drives and Controls

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70

Compare

It is possible to compare data


from one timer to another, or
even to a backup stored on
the hard drive.
The data compared will be
displayed under the titles
here.
Then click Compare

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71

Compare
The number and
type of differences
are then listed.
To view them select
Detail view

Please wait while the


data is compiled

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72

Compare Details

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73

Protocols

You can view the


protocols from the
following sub titles.
Error Protocols
Weld fault Protocols
Data Change
Protocols
Weld current
Protocols
Each one will give you
information about an
event, that has
occurred.

Electric Drives and Controls

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74

Protocols

You can also select


specific dates to view.
Dependent on the size
of the database, you
can have between
50,000 and 250,000
entries in the protocol
database

Electric Drives and Controls

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75

Data Change Protocols

Each entry will give


you information
Date / Time
Timer name
Name of parameter
Program Number
Old data
New data
Name of user who
has changed the data
Any comments
entered by the user at
the time of the change

Electric Drives and Controls

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76

Data Change Protocols

Weld current
protocols are
activated from the
Timer reference
page on start up.
If this option is
NOT selected this
page and the UIR
Monitoring page
will not show any
data.

Electric Drives and Controls

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77

Overview

The overview page is very useful for


quickly finding out the status of all the
programs at a glance

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Select the button on the right and side


and the active programs for your
selection will appear in pink

78

Error table
Access to the fault table can also be via the F3
function key.
If more information is required for the actual fault,
double click the error description, and more detailed
information will appear.
If still more information is required, click the help
page

Electric Drives and Controls

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79

Error table

The help page will


appear with a complete
description on the fault,
and a possible remedy.
The Error page is also
used to display status
messages.

Electric Drives and Controls

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80

Pre-Warning F2

To Access the PreWarning page, click on the


pre-warning Icon or press
the short cut key F2

F2
The information held on this page,
can be critical for
identifying
1.

Wear on the caps

2.

Number of remaining parts

3.

Electrode status,
1.

Green : - healthy

Electric Drives and Controls

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81

Pre-Warning F2

To Access the PreWarning page, click on the


pre-warning Icon or press
the short cut key F2

F2
The information held on this page,
can be critical for identifying
1.

Wear on the caps

2.

Number of remaining parts

3.

Electrode status,
1.

Green : - healthy

2.

Orange: - Tip dress


required

Electric Drives and Controls

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82

Pre-Warning F2

To Access the PreWarning page, click on the


pre-warning Icon or press
the short cut key F2

F2
The information held on this page,
can be critical for identifying
1.

Wear on the caps

2.

Number of remaining parts

3.

Electrode status,
1.

Green : - healthy

2.

Orange: - Tip dress


required

3.

Yellow: - Prewarning
active

Electric Drives and Controls

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83

Pre-Warning F2

To Access the Pre-Warning


page, click on the prewarning Icon or press the
short cut key F2

F2
The information held on this page,
can be critical for identifying
1.

Wear on the caps

2.

Number of remaining parts

3.

Electrode status,
1.

Green : - healthy

2.

Orange: - Tip dress


required

3.

Yellow: - Prewarning
active

4.

Red: - End of stepper


life

Electric Drives and Controls

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84

Correction

These are the default


correction figures that are
displayed on the actual
correction page.
If these parameters are not
programmed , then the
correction parameters can
not be utilised.
So limits need to be set.

Electric Drives and Controls

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85

Correction

The limits set on the


previous page can
be seen here, (P) is
for this specific
program.
(E) Is for the
complete electrode

Electric Drives and Controls

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86

BOS6000 & PSI6000 Weld Control

Force Calibration For Welding Guns

Electric Drives and Controls

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87

Force Calibration
Please select the correct timer,
from the drop down menu
Select the calibration routines. These
can found on the Electrode Page

Ensure that the Transformer Type,


and Upper current limit are set
correctly

To access Force Calibration


Press the Force Calibration Key

Electric Drives and Controls

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88

Force Calibration

1) Type here the upper


and lower pressure
limits for the calibration
routine ( ensure that
you are not in the force
limitation)

3) Select here the


Program you wish to use
for the calibration
routine. You should
select a program that is
associated with the
relevant electrode you
wish to calibrate

The lower limit should


be set to around 20%
to allow for accurate
pressure for tip Dress
Routines.

2) If you want to
change the values,
place a tick in the box
before you type in the
new values. The
changes will then be
stored for the next time
the routine is entered.

Electric Drives and Controls

4) Press the OK
button to enter the
next screen

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The KN display is only


used with Servo Guns.

89

Force Calibration

5) As this screen appears


you should hear the
proportional valve either
pressurise or exhaust to
the upper limit value set in
the previous screen.
6) You should now
manually close the Gun
onto the force meter.
7) Enter the read value
into the upper box.
8) To proceed press Enter
on your PC this enters the
upper limit actual value
into the timer.
9) open the gun

Electric Drives and Controls

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90

Force Calibration

As a rule: the upper and lower value must be in


the operating range of the gun !

As Enter is pressed you should


hear the Parker Proportional valve
exhaust to the lower limit set on the
previous screen.
10) Again close the Gun onto the
force meter.
11) Enter the read value into the
lower box and press the Enter key
on your PC
This enters the lower limit actual
value into the timer.
12) As the OK button is pressed an
information point appears showing
the value of the now calibrated
Max. Pressure.
If this is ok. for your gun =>
Press OK to Accept this.

Electric Drives and Controls

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13) As the OK button is pressed an


information point is displayed.
Press OK to accept this.

91

Force Calibration
14) You should now return to the
Sequence page and close the
Gun on the force meter to test the
Programmed Pressure set in the
Base Pressure Value.
Please note:- check the I/O
page to see which program
is being activated.
The pressure in this program
Will be output to the prop valve.

Electric Drives and Controls

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92

Force Calibration

15) The calibration routine has set the


figures shown .
If after adjustment the measured
values are found to be out of range
another Force Calibration routine
should be carried out.

Electric Drives and Controls

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93

BOS6000 & PSI6000 Weld Control

Current Calibration For Welding Guns

Electric Drives and Controls

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94

Current Calibration
Preparation
Ensure that the following
settings are made
In the General Tab the
Current Measurement
Mode should be set
correctly.
1) If you have a
secondary toriod
attached to the gun arm
or in the transformer,
then secondary should
be selected.
If not, then primary
should be selected.

Electric Drives and Controls

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95

Current Calibration

2) Select the calibration routines


which are located on the Electrode
Page
3) Ensure that the Transformer
Type, and Upper current limit are
set correctly

4) Ensure that the Diodes


settings are as follows

5) To access Current Scaling


Press the Current Scaling Key

Electric Drives and Controls

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96

Current Calibration

6) Type here the upper


and lower heat limits for
the calibration routine
( As a rule the upper
limit should be 20 more
than the value of the
lower limit)

7) If you want to
change the values,
place a tick in the box
before you type in the
new values. The
changes will then be
stored for the next time
the routine is entered.

Electric Drives and Controls

8) Select here the


Program you wish to use
for the calibration
routine. You should
select a program that is
associated with the
relevant electrode you
wish to calibrate.

9) Press the OK
button to enter the
next screen

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97

Current Calibration

10) You should now


place a calibrated DC
Current meter over
the secondary of the
Gun.
11) Ensure the gun
head is closed before
you start the weld.
12) Press the Start
Wld button to perform
a short circuit weld

Electric Drives and Controls

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98

Current Calibration

13) Read the recorded


value from the Current
Meter and enter it into
the Upper Heat
Measured Current box
as shown
14) Press the Enter Key
and a 1 appears at the
side of the box indicating
that the first reading
attempt has been carried
out and the data has
been sent to the timer.
15) Again press the Start
Wld button to perform
another Short Circuit
Weld and repeat the
steps above. This time
when the Enter Key is
pressed a 2 appears
indicating the second
attempt.

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99

Current Calibration

16/ Now press the continue


key to proceed to the lower
heat limit calibration routine

17/ Again press the Start


Wld button to perform
another Short Circuit Weld.

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100

Current Calibration
18) Read the recorded
value from the Current
Meter and enter it into
the Lower Heat
Measured Current box
as shown.
19) Press the Enter Key
and a 1 appears at the
side of the box indicating
that the first reading
attempt has been carried
out and the data has
been sent to the timer.
20) Again press the Start
Wld button to perform
another Short Circuit
Weld and repeat the
steps above. This time
when the Enter Key is
pressed a 2 appears
indicating the second
attempt.

Electric Drives and Controls

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101

Current Calibration

21) Now press the continue


key to exit the Current
Calibration Routine

22) When the Continue Key


is Pressed an Information
point appears that shows the
new calibrated Toroid Sens.
23) At this point the
Secondary of the Gun can
be opened and you can
proceed with OK

Electric Drives and Controls

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102

Current Calibration
24) You should now return to the
Sequence page and manually close the
Gun. The Current meter should
Still be in place to test the
Programmed Current set in the
Weld 2 Heat Value.
You can either fire the Short circuit
Weld from the control panel or fire
the sequence with the bos6000
Software by using the procedure on
the next page.

Electric Drives and Controls

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103

Bos6000 Set-Up, Heat Stepper Curves

Heat stepper curves


can be accessed via
the setup icon.
Several curves are
standard, they can be
selected by the curve
number.

You can also create


your own curve, by
dragging the line into
the required position or
by typing the required
figure directly into the
specific box

Electric Drives and Controls

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104

Bos6000 Set-Up Continued

Tip dress curves, as with


heat stepper curves are
selectable, or can be
created.

Communications page
shows confirmation of
the Ethernet address,
with the subnet mask.

With error reference page, you have


the ability to program the severity of
the fault into a warning if required. A
fault will inhibit the weld from starting,
A warning will not inhibit the weld

Electric Drives and Controls

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105

Backing up ..!
From any page the drop
down menu should be
visible,
Select Edit, and then
backup
Or Ctrl + B

Once selected , the


next option is to pick
which Timer or Timers
are to backed up.
By clicking on the top
box, all timers will be
selected, or individual
timers can be selected
by clicking on the box
adjacent to the timer
name
The backup path and folder is located here.
An alternative can be selected by selecting the button,
and choosing a new location
When ready press
Electric
Drives
and
Controls

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Bosch Rexroth AG,
even and
especially in cases of proprietary rights applications.
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106

Backing up ..!

The status of each timer


can be seen as the
backup is proceeding

Electric Drives and Controls

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107

Backing up ..!

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108

Restoring Data.

1. From the next page,


you have to select
which backup needs to
be restored, select the
browse key

1. From the Timer


reference page, select
the Restore Button

Electric Drives and Controls

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109

Restoring Data.

2. Find the backup file


that will be restored.
Note: this will be a zip
file.
Then select open

Electric Drives and Controls

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110

Restoring Data.

3. Select OK to start the


restore process.

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111

Restoring Data.

4. With the next screen


you have a chance to
review the file data you
are restoring, you can
also see what is already
in the timer, Select OK
to start restoring the
data back into the
database

Electric Drives and Controls

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112

Restoring Data.
5. The data is now
being sent to the
database,
after a short while, you
will get notification of
completion

7. Click Continue
to complete the
restore function

Electric Drives and Controls

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113

Help page F1
The Help page can be
accessed by pressing
the F1 function key on
your keyboard, or by
clicking on the Help
menu.
If you have a specific
query, 1st highlight the
specific parameter, then
press the F1 key.

F1

Electric Drives and Controls

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114

Help page F1
The Help page can be
accessed by pressing
the F1 function key on
your keyboard, or by
clicking on the Help
menu.
If you have a specific
query, 1st highlight the
specific parameter, then
press the F1 key.

F1
The help page that now
appears will be relevant
to the parameter that
you have high lighted

Electric Drives and Controls

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115

How to extract spatter data from the BOS6000


software

Within the BOS6000 software is a Spot / Expulsion overview page.


This can show the user an over view of the spatter that exists on a complete
line PC, or on an individual timer, thereby assisting in spatter detection and
subsequent removal.
This page can be exported as a text file and then imported into excel.
Data can be shown program specific or spot number specific.
If you wish to view the data with the spot table an additional requirement is
to ensure the spot table has been extracted from the timer first. See the
next few slides for details on how to extract the spot table.

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116

How to extract the spot table from the BOS6000


software

Ensure that before


you extract the
spatter data, the spot
table has been
extracted.

Click on add

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117

How to extract the spot table from the BOS6000


software

Select Spot Table <=


Timer.

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118

How to extract the spot table from the BOS6000


software

The spot table then


be displayed.

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We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

119

How to extract spatter data from the BOS6000


software
Within the BOS6000.
Drop down menu,
Function.
Spot / Expulsion
Overview (Ctrl+F3)

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120

How to extract spatter data from the BOS6000


software
This screen will be shown.
Select the configuration of the data, Spot name
or program No
Select a date and time from the drop down
menu, this will be the start of the data to be
extrapolated.

Select a date and time from the drop down


menu, this will be the end of the data to be
extrapolated

If you wish all programs or spots to shown


regardless of the expulsion status tick the box

Select update to display the data

Electric Drives and Controls

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121

How to extract spatter data from the BOS6000


software

Data is displayed and can be


sorted according to your
requirements via the headings
at the top of the page.
This information can be
exported, and displayed in excel
for further diagnosis.
The %expulsion data is
calculated and displayed
graphically as well as
numerically

Electric Drives and Controls

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