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PSI6000 Inverter
Hardware and
BOS6000 Software
Training Package 2011
Klaus Klick
DCC/SVC15
Version 1.36.0
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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
Electric Drives and Controls
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Pg 7
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Pg 15
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Pg 22
Pg 23
Pg 25
Pg 29
Pg 30
Pg 31
Pg 35
Pg 36
Pg 37
Pg 46
Pg 52
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
Electric Drives and Controls
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Pg 53
Pg 55
Pg 56
Pg 58
Pg 62
Pg 63
Pg 66
Pg 67
Pg 68
Pg 69
Pg 72
Pg 76
Pg 80
Pg 81
Pg 83
Pg 87
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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Pg 89
Pg 96
Pg 106
Pg 107
Pg 108
Pg 111
Pg 116
Pg 118
System Overview
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Welding Equipment
Mains Input
Machine Interface,
I/O Bussystem
Rectification
DC-Link
Inverter
1 kHz
24 VDC Supply /
Stop Circuit
Voltage-Feedback
Optional Voltage-Feedback
Current-Feedback
Welding
Gun
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Welding Gun
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
Electric Drives and Controls
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WLD
Weld time
HLD
Hold time
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]
Electric Drives and Controls
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Q = R x I x t
9
Hardware Familiarisation
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10
7.) 2x PST6250.333L1
8.) 2x Main Switch
9.) Fuses
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11
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12
Side View
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13
Welding controls
PSI6300.100L1
PSI6300.333L1
PSI6300.350L1
PSI6300.773L1
PSI63C0.357L1
PSI63S1.259L1
Transformers
PSG6130
Electric Drives and Controls
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14
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
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
+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
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19
Software Communication
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20
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21
A further
configuration screen
will appear
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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22
BOS6000
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23
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24
Timer Reference
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Timer Status
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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)
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
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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
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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)
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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,
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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
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36
Sequence
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
Half-cycle of
mains
voltage
31
130
- Electrical
degrees
0
180
120
High current
99
0
Programmable range
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-15
Low current
39
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40
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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.
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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
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
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49
Extended Sequence
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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
Wear/comp:- The
number of welds taken
to complete
cycleby
Electric
Drives
and
Controls
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51
Heat Stepper
Heat increase
% between tip
dresses
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52
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
Electric
Drives
and
Controls
53
General set-up
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
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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
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59
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60
Start signal;
this is a signal sent from
the robot, to initiate the
start of a weld sequence
depending on the
program- /spotselection.
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61
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62
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63
At the position
Start with Ignition
click once in the On tab
The timer will now execute
a weld
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64
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65
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66
Plant Layout
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67
Plant Layout
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68
Plant Layout
1.
2.
End of stepper
3.
Offline
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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
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70
Compare
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71
Compare
The number and
type of differences
are then listed.
To view them select
Detail view
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72
Compare Details
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73
Protocols
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74
Protocols
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75
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76
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.
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77
Overview
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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
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79
Error table
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80
Pre-Warning F2
F2
The information held on this page,
can be critical for
identifying
1.
2.
3.
Electrode status,
1.
Green : - healthy
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81
Pre-Warning F2
F2
The information held on this page,
can be critical for identifying
1.
2.
3.
Electrode status,
1.
Green : - healthy
2.
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82
Pre-Warning F2
F2
The information held on this page,
can be critical for identifying
1.
2.
3.
Electrode status,
1.
Green : - healthy
2.
3.
Yellow: - Prewarning
active
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83
Pre-Warning F2
F2
The information held on this page,
can be critical for identifying
1.
2.
3.
Electrode status,
1.
Green : - healthy
2.
3.
Yellow: - Prewarning
active
4.
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84
Correction
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85
Correction
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86
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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
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88
Force Calibration
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.
4) Press the OK
button to enter the
next screen
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89
Force Calibration
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90
Force Calibration
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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.
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Force Calibration
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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.
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Current Calibration
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Current Calibration
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.
9) Press the OK
button to enter the
next screen
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Current Calibration
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We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Current Calibration
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We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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Current Calibration
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We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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.
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Current Calibration
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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.
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Communications page
shows confirmation of
the Ethernet address,
with the subnet mask.
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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
106
Backing up ..!
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Backing up ..!
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108
Restoring Data.
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Restoring Data.
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Restoring Data.
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Restoring Data.
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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
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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
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We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
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
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116
Click on add
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All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.
We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
118
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.
We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
119
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.
We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
120
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.
We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
121
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.
We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
122