Bosch Manual REXROTH BOS6000 Users Manual

Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
Rexroth BOS 6000 1070087074

Edition 01
User Manual
Bosch Rexroth GmbH | Electric Drives BOS 6000 | 1070087074 / 01
and Controls
Title Rexroth BOS 6000
Type of Documentation User Manual
Document Typecode DOK-PS6000-BOS6000****-AW01-EN-P
Purpose of Documentation The content of this manual refers to

• the structure and the functionality
of the BOS 6000 user interface.
Record of Revisions Previous editions Release Notes

Date
DOK-PS6000-BOS6000****-AW01-EN-P 06.2006
Copyright © Bosch Rexroth Electric Drives and Controls GmbH, 2006

Copying this document, giving it to others and the use or
communication of the contents thereof without express authority,
are forbidden. Offenders are liable for the payment of damages. All
rights are reserved in the event of the grant of a patent or the
registration of a utility model or design (DIN 34-1).
Validity The data specified above only serve to describe the product. No
statements concerning a certain condition or suitability for a certain
application can be derived from our information. The given
information does not release the user from the obligation of own
judgement and verification. It must be remembered that our
products are subject to a natural process of wear and aging.
Published by Bosch Rexroth Electric Drives and Controls GmbH

Postfach 11 62
D-64701 Erbach
Berliner Straße 25
D-64711 Erbach
Tel.: +49 (0) 60 62/78-0
Fax: +49 (0) 60 62/78-7 28
Abt.: BRC/PAW1
1070087074 / 01 | BOS 6000 Electric Drives | Bosch Rexroth GmbH iii
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Contents
Contents
The BOS 6000 Help System................................................9

Software version.........................................................................9
Activating Help .........................................................................10
Description of the symbols in the menu lines ...........................11
Show (Unhide)/Hide.............................................................11
Previous (Back) ...................................................................11
Next .....................................................................................11
Start page (Home) ...............................................................11
Print .....................................................................................11
Show Contents (structure) view ...............................................12
Keyword search........................................................................12
Text search...............................................................................13
Use favorites ............................................................................14
Including topics in the Favorites list .....................................14
Displaying the topics in the Favorites list.............................14
Deleting topics from the Favorites list..................................15
Renaming the topics in the Favorites list .............................15
Safety Instructions ............................................................ 17

Why” and “What for”? ...............................................................17
Symbols used...........................................................................18
Proper use................................................................................19
Qualified personnel ..................................................................20
Safe working practices .............................................................21
Trademarks, copyright..............................................................22
Getting to know the BOS 6000 user interface................. 23

Basics.......................................................................................23
Overview of the interface structure...........................................24
Meaning of important icons ......................................................26
Functions in the menu line .......................................................28
File | Para. data import/export | Export …............................28
File | Para. data import/export | Import …............................28
File | Exit ..............................................................................28
Edit | Programming ..............................................................28
Edit | Diagnosis....................................................................28
Edit | Setup ..........................................................................29
Edit | Correction ...................................................................29
Edit | Oscilloscope function..................................................29
Edit | Export record set ........................................................29
Edit | Autobackup.................................................................29
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Edit | Timer change..............................................................29

Edit | Copy ...........................................................................29
Edit | Firmware changing .....................................................29
Edit | Login...........................................................................29
Language.............................................................................29
Functions | Timer reference.................................................30
Functions | Spot reference...................................................30
Functions | Prewarning ........................................................30
Functions | Error table .........................................................30
Functions | Network overview ..............................................30
Functions | Protocol .............................................................30
Functions | Compare ...........................................................30
Functions | Parameter overview ..........................................30
Functions | Rights administration.........................................30
Help | Help ...........................................................................30
Help | About .........................................................................30
The available windows .............................................................31
Login ....................................................................................31
Timer Reference ..................................................................32
Add/ChangeTimer................................................................35
Connection set-up................................................................38
Programming .......................................................................41
Programming: Schedule ......................................................42
Programming: Seq. Pg.2 .....................................................55
Programming: Stepper.........................................................61
Programming: General ........................................................72
Programming: Electrode ......................................................80
Programming: Thyristor-Unit-Parameter..............................93
Diagnosis .............................................................................96
Diagnosis: Diagnostics I/O...................................................97
Diagnosis: Users Diagnostics I/O ......................................100
Diagnosis: Start Simulation................................................101
Diagnosis: Timer-Information.............................................104
Diagnosis: Last Weld .........................................................106
Setup .................................................................................107
Setup: Stepper curves .......................................................108
Setup: Tipdress curves ......................................................110
Setup: Fault-Setup.............................................................111
Setup: Communication ......................................................112
Correction ..........................................................................116
Correction: Correction........................................................117
Spot Reference..................................................................119
Prewarning.........................................................................121
Error table ..........................................................................123
Network overview ..............................................................125
Protocol..............................................................................127
Compare ............................................................................131
Parameter Overview ..........................................................133
Set Access Level ...............................................................134
FTP-Upload .......................................................................134
Backup...............................................................................136
Restore ..............................................................................136
Autobackup........................................................................137
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Timer change.....................................................................139
Copy ..................................................................................140
Firmware change ...............................................................141
Para.-Data Import/Export (Parameter-Backup) .................143
Para.-Data Import/Export (Parameter-Restore).................144
Set Counter........................................................................145
Current calibration .............................................................146
Force calibration ................................................................147
Corresponding Programs...................................................148
Spot Comment...................................................................149
Detail Info...........................................................................150
How to ….......................................................................... 153

Exit BOS 6000........................................................................153
Log in timers to BOS 6000 .....................................................153
Delete timers from BOS 6000 ................................................154
Change the communication data of logged-in timers .............155
Export Timer Reference .........................................................156
Import Timer Reference .........................................................156
Print Timer Reference ............................................................156
Copy Timer Data ....................................................................157
Export timer data (backup) .....................................................158
Restore Timer data (download)..............................................159
Compare Timer Data..............................................................160
Influence data comparison at program start...........................162
Define access levels for individual objects .............................163
Copy the contents of a numerical input field ..........................165
Sort tables ..............................................................................166
Filter tables.............................................................................166
Show / Print / Export logs .......................................................167
Change parameters and transfer to timer ..............................169
Export spot reference .............................................................171
Export spot reference to an Excel file.....................................171
Import spot reference .............................................................171
Print spot reference ................................................................172
Compare spot reference.........................................................172
Enter/change spot references ................................................172
Display spot comments ..........................................................172
Delete spot references ...........................................................173
Show electrode status ............................................................173
Confirm electrode change ......................................................174
Set electrode counter .............................................................175
Export parameter data to ASCII file........................................175
Import parameter data from ASCII file....................................176
Replace a defective timer.......................................................177
Upgrade the timer firmware....................................................179
Reset faults ............................................................................181
Add fault information ..............................................................183
Perform current calibration .....................................................184
Perform force calibration ........................................................187
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Fault messages ............................................................... 191

Stop / No 24V .........................................................................191
Stop circuit closed ..................................................................191
Weld without Command .........................................................192
Control stop ............................................................................192
Power-Unit not ready..............................................................192
External Over-Temperature....................................................193
Cooling temperature too high .................................................193
Transformer temp too high .....................................................193
Battery-Low ............................................................................194
Memory deleted......................................................................194
Data download started ...........................................................194
No schedule programmed ......................................................194
Hardware Fault.......................................................................195
I/O-Bus Fault ..........................................................................196
Half-Cycle Monitoring .............................................................196
Circuit Breaker Off..................................................................196
Sync / Power Fault .................................................................196
Synchronization OK................................................................197
Start Inhibited .........................................................................197
Sequence externally cancelled...............................................197
Program Parity Fault ..............................................................197
24V off/to low..........................................................................198
Supply Voltage Fault ..............................................................198
Timer switched on ..................................................................198
Power voltage to high.............................................................198
Power voltage off/to low .........................................................199
Power voltage off/to low receipt .............................................199
No Weld external....................................................................199
Weld external .........................................................................200
No Weld internal.....................................................................200
Weld internal ..........................................................................200
With stroke, with weld.............................................................200
No stroke, no weld..................................................................200
%I too large/Force/Pressure too high/PHA is too high ...........200
Extend stepping request.........................................................201
Extended electrode life Near End of Stepper .........................201
End of stepper ........................................................................201
End of stepper ........................................................................202
Electrode changed .................................................................202
Stepper exceed ......................................................................202
Prewarning reached ...............................................................202
Dress-Request reached .........................................................202
Dressing necessary................................................................203
Max. number of spots welded before dressing.......................203
Electrode dressed ..................................................................203
Tipdress prewarning...............................................................203
Electrode life tipdress .............................................................203
Cutter blade changed .............................................................204
Cutter1: Cutter not running.....................................................204
Cutter1: Dressing process aborted.........................................204
Cutter1: Max. mill duration exceeded.....................................204
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Cutter1: Temperature fault .....................................................204

Cutter1: Motor protection trip..................................................205
Cutter1: Emergency-Stop.......................................................205
Cutter2: Cutter not running.....................................................205
Cutter2: Dressing process aborted.........................................205
Cutter2: Max. mill duration exceeded.....................................205
Cutter2: Temperature fault .....................................................206
Cutter2: Motor protection trip..................................................206
Cutter2: Emergency-Stop.......................................................206
Phase Angle prewarning reached ..........................................206
Maximum Phase Angle Reached ...........................................206
Secondary monitoring circuit is open .....................................207
Secondary monitoring circuit is shorted .................................207
Termination of Weld / no current ............................................207
No voltage 1.HW ....................................................................208
Primary Voltage Measuring Fault - KUR Mode ......................208
Reweld By Timer Active .........................................................208
Inhibit Monitoring Mode Active ...............................................208
No Weld..................................................................................208
Without regulation, without monitoring ...................................209
No current … ..........................................................................209
Low Current … .......................................................................209
Over Current … ......................................................................209
Low Current-series of welds-… ..............................................210
Current measurement range exceeded … .............................210
Weld time too short …............................................................210
Weld time too long … .............................................................211
Diode Over Current ................................................................211
Diode defect ...........................................................................211
Overcurrent or Earth-fault.......................................................212
Max. primary current reached ................................................212
Driver-Fault.............................................................................213
No weld contactor enable.......................................................213
Isolation contactor feedback fault...........................................213
No Weld Enable or Weld Pressure Input Gun 1.....................213
No Weld Enable or Weld Pressure Input Gun 2.....................213
No Water Flow Gun 1.............................................................214
No Water Flow Gun 2.............................................................214
Weld Contactor Gun 1 Open ..................................................214
Weld Contactor Gun 2 Open ..................................................214
Weld Contactor Gun 1 Did Not Open .....................................214
Weld Contactor Gun 2 Did Not Open .....................................214
Monitor contact open..............................................................215
Mains Power Balance Monitoring Activated ...........................215
Mains Power Balance Monitoring Ok .....................................215
Auxiliary contactor monitor .....................................................215
Fault-Reset.............................................................................216
Welding-Fault Reset...............................................................216
Slave error..............................................................................216
Current Measurement Range Exceeded................................216
Scaling: Communication error ................................................216
Scaling: no valid measuring value received ...........................217
Scaling: no measuring value received....................................217
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Scaling: protocol fault .............................................................217

Scaling: wrong mode..............................................................217
Scaling: Sequence aborted ....................................................218
Scaling: current out of range ..................................................218
Scaling: Diff. primary / secondary current too large ...............218
Scaling: result invalid..............................................................219
Force monitoring: time too long..............................................219
Force monitoring: time too short.............................................219
Force monitoring: Force/Pressure too high ............................219
Force monitoring: Force/Pressure too low .............................220
Error US measurement ..........................................................220
Error US control loop..............................................................220
PSQ Sequence Cancelled......................................................221
USP not calculated.................................................................221
USP too high ..........................................................................221
USP too low............................................................................221
spot repetition with US ...........................................................221
PSQ hardware fault ................................................................222
PSQ internal communication error .........................................222
PSQ temperature too high......................................................222
USP temperature too high......................................................222
USP hardware fault ................................................................223
PSQ watchdog fault................................................................223
PSQ not available...................................................................223
PSQ sequence error...............................................................223
USP communication error ......................................................223
US measuring loop fault .........................................................224
PSQ memory deleted .............................................................224
PSQ ok ...................................................................................224
Glossary ........................................................................... 225
Index ................................................................................. 235

1070087074 / 01 | BOS 6000 Electric Drives | Bosch Rexroth GmbH 9
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The BOS 6000 Help System
In this chapter, you will find basic information concerning the BOS
6000 Help system.
Software version
Help version: 2.0 (10.05.2005)
Valid as of BOS software version: 1.14.5 (20.12.2004)
Note: For more information on BOS:

File Readme.chm
(Directory "Bosch Rexroth AG"):
System requirements, installation, update or removal of
the software.
File History.htm (English) or
file History_GER.htm (German)
(Directory "Bosch Rexroth AG"):
Modification history of the individual BOS versions.
via menu item Help | About…:
Part numbers, version data
Copyright 2002-2006.
All rights reserved, including applications for protective rights.
10 Bosch Rexroth GmbH | Electric Drives BOS 6000 | 1070087074 / 01
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Reproduction or distribution by any means subject to our prior

written permission.
All information is provided for reference only and is subject to
change at any time. No liability is accepted.
Activating Help
The Help system can be activated in different ways:
• via Help menu item in a BOS 6000 window
• via Help command button (if available and not dimmed)
• via F1 button if any window of the BOS 6000 interface is active.
Note: In many areas, the Help is “context-sensitive“. That

means that the current system status (active window,
input field below mouse pointer) is detected and a
suitable help topic is called up when Help is invoked by
pressing F1.
The Help window displayed is divided into 3 major areas:
• top: Menu line.

Here, you may choose various Help functions.
• left: Display area for the following functions:

Show Contents (structure), Keyword search, Text search and
Use favorites.
• right: Field for displaying the contents of the subjects.

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Description of the symbols in the menu lines

The following functions/icons are offered in the menu line of the
Help window:
Show (Unhide)/Hide
• Shows or hides the left window area containing the “Content”,
“Index”, “Find” and “Favorites” tabs.
Previous (Back)
• While you navigate through the Help topics, the system
remembers all topics viewed in the order they have been called.
Previous (Back) jumps back one position towards the
beginning of the navigation path.
Next
• If Previous (Back) has been pressed at least once, Next jumps
forward one position towards the end of the navigation path.
Start page (Home)

• Jumps directly to the first Help topic.
Print
• Opens the ”Print help topics” window.
You can choose whether you only want to print the current Help
topic or its sub-topics as well (if existent). Then you confirm
your choice by pressing OK and follow your computer’s print
dialog.
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Show Contents (structure) view

In the left window area, you can view the structure of all available
Help topics.
1. If the left window area does not appear, you can show it using
the Show (Unhide) menu line symbol.
2. Click on the “Content” tab in the left window area.
The available Help topics are shown in a tree structure. By
clicking on a Help topic, the system displays the description
relating to the contents.
Note: Book symbols represent a topic with sub-topics. To

show/hide sub-topics, you simply have to double-click on
the book symbol.
Note: To fully extend the structure tree or to close the

branches except the main topics, move the mouse
pointer to the left window area, press the right mouse
button and then select “Open all” or “Close all” in the
pop-up menu appearing.
Keyword search
2. Click on the “Index” tab in the left window area.
All keywords are listed in alpha-numerical order in the
keywords list. The description relating to the topic can be
displayed by double-clicking on an index entry.
3. For searching, enter the desired term in the “Find keyword“
field.
After each character input, the system will select a
corresponding keyword from the index list. For this purpose, it
compares the string entered to the available index entries. If no
exact entry match is found, the system will choose the lower
next keyword from the list according to the sort sequence.
4. Click on the Show (View) command button to view the
relevant description.
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Text search
2. Click on the “Find” tab in the left window area.
3. For searching, enter the desired term(s) in the “Find term“ field.
If necessary, you may use the wildcard character “*” for any
possible string. The individual search terms can be logically
combined by the AND, OR, NEAR, NOT operators and the
bracket symbols “(“ and “)”. The search itself is not case-
sensitive, however, the operators have to be written in capital
letters.
Example: The query “help AND (version NOT 2003)” will find
all topics containing both the terms “help” and “version”, but not
“2003”.
4. Use the check boxes in the lower left part of the window to
define the desired search scope.
5. Click on the List topics command button to list all topics that
match the query. Now, the relevant topics can be displayed by
double-clicking on a list entry or by clicking on the Show
(View) command button after having selected a topic.
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Use favorites
Topics that are frequently needed or especially important can be
included in the permanent Favorites list that is listed in alpha-
numerical order (and can even be given a different name there!).
Thus, after closing and re-opening the Help function, the topics of
interest are immediately displayed again.
Including topics in the Favorites list

2. Use the functions "Contents (structure)", "Keyword search",
"Text search" or "Use favorites" in order to display the relevant
contents.
3. Click on the “Favorites” tab in the left window area.
In the lower left display area, the system will enter the name of
the topic in the “Current topic” field.
4. If desired, you can change the topic name according to your
requirements. The topics displayed can be included in the
Favorites list under the name displayed by clicking on the Add
command button.
Note: Alternative to Add command button:

• Right mouse click in Favorites list
• Select menu item ”Add”.
Displaying the topics in the Favorites list

3. If there are any entries in the list, you can display the relevant
topics by double-clicking on a list entry or by clicking on the
Show (View) command button after having selected a topic.
Note: Alternative to Show (View) command button:

• Right-click on the desired topic in the Favorites list
• Select menu item ”Show (View)”.
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Deleting topics from the Favorites list

3. Select the relevant list entry and click on the Remove
command button to delete the entry.
Note: Alternative to Remove command button:

• Right-click on the desired topic in the Favorites list
• Select menu item ”Remove”.
Renaming the topics in the Favorites list

3. Right-click to select the relevant topic and select the “Rename”
menu item
4. Enter the new name for the topic.
5. Acknowledge the new topic name with the Enter key.
Note: Renaming can be canceled by hitting the Esc key.

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Safety Instructions
Safety Instructions
This section contains important safety-related information.
Why” and “What for”?

The products described were developed, manufactured and tested
in compliance with the fundamental safety requirements of the EU
machinery directive. These products pose no danger to persons or
property if they are used in accordance with the handling
stipulations and safety notes prescribed for their configuration,
mounting, and proper operation.
Nevertheless, there still is some residual risk!
Ö Please note the information provided in the previous section in

this context!
The present information refers to the

• Functionality of the BOS 6000, the “Welding User Interface”.
Information concerning
• the mechanical construction
• the electrical connection (24V supply and I/O) and
• the functionality
of the hardware addressable via BOS is described more in detail in
the relevant manuals. There, you will also find safety information
that is important for product handling. Store this documentation in
a place to which all users have access at any time!
Ö You should know and understand the issues at stake before

installing, connecting or commissioning the products or
programming the system.
Ö In case of uncertainty, you should always contact your
supervisor!
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Safety Instructions
Symbols used
This symbol is used wherever insufficient or lacking
compliance with instructions may result in personal
injury.
DANGER
This symbol is used wherever insufficient or

lacking compliance with instructions may result in
damage to property.
CAUTION
Note: This symbol is used to draw the user’s attention to

special circumstances.
Ö This symbol indicates that you have to do something or have

to create certain conditions. If a special order has to be
observed, the relevant paragraph will start with a serial number
instead of an arrow.
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Safety Instructions
Proper use
Our weld timers
• serve for resistance welding of metals in connection with a
welding transformer and the appropriate power unit, and
• are suitable for operation in industrial environments in
accordance with the following standards: EN 50178, EN 60204-
1, EN 50081-2, EN 50082-2.
In residential environments, in trade and commerce as well as
small enterprises, class A equipment may only be used if it
does not inadmissibly interfere with other equipment.
The BOS 6000 user interface described here serves for

• Operation and
• Parameter input
of weld timers of the PSS 5000 and PSx 6000 series.
Any other application is deemed improper use!
The consequences of an improper use include

personal damages of the user or of third parties as
well as damages to property – the technical
DANGER equipment, the workpiece to be processed, or
environmental hazards.
Therefore, our products should only be used for
their intended purpose!
Note: For operating the hardware in residential environments,

in trade and commercial applications and small
enterprises, an individual permit of the national authority
or test institution is required; in Germany, please contact
the Regulierungsbehörde für Telekommunikation und
Post (RegTP) or its local branch offices.
The faultless, safe functioning of the product requires proper

transport, storage, erection and installation as well as careful
operation.
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Safety Instructions
Qualified personnel
The present documentation is designed for specifically trained
engineers with special knowledge of the welding technology. They
must have sound knowledge of the software and hardware
components of the weld timers, the power units used, and the
welding transformers.
Project engineering, programming, start and operation as well as
the modification of program parameters is reserved to properly
trained personnel! This personnel must be able to judge potential
hazards arising from programming, program changes and in
general from the mechanical, electrical, or electronic equipment.
Such personnel are
• those who, being well trained and experienced in their field and
familiar with the relevant norms, are able to analyze the jobs
being carried out and recognize any hazards which may have
arisen
• those who have acquired the same amount of expert knowledge
through years of experience that would normally be acquired
through formal technical training.
Risks for persons with cardiac pacemakers!

Due to the strong magnetic fields arising from
resistance welding, the function of cardiac
DANGER pacemakers may be disturbed. This may cause the
death or considerable health damages!
Therefore, these persons should avoid the welding
system.
Please note our comprehensive range of training courses. Please

refer to http://www.boschrexroth.com for the latest information on
training courses, teachware and training systems.
Our Erbach Didactic Center will be pleased to provide you with
further information,
telephone: (+49) (0) 60 62 78 600.
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Safety Instructions
Safe working practices
Program start is immediately possible after

fault reset!
If the start signal is present when a fault is reset
DANGER (acknowledged), the timer will start its program
run immediately! This may result in dangerous
machine movements!
Therefore, prior to fault reset, make sure that
there is no-one in the hazard area of the
welding equipment.
Strong magnetic fields!

Due to the strong magnetic fields arising from
resistance welding, the function of wristwatches,
CAUTION pocket watches or magnetic stripe cards (e.g., EC
cards) may be disturbed for ever.
Therefore, you should not carry such items on you
while working in the immediate vicinity of the
welding system.
Loss of data/Damage to floppy disks/CDs!

Never expose floppy disks to the effects of
magnetic fields! Therefore, you should not carry
CAUTION any floppy disks on you while working in the
immediate vicinity of the welding system. Provide
suitable packaging to protect data media against
hazardous external influences (such as dust,
moisture, heat) or store them in a proper place.
Note: Also note safety information that is important for product

handling. For more detailed information, please refer to
the relevant manuals:
Tampering with the hardware or software and ignoring
safety instructions/warnings can result in serious bodily
injury or property damage.
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Safety Instructions
Trademarks, copyright
• All trademarks of software installed on our products upon
delivery are the property of the respective manufacturers.
• Upon delivery, all installed software is copyright–protected. The
software may only be reproduced with our approval or in
accordance with the license agreement of the respective
manufacturer.
• Reverse engineering of our software/firmware is illegal.
Note: Interventions in the hardware and software of our

products, unless described otherwise in the product
documentation, are reserved to specialized personnel.
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Getting to know the BOS 6000 user interface
Getting to know the BOS 6000

user interface
In this section, you will be familiarized with important icons and the
functions of the menu bar as well as the structure of the user
interface and the purpose of the different windows.
Basics
The BOS 6000 software (i.e. the welding user interface) can be
used for weld timers of the PSS 5000 and PSx 6000 series.
While this ensures an identical operating philosophy of all timers,

there may be timer-specific differences in terms of scope of
functions. Within the user interface, this may result in certain
parameters/functions being invisible or dimmed.
Ö Therefore, please always note the documentation relating to

your specific timer including the safety instructions provided
there!
In order to work with the user interface, you need to have a rough
knowledge of the operating system (MS Windows 2000 or higher):
• operating the mouse and keyboard
• entering data with the keyboard into input fields, or selecting
data from lists.
• changing the size/position of a window, closing windows
• changing paths to folders via a dialog box if your settings differ
from the default.
Note: BOS 6000 can be operated using either the mouse or

the keyboard.
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Overview of the interface structure

The table below shows the following information for all windows
within the user interface
• the name of the window, and
• its branch structure.
In this way, you can find the path leading to a desired window
quickly and easily.
Description of the columns:

• Level 1:
Contains all windows that can be open at the same time. The
table entry “the BOS 6000 main window” represents a menu
shown in level 1a.
• Level 1a:
Contains all the menus that can be displayed in the BOS 6000
main window.
• Level 2:
Can be called up from level 1.
• Level 3:
Can be called up from level 2.
If the window name is written in brackets ( ), changing to another

open window is not possible unless the relevant window has been
closed.
Level 1 Level 1a Level 2 Level 3

()
Reference</LABEL ()
>
()
(Timer</LABEL>)
set-up</LABEL>
the BOS 6000 main
Schedule</LABEL>
window
Seq. Pg.2</LABEL>
(
Stepper</LABEL> Counter</LABEL
>)
General</LABEL>
Electrode</LABEL> calibration</LAB
EL>
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<LABEL
calibration</LAB
EL>
Thyristor-Unit-
Parameter</LABEL>
Diagnostics I/O</LABEL>
Timer-
Users Diagnostics
Information</LAB
I/O</LABEL>
EL>
Last
Weld</LABEL>
Start Simulation</LABEL>
Timer-
Information</LABEL>
Last Weld</LABEL>
Stepper curves</LABEL>
Tipdress curves</LABEL>
Fault-Setup</LABEL>
Communication</LABEL>
Correction</LABEL>
Reference</LABEL
>
(
( Info</LABEL>) Counter</LABEL
>)
table</LABEL>
overview</LABEL>
(
Overview</LABEL>
)
( Access
Level</LABEL>)
()
change</LABEL>
()
change</LABEL>
(
Import/Export (Para
meter-Backup) )
and Controls
(Para.-Data
Import/Export (Para
meter-Restore))
()
(
Programs</LABEL>
)
(Spot Comment)
Meaning of important icons

Within the BOS 6000 main window, you may access a number of
icons for opening other windows, retrieving information or
triggering certain functions by a simple mouse click.
opens the ”Corresponding Programs ” window.

Can only be activated if a spot has been selected in the “Spot
name” field (same row, left) which has not been assigned as the
only spot to a program. In this case, the background of the “Spot
Name” field additionally changes from white to yellow.
Opens the ”Spot Comment ” window.

Cannot be selected unless at least one comment has been
assigned to a spot (for assignment of comments: refer to Spot
Reference window”).
Opens the ”Login ” window.
Opens/selects the ”Timer Reference ” window.
Opens/selects the ”Spot Reference ” window.
Opens/selects the ”Prewarning ” window.
Opens/selects the ”Error table ” window.
Opens/selects the ”Network overview ” window.
Opens/selects the ”Protocol ” window.
Opens/selects the ”Compare ” window.
Opens the ”Parameter Overview ” window.

and Controls
Opens the ”Set Access Level ” window.

Will not be displayed unless the user has logged into BOS 6000 as
Administrator.
Opens the ”FTP-Upload ” window.

Will not be displayed unless function has been enabled in the
configuration tool.
Switches to the topic “Programming” in the BOS 6000 main

window.
Switches to the topic “Diagnosis” in the BOS 6000 main

window.
Can only be selected if an online timer has been selected in the
“Timer” field (same row, left) and a trouble-free connection has
been established with this timer.
Switches to the topic “Setup” in the BOS 6000 main

window.
Switches to the topic “Correction” in the BOS 6000 main

window.
Note: If the icons described above are not shown or are

dimmed, the function has not been enabled by the
Administrator for the user currently logged in.
and Controls
Functions in the menu line

The menu line within the BOS 6000 main window offers access to
a number of menu items for opening other windows, retrieving
information or triggering certain functions.
Note: Many menu items can also be directly accessed via the
keyboard. The corresponding key codes are displayed
by the system to the right of the relevant menu text.
Note: If the menu items are not shown or are dimmed, the
function has not been enabled by the Administrator for
the user currently logged in.
File | Para. data import/export | Export …

Opens the ”Para.-Data Import/Export (Parameter-Backup)”
window.
File | Para. data import/export | Import …

Opens the ”Para.-Data Import/Export (Parameter-Restore)”
window.
File | Exit
Closes the BOS 6000 application (also possible by clicking on )
Note: To exit the application, you must have the appropriate

user privileges. The setting can be modified by an
Administrator currently logged in using the “Set Access
Level” window.
Edit | Programming
Switches to the topic “Programming” in the BOS 6000 main
window.
Edit | Diagnosis
Switches to the topic “Diagnosis” in the BOS 6000 main window.
Can only be selected if an online timer has been selected in the
and Controls
“Timer” field and a trouble-free connection has been established

with this timer.
Edit | Setup
Switches to the topic “Setup” in the BOS 6000 main window.
Edit | Correction
Switches to the topic “Correction” in the BOS 6000 main window.
Edit | Oscilloscope function

Currently no function.
Edit | Export record set

Opens the Backup window
Edit | Autobackup
Opens/selects the ”Autobackup ” window.
Edit | Timer change

Opens/selects the ”Timer change ” window.
Edit | Copy
Opens the Copy window
Edit | Firmware changing

Opens/selects the ”Firmware change ” window.
Edit | Login
Opens the Login window
Language
Immediately changes over to the selected language.
and Controls
Functions | Timer reference

Opens/selects the ”Timer Reference ” window.
Functions | Spot reference

Opens/selects the ”Spot Reference ” window.
Functions | Prewarning
Opens/selects the ”Prewarning ” window.
Functions | Error table

Opens/selects the ”Error table ” window.
Functions | Network overview

Opens/selects the ”Network overview ” window.
Functions | Protocol
Opens/selects the ”Protocol ” window.
Functions | Compare
Opens/selects the ”Compare ” window.
Functions | Parameter overview

Opens the ”Parameter Overview ” window.
Functions | Rights administration

Opens the ”Set Access Level ” window.
Cannot be selected unless the user has logged into BOS 6000 as
Administrator.
Help | Help
Opens/selects the Online help function.
Help | About
Displays information concerning BOS 6000, and concerning the
runtime libraries and the BOS6000.exe and BOSServ.exe used
when clicking on the “Module List” button.
and Controls
The available windows

In the following sections, you will be familiarized with the purpose
of the individual windows.
Login
Purpose:
• at program start:
• User login to system
• to set the desired language
(if enabled in configuration tool)
• when BOS is already active:

• to change user without exiting the user interface.
From the login, the system detects the functions of the user
interface to be enabled or disabled. Functions that are disabled are
not displayed or will be dimmed.
Note: Automatic login can be configured with the user

administration function of the configuration tool. For this
purpose, a new user name must be generated and
assigned to the “AutoStart” user group. To deactivate
this function, the relevant user name must be deleted.
Note: In the configuration tool, you can define whether and

when automatic logout should be performed. If activated,
the “Everyone” user will be automatically logged in to the
system after a certain time has elapsed without activity.
and Controls
Username
Input the user name. Click on to select the desired user name
from the list of users.
Note: The user list can only be modified using the user
administration in the configuration tool.
User-Password
Enter the relevant password. An asterisk “*” will be displayed for
each character input.
Note: The user’s password can only be modified using the

user administration in the configuration tool.
Language
Language selection. Click on in order to select the desired

language.
Note: The ”Language” input field is only displayed at program

start. In order to change the language while BOS is
active, use the “Language “ menu item in the BOS menu
line.
Note: If the “Language” input field is dimmed, free language

selection has not been enabled. The language selection
options can only be modified using the user
administration in the configuration tool.
Timer Reference
Purpose:
• Display of basic communication parameters of all timers
assigned to the BOS 6000. For a description of the table
columns, also refer to window “Add/ChangeTimer”).
• to logon timers to BOS 6000 / delete timers from BOS 6000
• to define/change the ID and communication data of timers
• to export (Backup) timer data from the internal database, or
to import it into the internal database (Restore)
and Controls
• to save/restore/print the Timer Reference (table contents)

• only when logged in as Administrator:
to use the “determine user level" link to define the execution
privileges (=write privileges) for command buttons and menu
items in this window
• to set the desired language using the Language menu item

• to display basic communication parameters of all timers
logged into the BOS 6000.
• to save /print the timer reference
to use the “Set Access Level" link to define the execution
• to set the desired language using the Language menu item
If the field in column “Software version” has a green background, a

data record already exists in the internal database for the timer in
question. If no data record exists, the corresponding field has a red
background.
The check boxes at the left line margin

are used to select timers for a desired activity. Checking the
uppermost check box will select/deselect all check boxes in the
list.
Note: The check boxes cannot be selected unless the window

is opened while the program is started.
The check boxes in the “online” column

are used to toggle the mode of the relevant timer between ONLINE
and OFFLINE (for effects, refer to “Mode” in
window”Add/ChangeTimer”).
and Controls
Note: The check boxes cannot be modified unless the window

Import Recordset command button

Opens the ”Restore ” window
Note: The command button is not available unless the window

Export Recordset command button

Opens the ”Backup ” window

Add command button

Opens the ”Add/ChangeTimer ” window

Continue command button

Closes the window and pens the ”Connection set-up ” window

OK command button
Closes the window.
Note: The command is not available unless the window is

opened while BOS is active.
and Controls
Add/ChangeTimer
Purpose:
• To define/change the ID and communication data of timers

• To define the behavior when communication is built up if a
discrepancy between the data of the timer and the database is
noted.
• for TCP/IP link: to test the connection to online timers (ping)
Timer name
Input of a unique timer name.
Several identical names are not permitted in Timer Reference.
Number of characters: min. 1, max. 48.
Prohibited characters: / | \ " ? * < > ' :
Acknowledge your input by pressing the Tab key.
Timer comment
Explanation text (optional).
Number of characters: max. 65.
Prohibited characters: ‘
Acknowledge your input by pressing the Tab key.
Channel
Communication port used.
Depending on the currently available hardware, the possible
communication interfaces can be selected from a list box.
IP address
Timer address within an Ethernet network.
In order to ping an IP address already entered in the timer
reference table, click on .
and Controls
Possibility of malfunctions in the Ethernet

network
Entering any arbitrary address or changing
CAUTION existing addresses may produce malfunctions
in your Ethernet network!
Therefore, you should ask your systems
administrator which address ranges have
been reserved for the weld timers. Make sure
that an IP address cannot be assigned to
several devices. All IP addresses assigned
should be logged precisely!
Timer address
Timer address within a Field bus network.
Note: In OFFLINE mode, a serial address ID is automatically

assigned to the timer.
In connection with the V24 communication interface, the
address is always “1”.
Station
Station number of the timer within an INTERBUS network.
Note: The permitted station numbers can only be modified

using the configuration tool.
COM port
Defines the COM port (COM1, COM2) in connection with the V24
communication interface.
Operating mode
ONLINE:
When BOS 6000 is started, the system tries to establish a
connection with the timer under the given address.
OFFLINE:
In this mode, program preparations and programming exercises
can be made without a timer connected to the programming
terminal. The data of an offline timer is stored in the BOS 6000
internal database. Diagnosis or starting program execution is not
possible, however.
Software Version
Specification of the timer type and the necessary firmware version.
and Controls
Note: This input must always be made in OFFLINE mode.

In ONLINE mode, the list box will not be shown.
Direction
When establishing connection with an online timer, the system
checks whether the data in the timer and in the database is
identical.
If it is not, you can define the desired response here:
• Selection:
The system will offer a selection of further activities.
• Timer -> DB:
Default. Timer data is transmitted to the database. Current
actual values and counter statuses will not be transmitted.
• DB -> Timer:
Special case. Database data is transmitted to the timer. Actual
values and counter statuses stored in the database will not be
transmitted.
• FW-MODE:
values and counter statuses stored in the database will also be
transmitted.
Note: With “FW-Mode” you will have to remember that the

counter statuses and actual values transmitted to the
timer might not be up-to-date.
The counter statuses and actual values will be updated
in the database only when a record set has been
created by the function"Timer change", or in the course
of a Firmware change (using the Save actual values
command button) !
Note: In OFFLINE mode, the list box will not be shown.
Producing new data set

Creates a new record with default values in the internal database
for the relevant timer. The existing record will be deleted.
Note: When adding a new timer to the timer reference, this

check box will not be available.
and Controls
Connection set-up
Purpose:
• Status/error display
- Connection set-up to the online timers
- Data match between the data in the database and in the
timer
- Database initialization for new offline timers
The window will be opened as a status display during the

starting sequence and is automatically closed when
connection with all online timers included in the timer
reference has been successfully established.
Note: If configured accordingly, a dialog will be displayed for a

data mismatch between the database and timer data
where further activities can be manually specified.

• Self-acknowledging error display.
The window is automatically opened/closed when
communication with an online timer is interrupted/resumed.
and Controls
Possible field colors in column “Status”:

red: Communication error.
yellow: Data match/communication set-up running.
green: Record set is available.
Possible field colors in column “Online”:

blue: Timer in question has been parameterized for OFFLINE
mode.
green: Timer in question has been parameterized for ONLINE
mode.
Response to data mismatch

Depending on the configuration setting (refer to “Direction“ field in
window "Add/change Timer"), the timers and their corresponding
record sets are automatically synchronized in the internal database
at once, or after a dialog-controlled query.
If the query has been configured, the following dialog will be
displayed in the event of a data mismatch:
• Timer -> DB:

Default. Timer data is transmitted to the database. Current
actual values and counter statuses will not be transmitted.
• DB -> Timer:
values and counter statuses stored in the database will not be
transmitted.
• Display data:
In another dialog window, BOS 6000 shows the data that does
not match.
and Controls
Select the desired direction of the data match in this dialog and
confirm your selection by hitting OK.
The data match will start as soon as you have acknowledged
the query by hitting OK.
and Controls
Programming
Within the BOS 6000 main window, the “Programming“ menu
(selection by symbol ) offers the following options:
• Selection of “Spot-Name”, “Timer”, “Program”, “Electrode”, or

“Power-Unit” (the individual features depend on the selected
tab).
• Selection of the "Schedule" tab in order to program all
fundamental, basic settings for a welding program and to
display the %I-specific actual values during the last schedule of
the relevant welding program.
• Selection of the "Seq. Pg.2" tab in order to program specific
parameters for a welding program in connection with electrode
force (pressure profile, pressure stepping), the signal
characteristic of a freely programmable digital output and/or
time monitoring.
• Selection of the "Stepper" tab in order to program important
functions of the electrodes used (stepping, tip dressing, setting
the counts).
The %I-specific actual values during the last schedule welded
with the electrode in question are also displayed here.
• Selection of the "General" tab in order to define important
settings that apply to the entire module.
• Selection of the "Electrode" tab in order to define important
settings for the electrode gun and the transformer and to
perform current or force calibration.
• Selection of the "Thyristor-Unit-Parameter" tab in order to
perform settings specific to the power unit.
This function also displays information concerning the timer
type (Timer-Type) and the current firmware version.
Note: For information concerning the Status line, refer to

“Explanations“ section.
Note: In some cases, the settings are only possible at a certain

user level.
and Controls
Programming: Schedule
Note: First you have to select the relevant welding program

- indirectly via the “Spot-Name” field, or
- directly via the “Timer” and “Program” fields.
Use the Data ----> Timer command button to transfer modified

parameters to the timer (refer to sect. "Changing and transmitting
parameters to the timer").
and Controls
The values of the actual currents present can be accepted as new

Reference currents for the relevant weld times using the Act.-
>Com. command button. Any current portions included in the
actual currents based on active Correction and Stepper values are
previously stripped out.
Start-Inhibit (P)
If preset with the value “On”, execution of the program in question
is not permitted. Thus, for example, it is possible to prevent a
program that is not in use or to which no meaningful parameters
have been assigned from starting.
Starting a program for which “Start-Inhibit“ has been defined will

initiate the error message “Start inhibited".
For inhibiting all programs of a timer, refer to parameter “Start

Inhibit (T)“.
Weld/No Weld (P)

Defines whether the power unit is energized during the weld times
of the relevant program (parameter value “On”) or whether it is not
energized (parameter value “Off”).
Also refer to parameter “Weld/No Weld (Global)“.
Note: The power unit will not be energized unless the following
conditions are met:
Parameter “Weld/No weld (P)” = “On” and
Parameter “Weld/No weld (Global)” = “On” and (if
existent)
the “Weld external” input signal has been set.
Machine movements are also possible if

Weld/No weld is deactivated
If the WC contact is output at the end of the
DANGER program run, machine movements may be
initiated even if “No weld” has been specified.
Therefore, please make sure that there is no-
one in the hazard zone when the welding
program is started.
Schedule
Defines the desired sequence mode of the relevant program.
and Controls
Single:
A high level at the start input initiates the welding schedule (or
welding program) exactly once, starting with the pre-squeeze time
(Pre Sqz).
For the next program start, the Start signal has to be switched off
and back on.
Repeat:
The weld timer initially responds to the start signal as in "single
spot" mode and starts the welding schedule.
If the start signal is still present after the end of the hold time
(HLD), the solenoid valve signal will be switched off and the
electrode gun is opened.
The Off time (OFF) runs. During this time, the operator can pull on
the welding gun towards the next spot.
After the end of the OFF time, the solenoid valve will be energized
again, and the welding schedule will be restarted - this time
beginning with the SQZ.
This schedule will be repeated for as long as the start input is high.
Seam:
Offers 2 fixed, sequential heat blocks (1st and 2nd heat block) for
each start event, with the possibility of programming the duration
and amount of current separately for each block.
During the 2nd heat block, the weld time (WLD) and a cool time
(2.CT), if programmed, will be repeated for as long as the start
input remains high.
When the start signal becomes low, the timer will cancel the actual
current pulse and start the hold time (HLD).
1. Halfcycle after Pause-Time

Limits the phase angle of the 1st halfcycle after each cool time (=
transformer inrush current) for the relevant program.
This parameter is relevant and displayed for equipment with
thyristor power units only.
Note: The electrode-specific transformer inrush current can

also be limited using parameter "1. Halfcycle Limit".
Monitoring
Defines the desired monitoring mode of the relevant program. For
activation/deactivation of monitoring, refer to parameter "Current
monitoring".
Standard:
and Controls
The complete current profile is represented by a single actual

value, compared to the Reference current for the WLD and
monitored by a single tolerance band. The entire current profile
(1st, 2nd and 3rd heat block including cool times) is used for rms
value measurement and determination of the actual value.
Using this simple yet in many cases sufficient monitoring mode,
the amount of data to be monitored remains small, however, any
cool times and different current values existing in the individual
blocks may change the measured result.
Mixed:
The rms value is measured separately for each heat block,
compared to the relevant Reference current of a weld time and
monitored by separate tolerance bands (for the 1st, 2nd and 3rd
heat block). Any cool times programmed will not be accounted for
in the actual value generation for the individual heat blocks.
This results in a greater transparency of the individual heat blocks,
however, the amount of data to be processed becomes larger.
Regulation
Defines the desired regulation mode of the relevant program.
Standard:
The Regulation mode predefined for the 2nd heat block is
applicable to all 3 heat blocks.
Mixed:
The regulation modes of all 3 heat blocks can be defined
individually and independent of each other.
Electrode
Defines the electrode (gun) to be used by the relevant program.
The counts to be incremented by the timer in the course of the
relevant program is also determined by this setting.
Note: The max. number of electrodes supported depends on

the timer type.
Note: Programs used for real welding should only use

electrode numbers greater than/equal to 1. Electrode
number “0” has been reserved for special applications
(e.g., for a general reset of all electrode counters).
and Controls
Spot-Repetition
Turns the “Spot repetition” function on/off for the relevant program.
When spot repetition has been activated, the welding program
concerned is automatically repeated once if Current monitoring
has been activated and would respond by issuing the "Low
current" or "No weld current" error messages.
This function may possibly save user interventions.
Note: A spot weld below the tolerance band (refer to "Lower

tolerance band" parameter) is automatically rewelded no
more than once if spot repetition has been activated, its
%I values must be within the tolerance band during the
reweld.
Note: In order to avoid undesirable side effects under certain

system conditions, you should also adjust the "Max.
Repeat Welds" parameter to your requirements.
Time-Monitoring (Programming, Schedule)

Turns the “Time monitoring” function on/off for the relevant
program.
For more information, refer to sect. Programming: Seq. Pg.2 ."
Base pressure value (Programming, Schedule)

Defines the electrode force (in kN) used for welding by the relevant
program.
Note: The electrode force specified is only effective after

proper Force Calibration or a proper input in parameters
"Conversion-Factor" and "Zero-adjust" (refer to
"Programming" menu, tab "Electrode") ! Otherwise,
there is no defined correlation between the value input
and the resulting force at the electrode gun!
I% and pressure correction displays

Serve to display the parameters with the same names. The
settings can be made in the ”Correction” tab under the “Correction”
theme .
Pre Sqz
The Pre Sqz is processed immediately following the Start signal in
all three Sequence Modes ”single spot”, “repeat”, and “seam”.
and Controls
At the beginning of Pre Sqz, the timer activates the solenoid valve
signal to initiate the closing movement of the electrode gun. No
current flows during this period of time.
The Pre Sqz precedes the SQZ in order to ensure that the
electrode gun is completely closed even in the event of a long
travel, e.g., with manual guns.
When welding repeated spots, the Pre Sqz will only be processed
for the first spot of the series.
SQZ
During the SQZ, the working pressure of the electrodes is built up.
The electrode gun must be entirely closed at the end of SQZ. No
current flows during SQZ.
The following signals may prevent processing of the SQZ with
individual timer types
• Pressure contact
• Pressure feedback from pressure control valve
• NBS release
PreWld
Period of time for preheating the parts to be welded with the Pre
Weld kA.
If preheating is not desired, this parameter can be set to 0.
The maximum permitted period of time can be limited using the
"Programming" menu, tab "General".
Also refer to 1.CT“.
1.CT
Serves to reduce stress in the parts to be welded after the PreWld.
The welding gun remains closed within the 1.CT. There is no
current flow.
Note: The 1.CT is relevant and can be changed only if a value

greater than 0 has been programmed for the PreWld.
Slope
Turns the “Slope” function on or off.
When slope is active, the %I can be automatically sloped in the
2nd heat block.
This “Slope” function is defined via the following parameters:
UST (Slope-Time)
and Controls
Start-Slope-Current
DST (Down-Slope-Time)
End-Slope
Note: Activating/deactivating the Slope will result in a change

in the heat balance! This effect may adversely affect the
quality of the weld if the Main weld current is not
changed accordingly!
UST
Acts in conjunction with the "Slope" function.
Period of time during which the current is linearly changed from the
programmed Start-Slope-Current to the Main weld current if the
“Slope“ function is active.
The UST always starts at the beginning of the 2nd heat block and
is not interrupted by any cool times programmed in the 2nd heat
block (refer to 2.CT).
WLD
Period of time during which the parts are welded together with the
Main weld current taking a possibly activated Slope into account.
For more information, also refer to 2.CT“.
DST
Acts in conjunction with the "Slope" function.
Period of time during which the %I is linearly changed from the
programmed Main weld current to the End slope if the “Slope“
function is active.
The DST always ends at the end of the 2nd heat block and is not
interrupted by any cool times programmed in the 2nd heat block
(refer to 2.CT).
2.CT
With active pulse operation (Parameter "Impulse" has been
assigned a value greater than 1) this cool time serves to reduce
the stress in the parts to be welded after the WLD and separates
the individual pulses (duration of a pulse: corresponding to the
WLD).
The welding gun remains closed within the 2.CT. There is no
current flow.
and Controls

greater than 1 has been programmed for the Impulse
parameter (= impulse mode is active).
Impulse
Activates the impulse mode if assigned a value greater than 1.
If impulse mode has been deactivated, the duration of the 2nd heat
block exactly corresponds to the WLD.
If impulse mode is active, the WLD is repeated corresponding to
the value programmed for “Impulse”. This is the only case in which
the 2.CT is also active. The duration of the 2nd heat block now
depends on the number of WLD and the number of 2.CT.
3.CT
Serves to reduce stress in the parts to be welded prior to the
beginning of the PostWeld. The welding gun remains closed within
the 3.CT. There is no current flow.

greater than 0 has been programmed for the PostWeld.
PostWeld
Period of time for post-heating the parts to be welded with the . In
this way, the parts to be welded can be prevented from cooling
down too quickly (due to the electrodes cooling).
If post-heating is not desired, this parameter can be set to 0.
Also refer to 3.CT.
HLD
Period of time for cooling down the parts to be welded.
The welding gun remains closed during the HLD. There is no
current flow.
At the end of the HLD, the weld has been completed. The timer
resets the “solenoid valve” signal. The welding gun is opened.
If necessary, the weld complete contact (WC) is output.
OFF
Period of time until the next SQZ during which the gun is open in
Sequence mode "Repeat" and can be pulled to the next spot to be
welded..
and Controls
Note: The OFF is relevant and can be changed only if

parameter “ Schedule” has been set to “Repeat” mode.
Pre Weld kA
Desired base current during the PreWld.
In kA or %I, depending on the Regulation mode programming .
The maximum permitted %I is limited in the ”Programming” menu
using the “Electrode” tab (via parameter “Upper current limit”).
Start-Slope-Current
Desired base current at the beginning of the UST.
Main weld current

Desired base current during the WLD.
Is influenced by the "Slope" function.
End-Slope
Desired base current at the end of the DST.
Pst Wld kA
Desired base current during the PostWeld.
and Controls
Reference current
The parameters “Ref. current” serve as separate command values
for monitoring the individual heat blocks.
The weld timer compares the measured actual rms current values
(shown in the "Act. ref. current" fields) with these programmed
values and interprets them as “good” or “bad” with respect to the
relevant tolerance limits.
Unacceptable actual values result in a fault message if the relevant
Current Monitoring function has been activated.
Note: The reference current cannot be programmed unless

parameter Current Monitoring has been activated in the
relevant heat block.
Furthermore, the "Monitoring" parameter influences the
availability of the input fields for the 1st and 3rd heat
block.
Also refer to parameter Monitoring.
Regulation mode
Defines the desired regulation mode for the relevant program,
taking parameter "Regulation" into account.
PHA
Programming the phase angle of thyristor power units or the pulse
width of medium-frequency inverters. Programmed %I values will
be interpreted as command values for the power unit and input as
%I.
No regulation is active. The resulting current exclusively depends
on the conditions of the secondary circuit. A current sensor is not
necessary.
If a current sensor is available, it can be used to display the actual
current and for Current monitoring.
KSR
Activates constant-current regulation.
Programmed %I values will be interpreted as command values for
the %I controller and input as kA values.
Unless blocked by parameter "Control stopped", current regulation
is activated. For this reason, the resulting current is largely
independent of the conditions of the secondary circuit. A current
sensor must be available.
The Current monitoring function can be separately activated.
Please note that actual current values are not monitored for
programmed tolerance bands unless current monitoring is
switched on!
KUR (only available for some timer types)

and Controls
Activating constant-voltage regulation.

Programming the phase angle of thyristor power units or the pulse
width of medium-frequency inverters. Programmed %I values will
be interpreted as command values for the power unit and input as
%I.
A constant-voltage regulation is active for compensating line
voltage fluctuations. Voltage feedback from the secondary circuit is
necessary for this purpose.
The resulting current exclusively depends on the conditions of the
secondary circuit. A current sensor is not necessary.
If a current sensor is available, it can be used to display the actual
current and for Current monitoring.
Current monitoring
Note: A current sensor for measuring the actual current is

necessary in order to use the “Current monitoring”
function.
Turns the “Current monitoring” function in the relevant program

on/off for the individual heat blocks (independent of the regulation
mode).
If this function is active, the actual current values measured
• are interpreted as good or bad (refer to parameters "upper
tolerance band" and "lower tolerance band")
• are monitored for a continuous decrease (refer to parameters
"conditional tolerance band" and "repeat factor")
Note: Current monitoring is influenced by the "Control

stopped" parameter!
Upper tolerance band

Maximum permitted positive tolerance as a percentage of the
Reference current.
Actual values above this tolerance limit generate the message type
”Current too high/Over current”.
Note: The "Monitoring" parameter influences the availability of

the input fields for the 1st and 3rd heat block.
and Controls
Lower tolerance band

Maximum permitted lower tolerance as a percentage of the
Reference current.
Actual values below this tolerance limit generate the message type
”Current too low/Low current” or “no current”.

Conditional tolerance band

Input as a percentage of the reference current. Must be smaller
than parameter "lower tolerance band".
This parameter is used in connection with the "Repeat factor" in
order to determine “creeping” faults of the system that cause a
gradual yet continuous “decline” in actual values.
Together with the "lower tolerance band", it defines a current range
in the lower section of the tolerance band. The “Repeat factor”
determines the number of consecutive welds that may be within
the conditional tolerance band.
If this value is exceeded, the timer will output the message “Series
of welds below lower threshold point”.

and Controls
Repeat factor
For a description, refer to parameter "conditional tolerance band".
The display fields right of the repeat factor (MIX … tolerance band
error) indicate the number of consecutive welds already recorded
within the conditional tolerance band.

Active reference current (Programming, schedule)

The fields show the actual rms current values (in kA) measured in
the individual heat blocks.
Middle PHA (Programming, schedule)

Indicates the mean command value determined in KSR mode for
driving the power unit (in %I) for each heat block.
In PHA (and KUR) mode, the values displayed exactly correspond
to the programmed %I values.
and Controls
Programming: Seq. Pg.2

- directly via the “Timer” and “Program” fields.

Base pressure value (Programming, Seq. Pg.2)

program.

proper Force Calibration or a proper input in parameters
"Programming" menu, tab "Electrode") ! Otherwise,
and Controls
Pressure stepping
The “Pressure stepping” function automatically changes the
pressure value (electrode force) between two consecutive phases
(start phase and stepping phase) depending on the current
program, the count and the tip dress counter.
It is enabled or disabled for the respective electrode parallel to the
"Stepper" function via parameter "Stepper" (refer to "Programming"
menu, tab "Stepper").
It depends on the parameter settings whether or not the (enabled)
function is eventually active:
for the start phase:

Pressure for new electrode
• "Count"
for the stepping phase

Stepper curve
Pressure at end of 1.Stepper-Phase
• "Count"
additionally for the stepping phase with activated tip dressing

Dressing-Curve
Pressure after last Dressing
Pressure for new electrode

Acts program-specific in conjunction with the "Pressure stepping"
function during the start phase.
The parameter defines the pressure (in % of the program-specific
base pressure value) to be used for welding at the beginning of the
start phase (normally when the relevant electrode has been
replaced).
During the further development of the start phase, the pressure is
linearly changed up to 100% of the program-specific base
pressure value of a weld.
The length of the start phase for pressure stepping depends on the
electrode-specific parameter "Count" (refer to "Programming“
menu, tab "Stepper").
If the value 0 has been entered there, no start phase will be used.
In this case, you should enter 100% as “Pressure for new
electrode”.
and Controls
Pressure at end of 1.Stepper-Phase

function during the stepping phase.
In the course of the stepping phase, the pressure is increased up
to the value entered for this parameter (in % of the program-
specific base pressure value), starting from 100% of the program-
specific base pressure value. The course of this change (during
the stepping phase) can be influenced by parameter "Stepper-
Curve".
The starting point of the stepping phase for pressure stepping
depends on the electrode-specific parameter "Count" (refer to
"Programming" menu, tab "Stepper").
Its end is defined via the electrode-specific parameter "Maximum
count" (refer to "Programming" menu, tab "Stepper").
Note: If parameter “Pressure at end of 1.Stepper-Phase“ is set

to 100 (%), no Stepper-Curve is active during the
stepping phase.
Note: If parameter "Pressure after last dressing" is set to a

value other than 100 (%), a Dressing-Curve is
additionally active during the stepping phase.
and Controls
Stepper-Curve (Programming, Seq. Pg.2)

Defines one out of 10 possible curves (0 to 9) for calculating the
pressure change characteristic within the stepping phase.
The curve shape (pressure change as a function of counts) can be
programmed in the "Setup" menu, tab "Stepper curves".
Note: If parameter "Pressure at end of 1.Stepper-Phase" is set

to 100 (%), no stepper curve is active during the
stepping phase.
Note: If parameter "Pressure after last dressing" is set to a

value other than 100 (%), a Dressing-Curve is
additionally active during the stepping phase.
Pressure after last Dressing

function during the stepping phase.
The parameter serves for automatically calculating any pressure
changes to be activated after a dressing cycle. It initially
determines the complete pressure change desired in the course of
all dressing cycles until the last dressing (in % of the program-
specific base pressure value). The course of this change (i.e. the
pressure change after dressing) can be influenced by parameter
"Dressing-Curve".
A pressure change will be performed after each dressing cycle and
will remain constant until the next dressing cycle (stepper
function). It will act in addition to a pressure change generated
within the stepping phase by the Stepper-Curve
Note: If parameter “Pressure after last dressing“ is set to 100

(%), no Dressing-Curve is active for pressure stepping.
Dressing-Curve (Programming, Seq. Pg.2)

pressure changes after a dressing cycle. The pressure change will
be performed after each dressing cycle and will remain constant
until the next dressing cycle (stepper function). It will act in addition
to a pressure change generated by the Stepper-Curve.
and Controls
The curve shape (pressure change as a function of the dressing

counter) can be programmed in the "Setup" menu, tab "Dressing
curves".
Note: If parameter “Pressure after last dressing“ is set to 100

(%), no Dressing-Curve is active for pressure stepping.
Pressure profile
Turns the “Pressure profile” function on or off.
If this function is active, pressure changes can be input during
execution of the relevant welding program.
The pressure profile including the pressure value and pressure
time can be programmed in 10 steps (parameters "Force x.PV"
and "Time x.PT").
It starts with the squeeze time (SQZ) and ends with the hold time
(HOLD). If the total of the pressure times is longer than the entire
schedule duration from the Squeeze time (SQZ) until the Hold time
(HOLD), the pressure profile will be cut off at the end of the Hold
time. Afterwards, only the Base pressure value) will be active.
Force x.PV
Pressure values (force in kN) for the "Pressure profile" function.
The corresponding time spans are defined in parameter "Time
x.PV".
Time x.PT
Periods of time (in ms) during which the corresponding pressure
value ("Force x.PV") is output in conjunction with the "Pressure
profile" function.
FPO (freely programmable output)
Note: This function is not available for all timer types.
Turns the “freely programmable output” function on or off.

The freely programmable output generates a digital output signal
for driving external additional devices.
Its signal characteristic can be freely defined for the relevant
program from the beginning of the SQZ based on the order of the
related parameters (1. Off-time" to "3.On-time").
If the total of the programmed on and off times is longer than the
time from the beginning of the Squeeze time until the end of the
Hold time, the output will be automatically reset at the end of the
Hold time.
and Controls
Off-time
Acts in conjunction with the "freely programmable output" function.
Parameters 1.Off-time, 2.Off-time and 3.Off-time serve to define a
maximum of 3 periods of time during which the freely
programmable output is reset.
On-time
Acts in conjunction with the "freely programmable output" function.
Parameters 1.On-time, 2.On-time and 3.On-time serve to define a
maximum of 3 periods of time during which the freely
programmable output is high.
Time Monitoring (Programming, Seq. Pg.2)

Turns the “Time monitoring” function on/off for the relevant
program.
If this function is active, the timer monitors that the duration from
the beginning of the PreWld until the end of the PostWeld
(including all cool times) does not exceed or fall below a
configurable Reference time within specified Tolerance limits.
A response of the time monitoring function initiates the "Weld time
too long" or "Weld time too short" error message.
Note: Switching program-specific time monitoring on/off is also

possible under Programming: Schedule.
Reference time
Reference time (in ms) for the "Time monitoring" function.
Note: The actual time (time span from the beginning of the
PreWld until the end of the PostWeld including all cool
times) is displayed immediately after the end of the
relevant welding program in the "Diagnosis" menu, tab
"Last Weld".
Tolerance standard
+/- tolerance (in ms) for the "Time monitoring" function.
and Controls
Programming: Stepper
Note: As this window is used to program not only electrode-

specific data, but also the program-specific Count-
Factor, you should first select the relevant welding
program (via field “Spot-Name“ or via fields “Timer“ and
“Program").
The electrode-specific data displayed always belongs to
the electrode that was parameterized in the welding
program selected (display in field “Electrode”).

Using the Set counter command button, the Count and the
Dressing-counter of the relevant electrode can be manipulated.
Refer to sect. "Set counter".
and Controls
Stepping and dressing

In order to compensate for negative effects of the electrode wear
on the quality of the welded spots, 2 principal strategies can be
applied, depending on the objective, which can be separately used
during the electrode life, but may also be combined:
• Ensuring a desired welding diameter through periodical

preparation of a defined electrode contact surface. This strategy
is normally referred to as “Dressing”.
• Ensuring the current density in the spot weld by gradually

increasing the %I and, if necessary, the pressure. This strategy
is normally referred to as “Stepping” or “Stepper”.
The “Stepping” function automatically changes the %I value (%I

stepping) and the reference current (= monitor stepper) subject to
the current program, the wear count and the tip dress counter
between two consecutive phases (“start phase and “stepping
phase”).
The “dressing” function outputs various signals to ensure that
electrodes are mechanically worked on by external devices in
configurable time intervals.
Both functions are enabled or disabled for the relevant electrode

(in parallel to the "Pressure-Stepper ,function") via the "Stepper"
parameter.
It depends on the other parameter settings whether or not the

enabled functions are eventually active:
for %I and monitor stepper in the start phase

• %I for new electrode
• "Reference current for new electrode"
• "Count"
for %I and monitor stepper in the stepping phase

• "Stepper-Curve"
• “Pressure at end of 1.Stepper-Phase”
• "Ref.-Current at end of 1.Stepper-Phase"
• "Count"
• "Maximum Count "
• "Prewarning Count"
and Controls
for activating dressing as well as %I and monitor stepper in

the stepping phase with active dressing
• "Dressing-Curve"
• "Pressure after last dressing"
• "Reference current last dressing"
• "Count"
• "Dressings"
• "Tip dress request"
%I Step.-Value
Displays the currently active %I stepping as a percentage of the
base %I.
Monitor Step.-Value
Displays the currently active stepper value for the Reference
current in % of the base reference current (Monitor stepper).
Press. Step.-Value
Displays the currently active Pressure stepping as a percentage of
the base pressure value.
%I for new electrode

Acts electrode-specific in conjunction with the "Stepper" function in
the start phase.
The parameter defines the %I (in % of the program-specific base
%I) to be used for welding at the beginning of the start phase
(normally when the relevant electrode has been replaced).
During the further development of the start phase, the %I value is
linearly changed up to 100% of the program-specific base %I of a
weld, depending on the actual count value.
The length of the start phase depends on the electrode-specific
parameter "Count". If the value 0 has been entered there, no start
phase will be used. In this case, you should enter the value 100%
as “%I for new electrode.
and Controls
Reference current for new electrode

Acts electrode-specific in conjunction with the “Monitor Stepper"
function in the start phase.
The parameter defines the reference current (in % of the program-
specific reference current) to be compared to an actual current at
the beginning of the start phase (normally when the relevant
electrode has been replaced), taking into account the tolerances.
During the further development of the start phase, the reference
current is linearly changed up to 100% of the program-specific
reference current of a weld.
The length of the start phase depends on the electrode-specific
parameter "Count". If the value 0 has been entered there, no start
phase will be used. In this case, you should enter the value 100%
as “Reference current for new electrode.
Count
Defines the maximum count at the end of the start phase for the
stepper, monitor stepper and pressure stepper function.
Within the span indicated here, the individual stepper values will
be linearly increased to 100%.
The start phase is normally very small (approx. 5 – 50 spot welds)
and only has to be programmed for special applications, e.g.,
galvanized sheets.
In combination with tip dressing, the start phase may be used to
“run-in” a new electrode.
After each dressing
Note: This parameter is not available for all timer types.
If activated, the count status of the relevant electrode is reset to “0”

after the “Tips have been dressed” input signal has become high.
That means that the start phase is carried out after each dressing
cycle.
Otherwise, the count is set to the value of the "Count" parameter
after each dressing cycle. That means that the start phase is
carried out a single time when an electrode has been replaced.
and Controls
Stepper-Curve (Programming, Stepper)

change characteristic of the base %I and the reference current
within the stepping phase.
The curve shape (percent change as a function of wear) can be
programmed in the "Setup" menu, tab "Stepper curves".
Note: If parameter "%I at the end of 1st stepper phase" is set

to 100 (%), no stepper curve for changing the base %I is
active during the stepping phase.
If parameter "Ref. current at the end of 1st stepper
phase" is set to 100 (%), no stepper curve for changing
the reference current is active during the stepping
phase.
Note: If parameter "%I after last dressing" is set to a value

other than 100 (%), a Dressing-Curve additionally
influences the %I values during the stepping phase.
If parameter "Ref.-Curr. last Dressing" is set to a value
influences the reference current during the stepping
phase.
%I at the end of 1st stepper phase

Acts electrode-specific in conjunction with the "Stepper" function in
the stepping phase.
In the course of the stepping phase, the %I value is increased up
to the value entered for this parameter (in % of the program-
specific base %I) subject to the current count value, starting from
100% of the program-specific base %I. The course of this change
(during the stepping phase) can be influenced by parameter
"Stepper-Curve".
The length of the stepping phase depends on the electrode-
specific parameter "Count".
Its end is defined by the electrode-specific parameter "Maximum
Count".
Note: If parameter “%I at the end of 1st stepper phase“ is set

to 100 (%), no Stepper-Curve influences the %I value
during the stepping phase.
and Controls
Note: If parameter "%I after last dressing" is set to a value

influences the %I values during the stepping phase.
Ref.-Current at end of 1.Stepper-Phase

Acts electrode-specific in conjunction with the “Monitor Stepper"
function in the stepping phase.
The parameter defines the reference current (in % of the program-
specific reference current) to be compared to an actual current at
the end of the stepping phase (immediately before a dressing
cycle or before replacing the relevant electrode), taking into
account the tolerances.
In the course of the stepping phase, the reference current is
increased up to the value entered for this parameter (in % of the
program-specific reference current), starting from 100% of the
program-specific reference current. The course of this change
(during the stepping phase) can be influenced by parameter
"Stepper-Curve".
The beginning of the stepping phase depends on the electrode-
specific parameter "Count".
Its end is defined by the electrode-specific parameter "Maximum
Count".
Note: If parameter “Reference current at the end of 1st stepper

phase“ is set to 100 (%), no Stepper-Curve influences
the monitoring during the stepping phase.
Note: If parameter "Ref.-Curr. last Dressing" is set to a value

influences the reference current during the stepping
phase.
Counts
Indicates the current Counts of the relevant electrode.
New electrodes always start with a Count of 0. The actual count is
incremented by the program-specific Count-Factor after each spot
welded.
and Controls
Maximum count
Effect when dressing has been deactivated
(for activation/deactivation, refer to parameter Dressings"):
Defines the End of Stepper of the relevant electrode.
Within the span indicated here, the individual stepper, monitor
stepper and pressure stepper values will be increased from 100%
to the relevant target values.
When the maximum count has been reached, the “Prewarning”
signal will be reset, and “End of Stepper” will become high.
Increasing the Count further will not change the stepping values.
Effect when dressing has been activated

(for activation/deactivation, refer to parameter Dressings"):
Defines the maximum permitted counts of the relevant electrode
between 2 subsequent dressing cycles. Within this span, a
programmed Stepper Curve will be processed.
When the maximum count has been reached, the timer will output
the “Dressing” signal (increasing the count further will not change
the stepping values).
The “Tips have been dressed” input signal causes the timer to set
the count of the relevant electrode to the value programmed in
parameter "Count". With some timer types, it is also possible to
program a reset to “0” (set parameter "After each dressing" “ON”).
The desired number of these cycles is defined by the expression:
Dressings + 1. This results in the following End of Stepper:
maximum count * Dressings + 1.
Within the “maximum count * Dressings" span, a programmed
Dressing-Curve is processed.
During the last cycle, the timer resets the “Prewarning” signal
when the maximum count has been reached and outputs the “End
of stepper” signal. Increasing the Count further will not change the
stepping values.
The “Electrodes have been replaced” input signal resets the count
and the Dressing counter of the electrode in question (to “0”).
Prewarning Count
Defines the number of counts prior to the End of Stepper for which
the “Prewarning” signal is to be output for the relevant electrode.
and Controls
Dressing-Curve (Programming, Stepper)

change characteristic of the base %I and the reference current
after a dressing cycle. The change will be performed after each
dressing cycle and will remain constant until the next dressing
cycle (stepper function). It will act in addition to a change
generated by the Stepper-Curve
The curve shape (percent change as a function of the product of
dressings x count) can be programmed in the "Setup" menu, tab
"Dressing-curves".
Note: If parameter “%I after last dressing“ is set to 100 (%), no

Dressing-Curve is active for changing the base %I.
If parameter “Reference current last dressing“ is set to
100 (%), no Dressing-Curve is active for changing the
reference current.
%I after last dressing

Acts program-specific in conjunction with the "Stepper" function in
the stepping phase.
The parameter serves for automatically calculating any %I
changes to be activated after a dressing cycle. It initially
determines the complete %I change desired in the course of all
dressing cycles until the last dressing (in % of the program-specific
base %I). The course of this change (i.e. the %I change after
dressing) can be influenced by parameter "Dressing-Curve".
A %I change will be performed after each dressing cycle and will
remain constant until the next dressing cycle (stepper function). It
will act in addition to a %I change generated within the stepping
phase by the Stepper-Curve.
Note: If parameter “%I after last dressing“ is set to 100 (%), no

Dressing-Curve is active for %I stepping.
Note: If parameter "%I at the end of 1st stepper phase" is set

to a value other than 100 (%), a Stepper-Curve
additionally influences the %I values during the stepping
phase.
and Controls
Reference current last dressing

Acts program-specific in conjunction with the “Monitor Stepper"
function in the stepping phase.
The parameter serves for automatically calculating any reference
current changes to be activated after a dressing cycle. It initially
defines the reference current (in % of the program-specific
reference current) to be compared to an actual current after the
last dressing, taking into account the tolerances.
The course of this change (i.e. the reference current change after
dressing) can be influenced by parameter "Dressing-Curve".
A reference current change will be performed after each dressing
cycle and will remain constant until the next dressing cycle
(stepper function). It will act in addition to a reference current
change generated within the stepping phase by the Stepper-
Curve.
Note: If parameter “Reference current last dressing“ is set to

100 (%), no Dressing-Curve is active for monitor
stepper.
Note: If parameter "Reference current at the end of 1st stepper

phase" is set to a value other than 100 (%), a Stepper-
Curve additionally influences the monitoring values
during the stepping phase.
Actual value (Dressing counter)

Indicates how often the relevant electrode has already been
dressed.
Dressings
Indicates how often the relevant electrode should be dressed in
the course of its life cycle (including first tip dress. Refer to "Dress
new electrode").
Dress-Request
Defines the number of counts prior to the "Maximum Count" for
which the “Tip dress request” signal is to be output for the relevant
electrode.
and Controls
Stepper
If activated, the “Stepper”, “Dressing” and “Dress new electrode”
functions have been enabled for the electrode in question and
operate according to their parameter settings.
Only when activated will electrode-specific signals (“End of
Stepper”, “Prewarning”, etc.) be generated or checked by the
timer.
Count-Factor
Program-specific definition of the amount by which the count of an
electrode is incremented after each spot welded.
The count factor is an experimental value that may be adjusted to
the individual welding task. When set properly, the electrode can
be automatically used under optimum conditions even when
welding different sheet thicknesses or materials.
If only count factors of 1.0 are used, the counts correspond to the
spot count.
Wear per component

Defines the wear experienced by an electrode when manufacturing
a part with the electrode in question.
From this value, the timer calculates the number of remaining parts
that can still be manufactured using the relevant electrode (refer to
"Prewarning" window).
Dress new electrode
Turns the “first tip dress” function on or off.

“First tip dress” is used to ensure a defined condition (diameter,
shape, etc.) of a new electrode.
Extended electrode life
Indicates the number of wear counts that will be accepted before

the timer is inhibited when the relevant electrode has reached its
End of Stepper.
Also refer to parameter “ Stop at end of Stepper.
and Controls
Active reference current (Programming, Stepper)

The fields for the prewld to pstwld show the actual rms current
values (in kA) measured in the individual heat blocks.
The “Standard” field shows the mean actual rms current during all
3 heat blocks.
Average/Middle PHA (Programming, Stepper)

Indicates the mean command value obtained in KSR mode for
driving the power unit (in %I) for the prewld to pstwld.
The “Standard” field indicates the mean command value of all 3
heat blocks for driving the power unit (in %I).
In PHA (and KUR) mode, the values displayed exactly correspond
to the programmed %I values.
and Controls
Programming: General
Note: First you have to select the relevant timer

- directly via the “Timer” field.

Stop at end of stepper

If assigned the value “ON”, another welding schedule is no longer
possible using the relevant electrode if this electrode has reached
its end of stepper condition.
Exceptions can be programmed via the "Extended electrode life"
function).
Max. %I correction
Defines the maximum %I correction (increase) of the relevant
timer (refer to "Correction" menu, tab "Correction", parameter "%I
correction (x)").
and Controls
Min. %I correction
Defines the maximum %I correction (decrease) of the relevant
timer (refer to "Correction" menu, tab "Correction", parameter "%I
correction (x)").
Max. Pressure-Correction
Defines the maximum pressure correction (increase) of the
relevant timer (refer to "Correction" menu, tab "Correction",
parameter "Pressure correction (x)").
Min. Pressure-Correction
Defines the minimum pressure correction (decrease) of the
relevant timer (refer to "Correction" menu, tab "Correction",
parameter "Pressure correction (x)").
Start-Inhibit (T)
If programmed as “ON”, starting any program of the selected timer
will initiate the error message “Start inhibited".
Also refer to parameter “Start-Inhibit (P)”.
Weld/No weld (Global)

Defines whether the power unit can generally be energized when
running any programs of the selected timer (parameter value “On”)
or whether it is not energized (parameter value “Off”).
Also refer to parameter “Weld/No Weld (P)“.
Note: The power unit will not be energized unless the following
conditions are met:
Parameter “Weld/No weld (P)” = “On” and
Parameter “Weld/No weld (Global)” = “On” and (if
existent)
the “Weld external” input signal has been set.

program is started.
and Controls
Max. welding time

Limits the maximum weld times that can be programmed for the
prewld, WLD and postweld for the relevant timer.
Control stopped
If programmed as “On“, this function will inhibit KSR mode (refer to
parameter "Regulation mode") for all programs of the relevant
timer. This condition will be symbolized by a red frame surrounding
the timer symbol in question in the Network overview.
If the current sensor or the connection cable is defective, Control
stopped may be activated, e.g., for emergency operation.
Possibility of incorrect welds

When control has been stopped, the current
in the secondary circuit is no longer regulated
CAUTION with respect to the programmed value.
Therefore, changes in resistance in the
secondary circuit (since the last weld of a
program with operative regulation) will directly
affect the quality of the spot weld!
You should never activate Control stopped
without good reason!
Make sure that all spot welds are checked if
Control stopped has been activated.
and Controls
Monitoring stopped
If programmed as “On“, this function will prevent a response of
Current monitoring for all programs of the relevant timer. This
condition will be symbolized by a red frame surrounding the timer
symbol in question in the Network overview.
If the current sensor or the connection cable is defective,
Monitoring stopped may be activated, e.g., for emergency
operation.

If current monitoring is inhibited, the current in
the secondary circuit will not longer be
CAUTION compared to the programmed Reference
current. Actual currents outside the
programmed tolerance bands will no longer
be signaled in this condition. Possible
consequences include direct effects on the
quality of the spot weld!
You should never activate Monitoring stopped
without good reason!
Make sure that all spot welds are checked if
Monitoring stopped has been activated.
Max repeat welds (max. repetition in series)

In order to prevent the Spot repetition from responding all the time
(in the event of “creeping“ system faults), this parameter may be
used to specify the number of directly consecutive welding
programs for which the spot repetition may respond.
and Controls
Choose parity
To select the type of parity check. If the parity check has been
activated, the timer can verify, through the additional “Parity” input
signal, whether or not the “Program selection xx” input signals
have been properly transmitted.
Possible settings:
• Off: no parity check.
• Even: Parity check on.
The number of active input signals “Program selection xx” must
be even if the “Parity” input signal is not high.
• Odd: Parity check on.
The number of active input signals “Program selection xx” must
be odd if the “Parity” input signal is high.
WC with error
Defines whether the “WC” signal is to be output after the end of a
welding schedule for “good” welds only, or after any welds.
In connection with the WC signal, also refer to parameters "WC
Period" and "WC Start time".
WC Period
If the start signal is no longer present in “Single spot“ Mode at the
end of a welding schedule, the WC will be automatically reset after
the period of time defined in this parameter..
WC Start time
Influences the time when the WC is output.
• Input = 0:
The positive edge of the WC will be simultaneously output at
the end of HLD.
• Input > 0:
The positive edge of the WC is delayed by max. 1000 ms with
respect to the end of HLD.
• Input < 0:
The positive edge of the WC will be output before the end of
HLD. This allows you to reduce constant delays in the
subsequent handling sequence.
Although 1000 ms can be maximally programmed as the time
period for accelerating the WC, this time must always be shorter
than the currently programmed HLD.
and Controls
Mode pressure output
Defines the physical influencing variable for generating the

electrode force at the timer’s pressure output.
• 0...20mA:
The desired electrode force can be output as a current value
within the absolute limits of 0 to 20 mA.
Maximum permitted burden: 500 Ohm
• 0...10V:
The desired electrode force can be output as a voltage within
the absolute limits of 0 to 10 V.
Maximum output current: 20 mA
• 4...20mA:
The desired electrode force can be output as a current value
within the absolute limits of 4 to 20 mA.
Maximum permitted burden: 500 Ohm
Note: The characteristic for converting the electrode force into

the relevant manipulating variable is influenced via the
"Conversion-Factor" and "Zero adjust" parameters.
Fade-out time
Time span immediately after current activation by which

measurement of the rms value of the actual current is to be
delayed.
Using this function, you can prevent the current rise from
influencing the rms measurement of the actual current.
and Controls
For other possiblities of influencing the rms value measurement,

refer to parameter “ Trail current".
Note: The programmed fade out time is identical for all weld
times and for all welding programs! Therefore, you
should make sure that the fade out time is always
shorter than the shortest programmed weld time.
Note: The fade out time must match the corresponding

settings of the external current meter for comparative
measurements (current calibration).
Trail current
Defines whether the current drop caused by the very operating

principle at the end of a weld time is to be included in the rms
value measurement of the actual current.
If defined as “Off”, rms value measurement of the actual current
will stop exactly at the end of a weld time. Using this function, you
can prevent the current drop from influencing the rms
measurement of the actual current.
and Controls
For other possibilities of influencing the rms value measurement,

refer to parameter “ Fade out time".
Note: This setting is identical for all weld times and for all
welding programs.
Note: The fade out time must match the corresponding

settings of the external current meter for comparative
measurements (current calibration).
Measuring loop check

If defined as “On”, the external current sensor circuit will be
checked before a weld time is started. If this check reveals an
inadmissible volume resistance, the timer will cancel the running
program and generate an error message.
Note: If no external current sensor is used, the measuring loop

check must be deactivated.

If the measuring loop check is deactivated
although an external current sensor is used,
CAUTION the system will not be able to detect any
errors in the sensor loop. Possible
consequences include direct effects on the
quality of the spot weld!
Therefore, you should activate the measuring
loop check if you use external current sensing
equipment.
Current supervision
Defines the type of current measurement for the relevant timer:

• primary:
Actual currents are determined by a current sensor integrated in
the primary circuit, but transformed into secondary current
values for further processing (e.g. for display in BOS).
This option is cost-effective, easy to implement, and suitable for
weld times longer than 1 second as well as seam operation.
Compared to the “secondary” option, it has higher tolerances for
and Controls
the boundary regions of the output current range.

Calibration should also be performed for primary current
measurement.
• secondary:
Actual currents are directly determined in the secondary circuit
using an external current sensor.
In connection with current calibration, this option ensures highly
precise secondary currents yet is not suitable for weld times
longer than 1 second or for seam operation.
An external current sensor (e.g. integrated into the welding
transformer) is necessary in order to measure the secondary
current .
Programming: Electrode
Note: First you have to select the relevant electrode

- directly via the “Electrode” field.

Click on the Current calibration command button to open the

"Current calibration" window.
Click on the Force calibration command button to open the

"Force calibration" window.
and Controls
%I Limitation
Limits the maximum permissible %I values for the electrode in
question.
Note: The value input must not be lower than the value of
parameter “%I Prewarning ”.
%I Prewarning
Defines the current in %I for the relevant electrode which is to
trigger a %I Prewarning.
Note: The value input is limited by the value of parameter

“%I Limitation”.
1. Halfcycle limit
Limits the phase angle of the 1st halfcycle within the welding
schedule (= transformer inrush current) to the value input for the
relevant electrode.
This parameter is relevant and displayed for equipment with
thyristor power units only.
Note: The program-specific transformer inrush current can

also be limited using parameter "1. Halfcycle after
Pause-Time".
Upper current limit

Limits the maximum configurable %I values for the electrode in
question.
In order to determine the maximum configurable %I values, the
system may strip out any %I compensation from the value input.
Example:
Input value: 16.8 kA
Maximum %I stepping: 120%
In input fields for %I values, inputs greater than 14.00 kA are not
possible.
Toroid sensitivity
Specifies the toroid sensitivity (in mV/kA) of the current sensor for
the relevant electrode (gun).
and Controls
The sensitivity of our sensors is 150 mV/kA.

When using third-party sensors, the appropriate sensitivity can be
programmed using this parameter.
Note: As the accuracy of current measurement is subject to

this value, you should in any case use the "Current
calibration" function!
Possibility of incorrect welds!

The value is automatically adjusted by the
timer in the course of current calibration.
CAUTION Making arbitrary changes to the toroid
sensitivity will render current calibration
useless. The accuracy of current
measurement is no longer guaranteed.
Therefore, you should never make any
arbitrary changes to the value displayed!
2. Toroid sensitivity
With some timer types, an external sensor can be used to check

the plausibility of the current measured by primary current
measurement (refer to "Programming" menu, tab "General",
"Current supervision") parameter.
In these cases, it is necessary to manually enter the toroid
sensitivity (in mV/kA) of the relevant current sensor with respect to
the electrode (gun) in question.
The sensitivity of our sensors is 150 mV/kA.
When using third-party sensors, manually enter the appropriate
sensitivity in this parameter.
Possibility of error messages!

Arbitrary changes of the 2nd toroid sensitivity
may result in recurring error messages!
CAUTION Therefore, you should never make any
Electrode range

and Controls
The electrode range depends on the welding transformer used and

on the current sensor, therefore, this value may be programmed
separately for each electrode (gun).
Timers offering automatic measuring range changeover display the
currently active measuring range in this parameter.
For timers with a programmable measuring range, the electrode
range must be manually entered here, depending on the toroid
sensitivity.
Electrode ranges with PS 5000 and AC power unit:

measurable currents in kA with given toroid sensitivity
Electrode
range 50 100 150 500 1000 1500
mV/kA mV/kA mV/kA mV/kA mV/kA mV/kA
0 1.5 – 15.0 0.7 – 7.5 0.5 – 5.0 0.1 – 1.5 0.0 – 0.7 0.0 – 0.5
1 7.5 – 75.0 3.7 – 37.0 2.5 – 25.0 0.7 – 7.5 0.5 – 3.7 0.3 – 2.5
2 30.0 – 300 15.0 – 150 10.0 – 100 3.0 – 30.0 1.5 – 15.0 1.0 – 10.0
3 75.0 - 750 37.0 - 375 25.0 - 250 8.0 – 75.0 3.7 – 37.0 2.5 – 25.0
Electrode ranges with PS 5000 and medium-frequency

inverter:
Electrode
range 50 100 150 500 1000 1500
mV/kA mV/kA mV/kA mV/kA mV/kA mV/kA
0 2.4 – 24.0 1.2 –12.0 0.8 – 8.0 0.2 – 2.4 0.0 – 1.2 0.0 – 0.8
1 12.0 – 120 6.0 – 60.0 4.0 – 40.0 1.2 – 12.0 0.6 – 6.0 0.4 – 4.0
2 48.0 – 480 24.0 – 240 16.0 – 160 4.8 – 48.0 2.4 – 24.0 1.6 – 16.0
3 120 - 999 60.0 - 600 40.0 - 400 12.0 – 120 6.0 – 60.0 4.0 – 40.0
Electrode ranges with PS 6000:

Electrode
range 150
mV/kA
*
10 0.25 – 2.5
*
11 0.5 – 5.0
*
12 1.0 – 10.0
*
13 2.0 – 20.0
*
14 4.0 – 40.0
*
15 8.0 – 80.0
*
16.0 –
16
160
* Lower values are displayed with an undefined accuracy.
Current at 0% I
Input of the appropriate current value that is generated by the

inverter (PSU) at 0 %I with a linear current control characteristic.
and Controls
Current at 50% I
Input of the appropriate current value that is generated by the

inverter (PSU) at 50 %I with a linear current control characteristic.
Type (transformer)
Serves to select the welding transformer for the electrode (gun) in

question.
The necessary information is shown on the nameplate of the
welding transformer (e.g. “PSG 3100.00”).
If the proper transformer type cannot be selected from a list box,
you have to select the “Other transformers” option. In this case, the
following information must be additionally entered:
Transformer ratio
Nominal current
Type of diode and
No. of parallel Diodes
Possibility of damaging the transformer!

The timer derives additional important
information from the transformer type
CAUTION specified here that is necessary for safe
operation.
arbitrary changes to the input value!
Type of connection (transformer)
Note: This parameter will not be displayed unless values

greater than “1“ have been entered in "Number of
transformers".
You specify whether the transformers on the primary side are

connected in parallel or in series.
and Controls
Possibility of damaging the transformers!

information from this parameter that is
CAUTION necessary for safe operation.
Number (of transformers)
Note: This parameter is only relevant for weld timers of the PSI
6000 series.
Number of welding transformers connected.

Ö If several welding transformers are connected, the electrical
characteristics of these transformers must be identical.
Ö Use connection leads of the same conductor area and length
for all transformers in question.

and Controls
Primary transformer ratio (transformer)
Note: This parameter will not be displayed in conjunction with

PSI 6000 unless “Other transformers“ has been selected
in Transformer-Type.
Transformer ratio of the primary transformer used.

This information is normally shown on the nameplate of the
welding transformer.
The timer needs the transformer ratio information for converting
the primary current into the secondary current (for primary current
measurement, refer to "Programming" menu, tab "General",
"Current supervision" parameter).

Nominal current (transformer)
Note: This parameter will not be displayed unless “Other

transformers“ has been selected in Transformer-Type.
Nominal current of the welding transformer in kA.

This information is normally shown on the nameplate of the
welding transformer.
The timer limits the maximum welding current to the value
specified in this parameter in order to protect the transformer.

and Controls
Supervision (diodes)
If activated, the high-current diodes in the transformer’s secondary
circuit will be monitored for excessive junction temperatures.
For this purpose, the system checks - with reference to a cooling
water temperature of 30 degrees Centigrade - whether the
(internally calculated) junction temperature of the diodes (value
displayed in field "Diode temperature") exceeds the "Switch-off
temperature" configured. If yes, the welding sequence is
immediately aborted.

If diode supervision is deactivated, the diodes
may be destroyed in the event of overload.
CAUTION Therefore, we strongly recommend to leave
diode supervision active at all times!
Type (diodes)

transformers“ has been selected in Transformer-Type
and "Diode supervision" is active.
Diode type used for the welding transformer.

and Controls
No. parallel (diodes)

transformers“ has been selected in Transformer-Type
and "Diode supervision" is active.
Number of diodes used for each secondary branch.

Switch-off temperature (diodes)

transformers“ has been selected in Transformer-Type.
Refer to parameter Supervision (diodes).

and Controls

Diode temperature
Displays the calculated junction temperature of the high-current
diodes during the last weld performed with the relevant electrode
(gun).
Mains voltage
Displays the mains voltage during the last weld performed with the
relevant electrode (gun).
Maximum pressure
Limits the maximum permissible electrode force values for the
electrode (gun) in question.
In order to determine the maximum configurable values, the

system strips the Final values of active stepper data configured or
the maximum permissible pressure correction data out from the
input value.
Example:
Input value: 3.9 kN
Maximum pressure stepping: 120%
Max. pressure correction (+): 10%
and Controls
No input greater than 3.00 kN can be made afterwards in the

relevant input fields.
Possibility of damaging guns!

Before pressure calibration has been properly
carried out, there is no defined correlation
CAUTION between the programmed force and the
resulting force at the electrode gun!
For this reason, the value input cannot
protect the gun unless pressure calibration
has been properly completed.
You should never make any arbitrary
changes to the value displayed!
and Controls
Conversion-Factor
Determines the slope of a linear characteristic that defines the
resulting gun force as a function of the force influencing variable
(refer to "Programming" menu, tab "General, Parameter"Mode
Pressure Output") parameter.
The following relationship applies in general:
F(St) = <Conversion factor> x St + <Zero-adjust>
where F is the resulting force in kN and St the force-influencing
variable.
Possibility of damages to guns and/or

incorrect welds!
The value is automatically determined by the
CAUTION timer in the course of pressure calibration and
entered in this parameter.
By making arbitrary changes of the parameter
value the defined correlation between the
value input and the resulting force at the
electrode gun will be lost!
Examples:
Input value “1”: the timer converts a programmed force into the
force-influencing variable at a 1:1 ratio using a 45 degrees
characteristic.
and Controls
Note: Also refer to parameter Zero adjust".
Zero adjust
Determines the offset by which the linear characteristic (refer to
parameter "Conversion-Factor") intersects with the force axis (F).
Possibility of damages to guns and/or

incorrect welds!
The value is automatically determined by the
CAUTION timer in the course of pressure calibration and
entered in this parameter.
By making arbitrary changes of the parameter
value the defined correlation between the
value input and the resulting force at the
electrode gun will be lost!
and Controls
Programming: Thyristor-Unit-Parameter

- directly via the “Thyr.” field.
Note: Entries in the “Thyr.” field are only possible if the timer is
capable of driving several power units in parallel.

Nominal voltage (Thyristor-Unit-Parameter)
Note: This parameter is only shown in Regulation mode "KUR"

(refer to "Programming" menu, tab "Schedule").
Input the nominal voltage of the power unit.

and Controls
Turns ratio (Thyristor-Unit-Parameter)
Note: This parameter is only shown in Regulation mode "KUR"

(refer to "Programming" menu, tab "Schedule").
A feedback transformer is used for voltage measurement with the

KUR regulation mode.
Enter the turns ratio of this transformer in this parameter.
Example: 380 V : 24 V = 15.833.
If your transformer is designed for a higher voltage, you should
nevertheless enter the calculated turns ratio.
Thyristor-Unit-Type
Adjusts the timer to the power unit connected.
Possibility of damages to the plant!

Thyristor-Unit temperature
Note: This parameter is only available for timers with an

external power unit.
Indicates the type of temperature contact at the power unit.

On : Contact is closed if overtemperature is present
Off: Contact is opened if overtemperature is present.
and Controls

Ignition Type
Note: This parameter is only relevant for connection of

CNOMO power units.
It is needed to set the control method for the AC power unit.

Standard (Burst): Default
CNOMO (Pulse): Special case

Timer type (Thyristor-Unit-Parameter)

Returns the exact timer type.
Software-Version (Thyristor-Unit-Parameter)
Displays the firmware version.
and Controls
Diagnosis
Within the BOS 6000 main window, the “Diagnosis“ menu (which is
called up by the icon) offers the following choices:
• Selection of “Spot-Name” or “Timer” to change over to the

desired timer.
• Selection of the "Diagnostics I/O" tab to display the condition of
all I/O signals.
• Selection of the "Users-Diagnostics I/O" tab to display the
condition of all I/O signals.
In contrast to the other tabs, customized names (set by the
configuration tool) are used for the signals in this case.
• Selection of the "Start Simulation" tab in order to start any
desired welding program with/without ignition, or in order to
output the WC contact.
If the timer is in an error condition, a “Fault reset” can be
performed before.
• Selection of the "Timer - Information" tab in order to display
various types of information concerning the timer status.
• Selection of the "Last Weld" tab in order to display various types
of information concerning the last welding schedule performed.
Note: The “Diagnosis” menu can only be activated for online

timers.

Note: In some cases, the settings/functions are only possible

at a certain user level.
and Controls
Diagnosis: Diagnostics I/O

and Controls
Using the New or Standard command buttons, you can switch

between the alternative types of display for the input/output
signals.
and Controls
Note: The signals displayed are timer-specific and may be

different for your relevant timer.
Program (display field in “Diagnosis” menu)

Shows the program number currently active at the digital inputs as
a decimal number.
Inputs / Outputs
Returns the current status of these signals.
For this purpose, all signals are cyclically updated and displayed
either in binary format (line by line from left to right, starting with
the lowest signal number) or one below the other (in table format),
depending on the type of display selected.
Signal status:
0: Signal is low (white background)
1: Signal is high (green background)
• If the signals are shown in binary format, you can click on a bit
field in order to display the signal number, signal type and
signal name in line “Description”. transmitted via the field bus
“discrete”: present at a hardware input/output
”internal”: is influenced/generated within the timer
• If the signals are displayed in table format, the following

applies to the identification of the signal types:
E: Signal is present at a hardware input
A: Signal is present at a hardware output
S: signal is transmitted via the field bus
I: Signal is influenced/generated within the timer
and Controls
Diagnosis: Users Diagnostics I/O

Note: In contrast to the other tabs, customized names (set by

the configuration tool) are used for the signals in this
case.
Click on the Timer-Information command button to call up the

data available on the "-Information" tab in a separate window.
Click on the Last Weld command button to call up the data

available on the "" tab in a separate window.
The information contained in the tables corresponds to the

description in the previous section, "Inputs / Outputs".
and Controls
Diagnosis: Start Simulation


program is started or the WC contact is
deliberately output.
Possibility of immediate welding schedule

start after “Fault reset with reweld”!
DANGER with reweld, the timer will immediately start
repeating its program run! Welding will be
repeated!
one in the hazard zone when fault reset with
reweld is started.
Possibility of immediate machine

movements after “Fault Reset with WC”!
If the start signal is still present at “Fault reset
DANGER with WC”, the timer will set the “WC” output
signal as soon as the fault has been reset!
This may result in machine movements.
one in the hazard zone when Fault reset with
WC is initiated.
and Controls
Possibility of delayed welding!

Under certain conditions, the timer will
automatically extend the SQZ before
DANGER proceeding to WLD (waiting for pressure
contact or pressure feedback).
Therefore, you should ensure that no-one
enters the hazard zone for as long as the
messages “No Schedule” (“Interval” field) or
“OK” (“Status” field) are not displayed in the
“Actual Cycle” area.
The timer can be reset to “Ready” state and the WC contact can
be output by hitting the Reset with WC command button.
When hitting Reset with Reweld, the timer will be reset to “Ready”
state after a current fault of the type “Low current” or “no weld
current …”, and the faulty welding schedule will be restarted if the
start signal is still present.
and Controls
Interval (Diagnosis, Start Simulation

Indicates the section of the welding schedule that is currently being
processed by the timer (schedule display).
Status (Diagnosis, Start Simulation

Additional information concerning the active interval. Indicates the
current condition (e.g. “Waiting for press.cont. 1/2", “WC on”, “No
schedule”).
Last weld program chosen

Display of the program no. of the program that was started last in
the relevant timer.
Weld program chosen

Input of the program number of the program to be influenced via
the "Start with ignition" or "Start without ignition" radio buttons.
Start with ignition (Diagnosis, Start Simulation

Ö Please note the safety instructions in the beginning of section
"Diagnosis: Start Simulation"!
• Radio button “On” :

chosen program starts with ignition
• Radio button “Off” :
a start signal previously given by the “On” radio button is
removed.
Start without ignition (Diagnosis, Start Simulation)


chosen program starts without ignition
a start signal previously given by the “On” radio button is
removed.
and Controls
WC (Diagnosis, Start Simulation)


WC contact is output.
a WC signal previously given by the “On” radio button is
removed.
For the WC parameters, also refer to "WC with error", "WC Start
time" and " Period" in the "Programming" menu, tab "General".
Diagnosis: Timer-Information

The timer can be reset to “Ready” state and the WC contact can
be output by hitting the Reset with WC command button.
When hitting Reset with Reweld, the timer will be reset to “Ready”
state after a current fault of the type “Low current” or “no weld
and Controls
current …”, and the faulty welding schedule will be restarted if the
start signal is still present.
Timer type (Diagnosis, Timer-Information)

Display of the exact timer type of the relevant timer.
Software-Version (Diagnosis, Timer-Information)

Displays the firmware version of the relevant timer.
Status (Diagnosis, Timer-Information, Timer)

Displays the active type of message:
• Ok (no message is active)
• Warning
• General fault
• Welding fault
Code (Diagnosis, Timer-Information)

Display of the message text.
Addition (Diagnosis, Timer-Information, Timer)

Additional information concerning the timer message displayed.
Displays either the program number, electrode number, or an
additional message text.
Interval (Diagnosis, Timer-Information)

Indicates the section of the welding schedule that is currently being
processed by the timer (schedule display).
Status (Diagnosis, Timer-Information, Actual Cycle)

Additional information concerning the active interval. Indicates the
current condition (e.g. “Waiting for press.cont. 1/2", “WC on”, “No
schedule”).
Program (Diagnosis, Timer-Information)

Number of the program that was last started in the relevant timer.
Schedule (Diagnosis, Timer-Information)

Active schedule status of the program that was last started (e.g.
“finished”).
and Controls
Addition (Diagnosis, Timer-Information, Last Weld)

Additional information concerning the last weld (e.g. “Welding fault”
or “OK”).
Diagnosis: Last Weld

The following information will be displayed for the relevant weld

timer:
• welding program that was started last and spot name
• Time of the last weld
• Wear counter status of the electrode in question
• Reference current and actual current, separately for each WLD,
or as an average value for all WLD (“Standard” line).
Reference time and time actually needed
• the necessary/programmed phase value, separately for each
WLD
and Controls
Setup
Within the BOS 6000 main window, the “Setup“ menu (which is
called up by the icon) offers the following choices::
• Selection of “Spot-Name” or “Timer” to change over to the

desired timer.
• Selection of the "Stepper curves" tab in order to define up to 10
different stepper curves (0 to 9)..
• Selection of the "Tipdress curves" tab in order to define up to 10
different tipdress curves (0 to 9).
• Selection of the "Fault-Setup" tab in order to define messages
as faults or warnings.
• Selection of the "Communication" tab in order to display various
communication parameters of the Ethernet interface.


and Controls
Setup: Stepper curves

You can transfer all stepper curves to the timer by hitting the
Apply command button.
Each curve (0 to 9) influences the %I, reference current and

pressure and defines the desired change of all these quantities
subject to the electrode count during the stepping phase.
Select the desired curve in the “Curve number field. You may enter
remarks concerning the curve in the input field to the right of the
curve number.
• The starting point (%I change of 0% with a count of 0%) refers

to the respective base value of the %I, Reference current and
Pressure.
• The final point (%I change of 100% with a count of 100%) refers
to parameter "Pressure at end of 1.Stepper-Phase" for the
pressure, to parameter "%I at end of 1.Stepper-Phase" for %I,
and to parameter "Reference current at end of 1.Stepper-
Phase" for the reference current.
and Controls
• The starting point and the end point of a curve (white points) are
always fixed.
A total of 8 intermediate points are available between the
starting point and the end point for influencing the curve
characteristic.
For this purpose, you must drag the black points with the mouse
to the desired position, or enter the corresponding values right
below the “%I change” and the “Count Value” parameters.
For reasons of plausibility, count values can only be entered in
ascending order into the input fields from left to right.
Linear interpolation will be carried out between any 2
intermediate points.
In a first approximation, these curves approximately resemble the

shape of an e-curve, rising sharply in the beginning and becoming
flatter afterwards. The actual shape of a %I stepping curve is an
experimental value. Normally, it does not really depend on the
actual heat value, or the electrode shape used by a welding
program, but rather the electrode alloy and the parts to be welded.
Therefore, two curves – one for sheet steel and one for galvanized
sheets – are normally sufficient.
and Controls
Setup: Tipdress curves

Input window as in "Setup: Stepper curves".
You can transfer all data displayed to the timer by hitting the Apply
command button.
Each curve (0 to 9) influences the %I, reference current and

pressure. Based on the curve, the timer defines the change of all
quantities specified after a dressing cycle subject to the electrode
count.
The change will remain constant until the next dressing cycle
(stepper function). It will act in addition to a change generated by
the Stepper-Curve
Select the desired curve in the “Curve number field. You may enter
remarks concerning the curve in the input field to the right of the
curve number.
• The starting point (%I change of 0% with a count of 0%) refers

to the respective base value of the %I, Reference current and
Pressure.
• The final point (%I change of 100% with a count of 100%) refers
to parameter "Pressure after last dressing" for the pressure, to
parameter "%I after last dressing" for %I, and to parameter
"Reference current last dressing" for the reference current.
• The starting point and the end point of a curve (white points) are
always fixed.
A total of 8 intermediate points are available between the
starting point and the end point for influencing the curve
characteristic.
For this purpose, you must drag the black points with the mouse
to the desired position, or enter the corresponding values right
below the “%I change” and the “Count Value” parameters.
For reasons of plausibility, count values can only be entered in
ascending order into the input fields from left to right.
Linear interpolation will be carried out between any 2
intermediate points.
The purpose of a dressing curve is to provide shape compensation

for the many shape changes of an electrode due to repeated tip
and Controls
dressing. Again, the optimum curve shape is an experimental

value which depends on the type of electrode maintenance
concept. A linear adjustment (ramp) may be used as an initial
approximate value.
Setup: Fault-Setup


For each message shown, a type can be defined.
• Checkbox “Fault” is active:

The message will be signaled as a fault. In contrast to a
Warning, the timer will not accept a start signal until it has been
restored to Ready state (refer to section “How to..“, "Reset
Fault" paragraph).
• Checkbox “Warning” is active:
The message will be signaled as a warning. The timer will
continue working. Any schedule-specific warnings will be
cleared by the next start.
and Controls
Possibility of downtimes and

misinterpretation of welding results on the
system!
CAUTION Arbitrary changes to a message type may
lead to undesirable downtimes and to a
misinterpretation of welding results on the
system!
Therefore, you should make sure that
changes do not affect the intended, proper
behavior of the system!
Setup: Communication

Note: The information displayed is not relevant for all timer

types.
Displays information concerning the Ethernet interface.

and Controls
IP Address (Setup, Communication)

IP address stored in the flash memory of the Ethernet adapter.
For more information concerning Ethernet, please refer to our
documentation on “Programming field buses”:
Subnet mask
Subnet mask stored in the flash memory of the Ethernet adapter.
Standard gateway
IP address of the standard gateway stored in the flash memory of
the Ethernet adapter.
SMTP Address
SMTP address stored in the flash memory of the Ethernet adapter.
Port Number
Port number stored in the flash memory of the Ethernet adapter.
and Controls
Address mode
Address mode Comment
DEF_IP_SWITCH If Anybus switch bank == 0:
IP, subnet and gateway from flash
If Anybus switch bank != 0:
Low-Byte IP from Anybus switch bank, High-IP from
Basic address switch, Subnet and GATEWAY from
object
ALL_IP_SWITCH If Basic switch banks == 0:
as LOW_AB_IP_SWITCH.
If Basic switch banks != 0:
IP = Basic switch banks,
subnet and gateway from object
NO_IP_SWITCH always: IP, subnet and gateway from object
LOW_AB_IP_SWITCH If Anybus switch bank == 0:
IP, subnet and gateway from flash
If Anybus switch bank != 0:
Low-byte IP from Anybus switch bank:
High-IP == 192.168.0.X
Subnet == 255.255.255.0
GATEWAY == 0.0.0.0
LOW_CPU_IP_SWITCH immer: Low-Byte IP from CPU switch bank,
High-IP, Subnet and GATEWAY from object
MIX_IP_SWITCH always: Low-Byte IP from CPU switch bank,
High-IP from Basic address switch,
Subnet and GATEWAY from object
Baudrate
Baudrate
Automatic
Fixed 10 MBd
Fixed 100 MBd

Mode
Mode
Automatic
Fixed, simplex
Fixed, duplex

and Controls
Functions (Setup, Communication)

Informs in binary format about the status of various server services
of the timer.
• Bit x is high: Service/function is active
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5

WEB- Modbus- FTP-Server TELNET- Ethernet SMTP
Server /TCP- Server
Server
MAC-Adress
Display of the worldwide unique MAC address of the Ethernet
adapter.
DIP switch
Displays the setting of the IP-ADR switch bank (on the front side of
the Ethernet adapter) in decimal format.
and Controls
Correction
Within the BOS 6000 main window, the “Correction“ menu (which
is called up by the icon) offers the following choices::
• Selection of “Spot-Name” or “Timer” or “Program”.

• Selection of the "Correction" tab in order to make temporary,
process-related %I and force changes quickly and without
altering the individual base values.


and Controls
Correction: Correction
Purpose:
• Program- and electrode specific %I correction within permitted

limit values (in %).
• Program- and electrode specific electrode force correction
within permitted limit values (in %).
Note: As this window is used to program not only program-

specific correction data, but also any electrode-specific
corrections, you should first select the relevant welding
program (via field “Spot-Name“ or via fields “Timer“ and
“Program").
The electrode-specific correction data displayed always
belongs to the electrode that was parameterized in the
welding program selected (display in field “Electrode”).

Note: The current parameter settings will be displayed in the

"Programming" menu, tab "Schedule".
and Controls
%I Correction (Prg.)
Corrects the demanded %I of the relevant program by the
percentage indicated.
The permissible correction value also depends on parameters
"Max %I-Correction" and "Min %I-Correction" within the
"Programming" menu, tab "General "".
The %I correction (Prg.) and the %I correction (Elec.) act in
addition to each other.
%I Correction (Elec.)
Corrects the demanded %I of all programs using the electrode
displayed by the percentage indicated.
"Max %I-Correction" and "Min %I-Correction" within the
"Programming" menu, tab "General "".
In order to enter correction values for other electrodes, you must
select a spot/a program that has been assigned to the desired
electrode as described above.
The %I correction (Prg.) and the %I correction (Elec.) act in
addition to each other.
Pressure-Correction (Prg.)
Corrects the electrode force (“base pressure value” parameter) of
the relevant program by the percentage indicated.
"Max Pressure-Correction" and "Min Pressure-Correction" within
the "Programming" menu, tab "General "".
The Pressure correction (Prg.) and the Pressure correction (Elec.)
act in addition to each other.
Pressure-Correction (Elec.)
Corrects the electrode force (“base pressure value” parameter) of
all programs using the electrode displayed by the percentage
indicated.
"Max Pressure-Correction" and "Min Pressure-Correction" within
the "Programming" menu, tab "General "".
In order to enter correction values for other electrodes, you must
select a spot/a program that has been assigned to the desired
electrode as described above.
The Pressure correction (Prg.) and the Pressure correction (Elec.)
act in addition to each other.
and Controls
Base pressure value (Correction, Correction)

program.

proper Force calibration or a proper input in parameters
"Programming" menu in tab "Electrode") ! Otherwise,
Spot Reference
Purpose:
To Add, change and delete spot names.

• To transfer the spot names from the spot reference table of
BOS 6000 to the relevant timer (without comments!) using the
Spot-Table --> WT command button.
This function is absolutely necessary in order to use spot
addressing and must be performed for all online timers
whenever the spot reference has been changed.
• To transfer the spot names from a timer to the spot reference
table of BOS 6000 using the Spot-Table <- WT command
button.
Note: The spot reference table existing in BOS 6000 is

completely replaced by this process!
To Backup/Restore the complete spot reference table on/from a

storage medium.
To Export the spot reference table to an Excel file (*.xls) for further
external processing.
To Compare the spot reference data of the logged-in timers and
the spot reference table in BOS 6000.
• To automatically generate a comment for the “comment 1” field
from the spot name using the Auto comment command button
if activated in the configuration tool.
Note: Automatic comment generation completely deletes all

comments already existing in the spot reference table
within BOS 6000!

to use theSet Access Level" link to define the execution
and Controls
Spot names serve to quickly address/identify all spot welds which

can be welded by the logged-in timers.
Therefore, the spot reference table contains the “spot name”,
program number, timer name, timer comment and a number of
user-specific comment fields for entering further information with
respect to each spot. Sort and Filter operations can be carried out
for the spot reference table.
If a spot weld has been entered in the spot reference table of BOS
6000, the spot name of this spot can be used within BOS 6000 in
connection with operation/programming (input/selection in the BOS
6000 main window, “Spot name” field). The information as to the
timer and program used to weld this spot is automatically taken
from the spot reference table by the welding system.
Spot name
Input of a unique spot name.
Several identical names are not permitted in Spot Reference.
Number of characters: max. 48.
Prohibited characters: '
Sched
Number of the program used to weld the spot.
WT
Name of the timer used to weld the spot.
Timer comment
Timer comment entered in Timer Reference.
Comment 1 to comment x
Comment field for describing the spot weld. The number of
comment fields can be specified in a configuration tool parameter.
Comments for a spot can be displayed by clicking on the icon
in the BOS 6000 main window (refer to window “Spot Comment".
Note: No comments will be stored in the timer.

and Controls
Prewarning
Purpose:
• General overview of the status of all electrodes with a count of

more than 0. Sorting the table is possible.
• To acknowledge tip change (reset counts)
• To set counts and dressing counter to certain values (using
Detail Info)
• Only when logged in as Administrator:
To define the execution privileges (=write privileges) for
command buttons in this window using the “ Set Access Llevel"
menu item.
Color codes of the electrode bars (count column)

green: Electrode status without specific message
yellow: Prewarning limit reached
red: End of stepper without timer stop
dark red: End of stepper with timer stop
bright orange: Tip dress request
orange: Dressing necessary without timer stop
dark orange: Dressing necessary with timer stop
Note: The electrode status is also displayed in clear text. Refer

to window "Detail Info", "Stepper" field.

are used to select electrodes for a desired activity. Checking the
list.
Update
To update the display manually.
Normally, the display is automatically updated once per minute
(parameter can be set in configuration tool), and this setting should
not be altered for reasons of performance.
and Controls
Detail Info
Can only be activated if precisely 1 electrode has been selected.
In addition to displaying information about all important counter
statuses (counts, spot counter, dressing counter), the system also
indicates the maximum count and the maximum dressings of the
electrode in question.
The following activities are also possible with respect to the
currently selected electrode
- acknowledge tip change
- set counts and dressing counter manually.

Arbitrary changes of the counters of an
electrode may result in incorrect welds,
CAUTION defective workpieces and the cooling water
leaks at the electrodes!
Therefore, you should make sure that an
electrode change is not acknowledged unless
the electrodes have actually been replaced!
changes to the counts or the dressing counter
values!
Electrode changed
Can only be activated if at least 1 electrode has been selected.
Acknowledges an electrode change for all electrodes selected.
The counts, spot and dressing counters of the electrodes in
question are set to 0.

and Controls
Error table
Purpose:
• To obtain a general, color-coded overview of all currently active

- faults (pink background),
- warnings and other important statuses (yellow background).
Note: Whether certain events should be interpreted as a fault

or a warning by the timer can be defined in the "Setup:
Fault Setup" window.
• To call up the detail display by double-clicking on a line (only

available for lines that contain a fault).
More detailed information concerning an entry is available
there.
The detail display also offers the following possibilities:
Fault reset with WC (Weld complete) or
Fault reset with Reweld
Refer to section "Reset".
The display is cyclically updated. For this reason, any self-

acknowledging faults will automatically disappear as soon as the
cause of the fault is no longer present. All other faults must be
reset by the operator.

repeated!
reweld is started.
and Controls

movements after “Fault reset with WC”!
If the start signal is present upon Reset with
DANGER WC, the timer will immediately output the “WC”
signal.
one in the hazard zone when Reset with WC is
selected.
and Controls
Network overview
Purpose:
• Status overview of all logged-in timers.

For a description, refer to section “The timer symbol” further
below.
• Quick selection of the BOS 6000 main window with the
“Programming“, “Diagnosis”, “Setup” and “Correction” menus.
Right-clicking on the relevant timer symbol will open a pop-up
menu containing further options.
Double clicking on the timer symbol of an offline timer will
open the “Programming” menu.
Double clicking on the timer symbol of an online timer will
open the “Diagnosis;Timer Information” menu.
Note: The “Diagnosis” menu is not available for offline timers.
Note: You can define in the configuration tool whether or not

the timer names should be displayed together with the
timer symbols.
When the timer name display has been deactivated, the
corresponding name can still be viewed using the
“tooltip”.
and Controls

and Controls
Protocol
Purpose:
• To Display all available protocol memories (including sort and

filter)
• To Export protocol data to an ASCII file in which the fields of a
protocol line are optionally delimited by the “;“ or “,“ characters.
• To Print protocol data (including preview)
• Statistical evaluation according to duration of fault and
frequency of fault (via Statistics menu item)
to define the execution privileges (=write privileges) for
command buttons and menu items in this window via the "Set
Access Level" link.
Protocols are permanently recorded in the background while BOS

6000 is active and cover all online timers logged into BOS 6000
including data changes as well as all events of any kind occurring
(e.g. faults, warnings) or current values.
Error protocol:
contains all events occurred with the exception of weld faults, data
changes by the user and actual values.
Weld fault protocol;
only includes the weld faults occurred.
Data change protocol:
contains all events by which data were changed.
Weld current protocol:
contains all schedules that have been started including all
important command values and actual values.
Note: The weld current protocol can be deactivated via the

configuration tool because it may cause extensive
network traffic, especially in the event of welding lines
comprising many timers.
and Controls
All Protocol memories are designed as ring memories (first in,

first out). The size of the ring memory can only be configured when
installing the BOS 6000 (40000 to 100000 entries). The
configuration tool is needed to empty the individual protocol
memories.
Description of the table columns…

... for all protocols:
ID
Sequential numbers of the protocol entries.
Date/Time
Time the entry was made.
Timer name
Name of the timer (as assigned in Timer Reference) that caused
the protocol entry.
… specifically for the Error protocol
Description
Cause of entry in plain text.
Addition
Additional message. Depending on fault, it includes the program or
electrode number; or other causes of the fault in the event of
welding faults.
Fault
Checkmark means: Protocol entry is defined as a fault.
No checkmark means: Protocol entry is an event or a warning.
Note: Whether certain events should be interpreted as a fault

or a warning by the timer can be defined in the "Setup:
Fault Setup" window.
… specifically for the Weld fault protocol
Program
Program in which the weld fault occurred.
Monitor status
Message of the current monitoring function.
and Controls
Reference current
Current value that is the basis for monitoring.
Active reference current

Current measured.
Programmed time
Maximum permitted time span between the program start and the
end of the hold time (HLD) in ms.
Entry is only made if time monitoring is active.
Actual time
Actual time span between the program start and the end of the
hold time (HLD) in ms.
Entry is only made if time monitoring is active.
Count
Count status of the relevant electrode at the time of occurrence of
the fault.
Spot-Name
Spot name (as assigned in the Spot Reference table) for which the
weld fault occurred.
… specifically for the Data change protocol
Parameter
Parameter that has been modified.
Prog./Elec.Nr.
Number of the program in which the parameter was changed,
or
number of the electrode that is affected by the modified parameter.
Old
The parameter value prior to the data change.
New
The parameter value after the data change.
Unit
Physical unit of the modified parameter.
Station number
Username
Username performing the data change.
and Controls
Comment
Comment text that was entered on the occasion of a data change.
… specifically for the weld current protocol
Number
Number of the last welding program executed.
Spot-Name
Name of the spot (as assigned in the Spot Reference table)
welded.
Count
Count status of the relevant electrode at the time the schedule was
executed.
Count in %
Relevant electrode wear (in %) at the time the schedule was
executed.
Monitor status
Message of the current monitoring function in connection with the
weld executed.
Schedule
Status of program schedule.
Addition
Additional message concerning the weld executed.
Spot Repet.
Setting of the “spot repetition” parameter used for the schedule.
Monit.-Mode
Setting of the “monitor” parameter used for the schedule.
tDem.s
tAct.s
RegStd
Setting of the “regulation” parameter used for the schedule.
iDem.11
Setting of the “reference current” parameter used for the PreWld of
the schedule (in kA).
and Controls
iAct.1
Actual current measured in the PreWld (in kA).
regulation1
Reg1
Setting of the “regulation mode” parameter used for the PreWld of
the schedule.
iDem.12
Setting of the “reference current” parameter used for the WLD of
the schedule (in kA).
iAct.2
Actual current measured in the WLD (in kA).
Reg2
Setting of the “regulation mode” parameter used for the WLD of
the schedule.
iDem.13
Setting of the “reference current” parameter used for the PostWeld
of the schedule (in kA).
iAct.3
Actual current measured in the PostWeld (in kA).
Reg3
Setting of the “regulation mode” parameter used for the PostWeld
of the schedule.
PHA Std
PHA1
Mean phase value in the PreWld (in %I).
PHA2
Mean phase value in the WLD (in %I).
PHA3
Mean phase value in the PostWeld (in %I).
Compare
Purpose:
and Controls
• To find out differences between 2 timers in the areas

- program data,
- electrode data, and
- timer-specific data
For the procedure, refer to section "Comparing timer data".

and Controls
Parameter Overview
Purpose:
• To display corrections activated in the selected timer

• To display invalid parameter values in the selected timer
Use the list box to select the desired display.

and Controls
Set Access Level

Purpose:
• To define/change the user level for individual objects.

In this way, functions, menu items or command buttons can be
protected against unauthorized access.
For the procedure, refer to section "Defining user levels for

individual objects".
FTP-Upload
Purpose:
• To load specific html sites into a timer.
A http server has been integrated into the timer (depending on

timer type) which provides a number of different remote services
via TCP/IP through port 80. The remote services are visualized
using specially created html sites in compressed zip files which
can be uploaded to the timer via an FTP Upload when necessary.
and Controls
Note: The “FTP-Upload” function can be activated/deactivated

via the configuration tool.
Condition: Timer with a 100 MBit Ethernet adapter
Filename
Name of the zip file containing all html files necessary for the
relevant timer in compressed format. The path and the filename
can be modified for the selected timer using the … command
button.

are used to select timers for the FTP upload. Checking the
list.
Loading new websites

If the correct files have been entered in the filename column for the
relevant timers, the FTP upload can be started for the timers
selected with the checkboxes.
and Controls
Backup
Purpose:
• To configure the backup function.
For the procedure, refer to section "Timer data backup".
Restore
Purpose:
• To configure the restore function.
For the procedure, refer to section "Restoring timer data".

and Controls
Autobackup
Purpose:
• To configure the automatic, time-controlled backup function.
Note: More settings for the autobackup function can be made

via the configuration tool:
- target directory of the backup data
- additional backup of the Timer reference table
- additional backup of the BOS 6000 Spot reference
table
- filename prefix for the backup files (station name)
Note: For as long as the autobackup function has not been

configured, there will not be any entries in the table. In
this case, you should use the All timers command
button in order to integrate timers in the autobackup.
Description of the table columns…
WT
Timer name for storing the data via the autobackup function.
Date/Time
Time at which the autobackup will be/has been performed for the
first time for the timer in question.
Filename
File name under which the timer backup data is stored in the target
directory.
Next schedule
Next time the autobackup will be performed for the timer in
question.
and Controls
Last cycle
Time at which the autobackup has been performed for the last time
for the timer in question.
Status
gray: no backup has been made so far
green: backup was properly made in the last cycle.
Meaning of command buttons:
Delete
Deletes a selected line without further queries. The relevant timer
is no longer taken into consideration for the autobackup.
All timers
First deletes all existing lines, then queries the time of the first
backup and the desired backup interval
and finally includes all online timers into the autobackup.
OK
Activates the autobackup function and closes the window.
and Controls
Timer change
Purpose:
• To copy all parameters and settings including the updated

electrode data (e.g., counter statuses) and other actual values
to a timer of the same type.
Note: In order to use the “Timer change” function,

communication with the timer to be replaced must still be
operative (“Status” field in “Timer change” window must
be green).
If no communication is possible via the currently
selected communication port, you should try and find out
whether communication still works using another
interface (e.g., V24 at X1).
For more detailed information and the procedure, refer to section

"Replacing a defective timer".
and Controls
Copy
Purpose:
• To configure the copy function.
For the procedure, refer to section "Copying timer data".

and Controls
Firmware change
Purpose:
• To update the timer firmware
Note: A suitable firmware file (*.hex) must be available to

perform a firmware update.
For a description of how to perform a firmware update, refer to

section "Updating the timer firmware".
Description of the table columns:

are used to select timers. Checking the uppermost check box will
select/deselect all check boxes in the list.
Timer type
Timer type including firmware version as defined in the Timer
Reference.
Timer type (memory)

If a firmware has already been loaded to the timer using the Load
FW command button, the system will display the timer type
including the current firmware version loaded in this field.
File
File name of the firmware to be loaded into the memory of the
relevant timer using the Load FW command button.
To select a firmware file, please click into the corresponding field.
Click on the … command button and select the desired firmware
file.
Status
red: no firmware has been loaded to the timer memory.
green: firmware has been/is being loaded.
and Controls
Load FW
Load the firmware file displayed in the “File” column to the RAM of
the corresponding timer. Welding can be continued during the
firmware load. This process will only be performed for the timers
selected via the appropriate checkboxes.
Note: To activate a firmware loaded into the timer’s RAM, it

must be transferred to the timer flash memory by clicking
on the Change command button.
Saving actual values

Writing actual values and counter statuses of the corresponding
timer to the database. This process will only be performed for the
timers selected via the appropriate checkboxes.
If no firmware has been loaded into the memory of the relevant
timer using the Load FW command button, the Save actual
values command button appears dimmed.
Change
Copies the firmware loaded into the timer RAM to the timer’s flash
memory. This process will only be performed for the timers
selected via the appropriate checkboxes.
If no firmware has been loaded into the memory of the relevant
timer using the Load FW command button, the Change command
button appears dimmed.
and Controls
Para.-Data Import/Export (Parameter-Backup)

Purpose:
• To select the desired parameter data. Possible data includes:

• Data of all programs/electrodes
• Data of certain programs/electrodes
• Data of all released programs (parameter "Start-Inhibit (P)":
Off) or all electrodes with active stepping (parameter
"Stepper": On)
• To output the parameter data into an ASCII file
Using this function, program/electrode data can be

configured/completed independent of timers and transmitted to the
desired weld timers using the "Parameter-Restore" function.
For the procedure, refer to sect. "Exporting parameter data to
ASCII file".
and Controls
Para.-Data Import/Export (Parameter-Restore)

Purpose:
• To import parameter data stored as an ASCII file-
Note: The structure of the parameter data necessary for

importing the data corresponds to the structure of the
Export.
For the procedure, refer to sect. "Importing parameter data from

ASCII file"
and Controls
Set Counter
Purpose:
To Set counts and dressing counter to specific values
Note: The program number is not displayed unless the dialog

is called up in window "Programming: Stepper" (and not
in window "Detail Info").

values!
and Controls
Current calibration
Purpose:
• To adjust all components of AC or DC systems involved in

current measurement to a reference current meter.
Benefits:
• Homogeneous spot weld quality.

• Reduction of max. error to values below +/-2% with respect to
the real value of a reference current meter.
• Reproducibility of logged current values (ISO 9000).
• More precise comparison of currents of all calibrated systems,
provided they have been calibrated using the same reference
current meter.
• Direct transferability of currents to other calibrated systems,
current meter.
Note: Welding is even possible without current calibration.

However, the benefits listed above are not reached in
this case at all or to a limited extent only.
For the procedure, refer to section “How to ...", "Performing current

calibration".
and Controls
Force calibration
Purpose:
• To adjust all components involved in force generation to a

reference force meter.
Benefits:
• Homogeneous spot weld quality.

• Direct input of gun force in kN.
• Reproducibility of logged force values (ISO 9000).
• More precise comparison of forces of all calibrated systems,
force meter.
• Direct transferability of forces to other calibrated systems,
force meter.
Note: Welding is even possible without force calibration.

However, the relationship between the programmed
force and the resulting force at the electrode gun must
be manually defined using parameters "Conversion
Factor", "Zero-Adjust" and "Maximum Pressure" in this
case.
For the procedure, refer to section "How to...", "Performing force

calibration".
and Controls
Corresponding Programs
Purpose:
• To display all spots welded with the program displayed in the

“Program” input field (BOS 6000 main window).
If the background color of the “Spot name” list box in the BOS
6000 main window changes to yellow, several spots are welded
with the program displayed in the “Program” input field.
By clicking on the icon, you can then display all of these spots
in the “Corresponding Program” window.
and Controls
Spot Comment
Purpose:
• Display of the comment fields (from the Spot Reference table)

of a selected spot.
For the procedure, refer to sect. "Displaying spot comments".

and Controls
Detail Info
Purpose:
• To display detailed information concerning the electrode

selected in the"Prewarning" window.
• To Acknowledge replacement of electrodes (reset counts)
• To Set counts and Dressing Counter to specific values
Stepping
Display of the electrode status in plain text.
Counts
Indicates the current Counts value for this electrode (= Counts).
Spots
Indicates the number of spots already welded by this electrode (=
spot counter).
Dressings
Indicates how often the electrode has already been dressed (=
Dressing Counter). Start tip dressing is not accounted for in this
case.
Max. Count
When dressing has been deactivated (Dressings = 0.0):
indicates the maximum permitted electrode count. Can be
configured in window"Programming: Stepper".
When dressing is active (Dressings > 0.0):
indicates the maximum permitted electrode count between 2
dressing cycles. Can be configured in window"Programming:
Stepper".
Dressings
Indicates how often the electrode may be dressed until the end of
stepper. Can be configured in window"Programming: Stepper".
and Controls
Electrode changed
Acknowledges an electrode change for the electrode displayed.
The counts, spot and dressing counters of the electrode in

Set counter
Sets the counts and dressing counter of the electrode displayed.

values!
Cancel
Close “Detail Info” window.
and Controls
How to …
How to …
In this section, you will learn how to carry out important activities
within BOS 6000. The descriptions are focused on the handling
and operation of the software.
Exit BOS 6000

Note: To exit the application, you must have the appropriate
user privileges. The setting can be modified by an
Administrator currently logged in using the “Set Access
Level” window.
Note: Logging of the plant condition (faults, changes, etc.) is

also terminated by exiting BOS.
1. In the title bar of the BOS 6000 main window, click on

or
select the File | Exit menu item in the menu bar of the BOS
main window.
2. Then confirm the query "Are you sure" by hitting OK.
The BOS 6000 user interface and the BOS 6000 server application
(BOSServ.exe) running in the background are closed.
Log in timers to BOS 6000

Note: This function can only be invoked in the course of
program start.
1. Close BOS 6000 and restart it.

2. In the “ Timer Reference” window, click on the Add command
button.
The “ Add/Change Timer” window will be displayed.
Note: As an alternative to the Add command button, you may

also right-click and then select the “Add” menu option.
3. Enter the relevant data.

4. Accept the data in the window by hitting OK.
and Controls
How to …
5. Close the “ Add/Change Timer window by hitting the Cancel

command button.
The new timer will be displayed in the “ Timer Reference
window as a new line in the table.
The field in column “Software-Version” initially has a red
background. This shows you that the corresponding record has
not yet been generated in the internal database.
6. Hit the Continue command button to start establishing the
connection.
The system creates a new record for the new timer in the
internal database.
For online timers, Connection setup will be started next. In the
event of a data mismatch between the database and the online
timer, a data comparison will be carried out.
Note: The system behavior in the event of data mismatch can

be selected in the “Direction” list box of the “
Add/Change Timer window.
Delete timers from BOS 6000

program start.
Note: BOS 6000 can no longer access a timer that has been
deleted. Parameter input, diagnosis and logging are not
possible for deleted timers!
Ö Do not delete any timers from BOS 6000 which you will still
need for programming or diagnosis, or for which continuous
logging is necessary!

2. In the “ Timer Reference window, select the timers to be
deleted. Use the check boxes at the left line margin for this
purpose.
3. Right-click with the mouse in the “ Timer Reference” window
and select the “Delete” menu item.
4. Confirm the query “Are you sure” by hitting OK to delete the
selected timers.
5. Click on Continue in the “ Timer Reference window to start the
connection setup.
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Change the communication data of logged-in timers

program start.

2. In the “ Timer Reference window, select the timer whose
communication data is to be changed. Use the cursor keys
CursorUp/CursorDown for this purpose. You may also left-
click on the relevant line.
The currently selected timer is shown as a line with a blue
background.
3. Right-click with the mouse in the “ Timer Reference window
and select the “Change” menu item.
4. Change the relevant data.

6. Click on Continue in the “ Timer Reference" window to start
the connection setup.
Note: The system behavior in the event of data mismatch can

be selected in the “Direction” list box of the “
Add/Change Timer" window.
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Export Timer Reference

Create a backup copy of the table shown in the“ Timer Reference"
window.
1. In the “ Timer Reference" window, select File | Export Timer

Reference.
2. Enter the directory and the filename under which the timer
reference is to be stored and confirm your entries by hitting the
Save command button.
The current timer reference will be stored as an ASCII file with
the filename extension *.txt.
Ö Never change this file manually. Otherwise, you may

experience problems when restoring the data!
Import Timer Reference

program start.
A previously exported timer reference is reimported into BOS

6000.
Ö Please note that the current timer reference is completely

deleted by this process!
1. In the “ Timer Reference" window, select File | Import Timer

Reference.
2. Confirm the query by hitting Yes and select the directory and
the name containing the timer reference to be imported.
Confirm your entries by hitting Open.
The selected timer reference is imported.
Print Timer Reference

1. In the “ Timer Reference" window, select File | Print.
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Copy Timer Data

You may copy data both within one and the same timer (e.g.
program or electrode data) or from one timer to another.
1. In the BOS 6000 main window, select the Edit | Copy menu
item from the menu bar. The “ Copy” window will be displayed.
2. First mark the data to be copied using the radio buttons

provided.
3. Select the “Source” from which timer the data is taken from the
list box.
4. Select the “Destination” to which timer the data is to be copied
from the list box.
5. If program or electrode data is to be copied, specify the
program or electrode data to be copied in the left numerical
input field (“Program” or “Electrode/Stepper”). Here, you must
enter the relevant program/electrode/stepper number.
destination program or electrode data in the right input display
field (“Program” or “Electrode/Stepper”).
Here, you may also enter more than one
program/electrode/stepper number(s). Use the “-“ and/or “,”
signs to define contiguous number ranges or separate
numbers.
Example: to copy the data of a program to programs 10 to 21,
41 and 52, you would write: 10-21,41,52
7. Confirm your entries by hitting OK.
The ”Data --> Timer” dialog is opened.
You may specify the reason for copying in the “Comment” field.
The text entered here will be shown in addition to the change
event in the data change log.
Note: At this point, the data has not been copied yet!
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8. Start the copying process by hitting OK.

Wait for the BOS 6000 message that the process has been
completed and confirm the message by hitting OK.
9. If no more data is to be copied, close the “ Copy" window by
hitting the Cancel command button.
Export timer data (backup)

All parameter settings of one/several timers are saved in a backup
file. By this process, all relevant data of the internal database is
stored in separate compressed files (*.zip) for each selected timer.
Note: This function does not affect any active welding

processes.
1. In the “ Timer Reference" window, click on the Export Record

set command button. The “ Upload" window will be displayed.
2. Select the timers the data of which should be included in the

backup. Use the check boxes at the left line margin for this
purpose. Checking the uppermost check box will
select/deselect all check boxes in the list.
3. The backup path may be changed, or a new backup directory
may be created, using the … command button.
Note: As a standard, backup files can be stored on any

available drive of the BOS 6000 computer, provided that
the user has the proper access privileges.
As an alternative, however, they may also be stored on
any FTP server because BOS 6000 already includes a
suitable FTP client. This function can be activated and
configured via the configuration tool.
4. Hit the OK command button to start the backup procedure.

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Restore Timer data (download)

program start.
The complete timer data contained in a backup file (*.zip) is

restored to the internal database of BOS 6000.
1. In the “ Timer Reference" window, click on the Import Record

set command button.
The “ Download” window will be displayed.
2. First, select the relevant zip file using the … command button
and confirm your selection by hitting Open.
3. From the right list box, you select the timer whose data record
in the internal database is to be replaced with the contents of
the zip file and confirm your selection by hitting OK.
In the “Import Record Set Comparison” window, the system
displays important information concerning the backup selected
and the specified target timer record set.
4. Hit the OK command button to start the restore procedure.
For more details, refer to window “ Connection setup".
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Compare Timer Data

1. In the BOS 6000 main window, select the Functions |
Compare menu item or
click on the symbol .
The “ Compare" window will be displayed.
2. Select the timers to be compared.

Use the “Timer 1” and “Timer 2" list boxes for this purpose.
3. Hit the Compare command button.
The differences between the two timers will be determined.
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4. In the “Detail view” tab, you will see the details of the
differences. Sort the table according to your needs.
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Influence data comparison at program start

In the course of the program start, the system will compare the
data of a timer and its corresponding record set in the internal
database (refer to "Connection setup") window. You can predefine
the desired system behavior in the event that differences are
detected.
Note: This setting can only be made in the course of program

start.

2. In the “ Timer Reference" window, select the timer whose
communication data is to be changed. Use the cursor keys
CursorUp/CursorDown for this purpose. You may also left-
click on the relevant line.
The currently selected timer is shown as a line with a blue
background.
3. Right-click with the mouse in the “ Timer Reference" window
and select the “Change” menu item.
4. Change the “Direction” field according to your requirements.

The effects of the possible list box entries have been described
in section “ Add/Change Timer".
6. Click on Continue in the “ Timer Reference window to start the
connection setup.
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Define access levels for individual objects

Note: This function is only available to logged-in
administrators.
For many objects/functions of the user interface (menu items,

command buttons etc.), access rights can be defined. Based on
these access attributes, the system decides whether or not a
logged-in user is entitled to read or write access for a certain
object.
The access attributes may be assigned “Access levels” from 1 to
9, with access level 9 corresponding to the highest security level.
Only administrators may access objects for which access level 9
has been defined.
Note: Each user can be assigned an access level in the user

administration of the configuration tool.
A user may access those objects/functions only for
which at least the same or a lower access level has
been defined.
Defining access levels of numerical input fields:

1. Log in to BOS 6000 as administrator (refer to sect. "Login").
2. Move the mouse pointer to the desired numerical input field
and right-click on it.
3. Select “Set read level” or “Set write level” as well as the
desired level in the pop-up menu.
Only those users whose access level is identical to or higher
than the access level just assigned will be able to access the
object accordingly in the future.
Defining access levels of menu items and command buttons:

1. Log in to BOS 6000 as administrator (refer to sect. "Login").
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2. In the BOS 6000 main window, select the Functions | Rights

Administration menu item or
click on the symbol .
The “ Set Access Level" window will be displayed.
Note: At some points within BOS 6000, the window "Set

Access Level" can also be called up via a link (e.g., in
the window "Timer Reference").
3. Use the tabs to select whether the access level of a menu item
(“Menu” tab) or a command button (“Button” tab) is to be
modified in the calling window.
The “Table” tab is only available in conjunction with a pop-up
menu which can be activated by right-clicking in the calling
window.
4. Select the line containing the relevant object and click on to
select the desired access level. If is not displayed, press
the Cursor-right key.
Only those users whose access level is identical to or higher
than the access level just assigned will be able to access the
object accordingly in the future.
5. Repeat the last two steps in order to assign all relevant objects
the desired access levels.
6. Confirm the current settings by hitting the Update button.
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Copy the contents of a numerical input field

1. Move the mouse pointer to the desired numerical input field
and right-click on it. If the copy function is available at this
point, a pop-up menu will be displayed.
2. Select “Copy” from the pop-up menu
In the upper area of the next dialog window, the system will
display information concerning the parameter to be copied.
Example:
3. First select the destination to which the parameter contents are

to be copied:
All programs: copy to all programs.
Electrode: Copy to programs working with the electrode
displayed.
Program/Electrode: copy to certain programs/electrodes.
destination program or electrode data in the next input field.
numbers.
Example: to copy the value to programs 1 to 3, and 8, you
would write: 1-3,8
5. The copying process is immediately started by hitting OK.
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Sort tables
Most tables can be sorted according to any criteria.
• Numerical columns will be sorted in numerical order by the
system.
• Columns containing strings will be sorted in alpha-numerical
order.
1. Click on the heading of the column containing the sortkey for

sorting the table. By clicking on the same column heading
again, you can invert the sorting direction.
If permitted by the column width, a symbolic arrowhead will
inform you of the current sort direction:
ascending: descending:
Note: In order to change width of a table column, move the

mouse pointer to the line that separates two adjacent
column headings. When the mouse pointer is on a
separation line, its appearance will change.
Then keep the left mouse button depressed while
dragging the line to the desired new position and then
release the mouse button.
Filter tables
Some tables (in which the Show filter command button is offered,
e.g., in some logging tables) can be conveniently filtered according
to topics. When filtering is active, only those table lines are
displayed/printed/exported that meet the filter criteria selected.
The filter topics are dynamic, i.e., all entries in a column are
automatically included in a list box by the system which also
avoids redundant entries. Filters are activated by selecting an
entry from one or several list boxes.
1. Select the Show filter command button.

Instead of the column headings, list box items will be displayed
where activated. The command button text changes to Hide
filter.
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2. In the relevant column, click on to display the available

topics and select a topic. The filter becomes immediately
active.
3. Repeat the previous step for all columns that require a filter. All
active filters act as a logic AND operator.
The currently active filters can be inferred from the text color of
the entries in the individual list boxes:
black: Filter off
blue: Filter active.
Select the uppermost list box entry (“…(*)”) to deactivate the
filter for the respective column.
To deactivate all filters, select the “Update” menu item.
4. If necessary, you can now export or print the filtered table.
Ö To exit the filter function, click on the Hide filter command

button. Instead of the list box items the column headings will
reappear. All active filters are deactivated.
Show / Print / Export logs

Protocol menu item or click on the icon.
The “ Protocol” window will be displayed.
2. Select the desired protocol using tabs “”Error Protocol”, “Weld

Fault Protocol”, “Data Change Protocol”, or “Weld current
Protocol”.
3. Use the “Start” and “End” date input fields to limit the scope of
the protocol data to be shown/printed to a certain period of
time.
4. Use the Show filter command button to limit the protocol data
to be shown/printed/exported to certain topics.
In addition, in order to print the protocol displayed:

Ö Select the “Print” menu item.
In the next dialog window, you may either preview the printed
protocol (Preview button) or define the print parameters (Print
button).
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In addition, in order to export the protocol displayed:

Ö Select the “Export” menu item.
In the next dialog window, you may enter the destination path
and file name (“Store values” tab) or select the separator
(“Setup” tab).
Enter the path and the filename and confirm your entries by
hitting the OK button.
The protocol data will be stored in an ASCII file.
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Change parameters and transfer to timer
Arbitrary parameter changes may lead to

dangerous conditions at the system!
Using BOS 6000, you may access all
DANGER parameters, and thus the fundamental behavior
of the connected timers.
Do not change any parameters without reason.
Do not change any parameters without knowing
the consequences. In case of uncertainty, you
should always contact your supervisor!
To change parameters, you may proceed as follows:

• Change a single parameter and then accept the new setting to
the timer.
• Change several parameters and then accept the new settings
to the timer.
Note: We recommend accepting single parameter changes to

a timer only. In this way, you can ensure a defined
control status at any time.
Note: If a timer can be addressed by several programming

terminals (with BOS 6000 running on each of them), you
can automatically visualize all data changes made by
any other programming terminal in a table.
For this purpose, the “Ext. data change”function must
have been activated in the relevant programming
terminals using the configuration tool.
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Procedure
1. Change the desired parameter(s).

2. Press the Enter key or click on the Data --> Timer button.
The ”Data --> Timer” dialog screen is displayed (Example):
... if a single parameter has been changed:
... if several parameters have been changed one after the other:
At this point, it is still possible to define the change to be actually

transferred to the timer by selecting the check box on the left
margin of the table.
3. Enter the reason for the parameter change in the ”Comment”
field. The text input will be displayed in the data change
protocol in addition to the change itself.
Note: In the configuration tool, you can define whether and

how many characters must be entered at minimum in
the comment field.
4. Hit the OK command button to transmit the changed data to

the timer.
The new data made will become effective in the system upon
the next program selection.
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Export spot reference

To create a backup copy of the table shown in the“ Spot
Reference" window.
1. In the “ Spot Reference" window, select File | Export…. .

2. Select the directory and the filename under which the spot
The current spot reference will be stored as an ASCII file with
the filename extension *.txt.
Ö Never change this file manually. Otherwise, you may

experience problems when restoring the data!
Export spot reference to an Excel file

1. In the “ Spot Reference" window, select File | Export --> Excel
Tab. .
2. Select the directory and the filename under which the spot
The current spot reference will be stored as an Excel file with
the filename extension *.xls.
Note: Saving a spot reference to an Excel file cannot replace

regular backups of the spot reference.
A spot reference that has been saved in an Excel file
cannot be retrieved to BOS 6000!
Import spot reference

A spot reference previously exported to an ASCII file is reimported
into BOS 6000.
Ö Please note that the current spot reference of BOS 6000 is

completely deleted by this process!
1. In the “ Spot Reference" window, select File | Import…. .

2. Confirm the query by hitting Yes and select the directory and
the name containing the spot reference to be imported.
Confirm your entries by hitting Open.
The selected spot reference is imported.
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Print spot reference

1. In the “ Spot Reference" window, select File | Print.
Compare spot reference

Shows the differences between the internal spot reference tables
of the individual online timers and the BOS 6000 spot reference
table.
1. In the “ Spot Reference" window, select File | Compare Spot
reference from the menu bar.
Enter/change spot references

1. In the “ Spot Reference" window, click on the Add button to
create a new spot reference
or
in the “ Spot Reference" window, select the spot reference to
be changed and select the “Change” menu item.
The “Add/Change spot” window appears:
Note: As an alternative to the Add command button, you may

also right-click and then select the “Add” menu option.
2. Enter the relevant data.

The new or changed spot reference is accepted to the spot
reference table.
4. Close the “Add/Change Spot” window by hitting the Cancel
command button if you do not want to add/change any other
spot references.
To add/change more spot references, first click on the Delete
command button and then continue as described under point 2
above.
Display spot comments

1. In the BOS 6000 main window, select the desired spot from the
“Spot-Name” list box.
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2. Click on the icon .

The “ Spot comment" window will be displayed.
Note: The icon cannot be selected unless at least one

comment has been assigned to a spot (for assignment
of comments: refer to “ Spot reference" window.
Delete spot references

1. In the “ Spot Reference” window, select the spot reference to
be deleted, right-click and select the “Delete” menu item.
2. Confirm the query “Are you sure” by hitting OK to delete the
selected spot reference from the table.
Show electrode status

Prewarning menu item or
press key F2 or
Click on the icon.
The “Prewarning” window will be displayed.
Note: If the “Prewarning” window had already been displayed

before, you may use the Update command button. By
this, you ensure that the BOS displays the most current
condition without a time delay.
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Confirm electrode change


press key F2 or
click on the icon .
The “ Prewarning” window will be displayed.
2. Use the check boxes on the left line margin to select the
electrodes you have changed.
3. Hit the Electrode changed command button.
The counts, spot and dressing counters of the electrodes in
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Set electrode counter

values!

press key F2 or
click on the icon .
The “ Prewarning” window will be displayed.
2. Use the check boxes on the left line margin to select the
electrodes you want to manipulate.
3. Hit the Detail-Info command button.
The “ Detail-Info” window will be displayed.
4. Hit the Set counter command button.
The “ Set counter” window will be displayed.
5. The counts of the electrode displayed can be set to a desired
value in the “Count” input field, and the “Dressings” input field
serves to specify a dressing counter value.
6. Hit the OK command button to activate the new values input.
Export parameter data to ASCII file

1. In the BOS 6000 main window, select the File | Para.-Data
Import/Export | Export menu item.
The “ Para.-Data Import/Export” window will be displayed.
2. Select the timer containing the source data from the list box
(top left).
3. In the input field (top right), you should change the file name to
which the ASCII data is to be saved, if necessary. As a default,
the file name is taken from the timer name.
To change the default destination path, use the … command
button. .
4. Use the “Program” or “Electrode/Stepper” tabs to select
whether you want to export program or electrode data.
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5. Make your selection more specific via the radio button.

If you select the “Program” or “Electrode/Stepper” button, enter
the desired numbers.
numbers.
Example: to export the parameters of programs 1 to 3, and 8,
you would write: 1-3,8
6. Hit the OK command button to save the data.
Note: If a file with the same name already exists in the

destination folder specified, the system will query
whether or not the existing file should be replaced.
Import parameter data from ASCII file

1. Select the timer to which the data is to be imported in the
“Timer” list box of the BOS 6000 main window.
2. In the BOS 6000 main window, select the File | Para.-Data
Import/Export | Import menu item.
The “ Para.-Data Import/Export” window will be displayed.
3. Enter the name of the ASCII file to be imported in the input
field. As a default, the file name is taken from the selected
timer name (refer to step 1).
To change the default source path, use the … command
button. .
4. Hit the OK command button to import the data.
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Replace a defective timer

In addition to the possibility of importing an existing (Backup) from
the previous timer into the new one (Restore), you may use the
“Timer change” function for this purpose.
In contrast to Backup/Restore, the “Timer change” procedures
include a transfer of the currently active parameter settings and
all current electrode data (e.g. counter statuses) and other actual
values to the new timer. Therefore, it is not necessary to replace
electrodes immediately after a timer change.
Note: In order to use the “Timer change” function,

communication with the timer to be replaced must still be
operative (“Status” field in “Timer change” window must
be green).
If no communication is possible via the currently
selected communication port, you should try and find out
whether communication still works using another
interface (e.g., V24 at X1).
1. In the BOS 6000 main window, select the Edit | Timer Change
menu item.
The “ Timer change” window will be displayed.
2. Select the desired timer by clicking on the relevant line.

3. Click on OK command button.
The system will retrieve all current counter statuses and actual
values from the relevant timer and update the BOS 6000
internal database with this data.
Since the BOS 6000 internal database always shows a
synchronous data map of all connected timers, no other data
has to be obtained from the relevant timer.
The BOS 6000 internal database now contains all data that is
required for the timer change. The BOS 6000 indicates this
status by the message “Change timer” in the “Description” field
and waits for the communication to be interrupted (“Status”
field becomes gray, text of the OK button changes to Timer
change).
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Dangerous mains voltage is present!

Possibility of electric shock through inadvertent
and inappropriate handling of the
DANGER inverter/power unit!
Therefore, you must ensure that units are
always replaced by properly qualified staff only!
Possibility of welding sequence and

machine movements!
At this point, welding sequences and machine
DANGER movements are possible if the timer to be
replaced is in READY condition.
Therefore, please make sure that the personnel
is not at risk at any time when accessing or
staying in the hazard zone!
4. Switch the defective unit off, safely isolate it from supply, and
replace it.
5. Make the necessary switch settings on the new unit (e.g. ADR
switch, NEXT/END switch for Interbus network).
6. Turn 24V logic supply on the unit on.
7. Select the Timer Change command button from the “Timer
change” window.The complete timer-specific record set will
now be automatically copied from the BOS 6000 internal
database to the timer.
Wait for the status messages at the end of the data
transmission (“Function was finished successfully.”).
8. Repeat force and current calibration.
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Upgrade the timer firmware

The firmware of a timer normally need not be changed. However, if
recommended by the service technician, a firmware update may
be necessary to correct errors.
Conditions for the firmware update:

• the firmware file (*.hex) must be available, stored on an
accessible data medium and match the hardware in question.
• the functionality of the new firmware must be compatible with
the existing application.
Procedure:
1. In the BOS 6000 main window, select the Edit | Firmware
Changing menu item. The “ Firmware Changing" window will
be displayed:
2. Check the information in column “Timer type (memory)”. The

correct firmware must be displayed there for the timers in
question. If this is the case, proceed with step 6.
3. Otherwise, first you have to load the firmware to the RAM of
the corresponding timers.
Select the desired timers by clicking on the relevant check
boxes.
4. Select the firmware file(s).
For this purpose, you should click into the corresponding field
in the “File” column for all desired timers, confirm the command
button … displayed there, and select the proper firmware file
(*.hex).
Check whether the entries for all selected timers in column
“File” are now correct!
5. Hit the Load FW command button.
The firmware is now loaded into the RAM of the selected
timers. Welding can be continued during the firmware load. A
status bar in the “Status” column shows the progress.
When the complete firmware has been loaded (“Status”
column: 100%), the name and version number of the firmware
loaded will appear in the “Timer type (memory)” column.
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6. Save actual values and counter statuses.

boxes.
7. Hit the Save actual values command button.
The actual values and counter statuses of the selected timers
will now be transferred to the BOS 6000 internal database.
Welding can be continued during this process. In column
“Status”, you will receive the message “Actual values have
been saved” when the function has been completed.
8. Initiate the firmware change.
boxes.
9. Hit the Change command button.
The system will request you to restart the BOS 6000. At this
point, welding is still possible.
10. Make sure that the relevant timers are no longer involved in a
welding process and confirm by hitting Yes.
The firmware previously loaded into the RAM will be copied to
the flash memory. Now, the new firmware will be permanently
stored in the relevant timer (even after a loss of RAM power
supply/backup power).
The system will restart the relevant timers and BOS 6000.
In the timer reference displayed after the login, the system will
temporarily set the timer-relevant fields in column “Direction” to
“FW-MODE”.
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11. In the “ Timer Reference" window, click on the Continue/Next

command button.
The Connection setup will be started. If there is a difference
between the data in the timer and the internal database, all
relevant data including counter statuses and actual values will
be loaded from the database to the relevant timer.
Reset faults
Note: As an alternative to the method described here, the
errors that occurred last can also be reset in the
“Diagnosis“ menu, tabs “Start Simulation" or "Timer
Info".
1. In the BOS 6000 main window, select the Functions | Error

table menu item or press key F3, provided that window “Error
table" is not yet active.
2. Select the line that contains the relevant fault (left click or
cursor keys “up”/”down”).
3. Call up the Detail information (double click or “Enter” key).
Functions of the command buttons offered here:
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Reset with WC:

- The timer is restored to “Ready” state.
- The Weld Complete contact is output if the start signal is still
high.
Reset with Reweld:
- The timer is restored to “Ready” state.
- The program sequence is repeated if the start signal is still
high.
Cancel:
Closes the "Detail info” window.
Help:
Opens the BOS 6000 Help function containing more
information concerning the error displayed.

movements after “Fault reset with WC”!
If the start signal is present upon Fault reset
DANGER with WC, the timer will immediately output the
“WC” signal.
WC is selected.

repeated!
reweld is started.
4. Depending on the desired behavior, click on the Reset with

WC or Reset with Reweld command button in order to reset
the fault.
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Add fault information

You may integrate your own information concerning fault
messages into the BOS 6000 Help system. For this purpose, the
“My notes” link is provided for each fault message within the Help
window.
This link leads to a fault-specific HTML file that may be designed
by the user himself in order to provide his own, detailed
instructions and methods for troubleshooting.
In very simple cases, you may proceed as follows to add your own
information:
1. Cancel the write protection of all files in the ..\Help\User
subdirectory.
2. Click on the “My notes” link for the relevant fault message in
the BOS 6000 Help window.
The file provided for user information will now be displayed in
the screen area in which the various contents are shown within
the BOS 6000 Help window.
3. Right click in this screen area and select Show source in the
pop-up menu displayed.
This will start the Windows text editor.
4. Enter the user-specific texts between the <BODY> and
</BODY> delimiters.
Example:
:
<BODY>This is my own text.</BODY>
:
Own formatting instructions, colors, fonts or graphics may be
included in the user-specific information if programmed in
HTML format.
5. Save the modified file under its original name in the \Help\User
subdirectory and close the editor.
When the function is called up the next time, the information
entered will be displayed.
and Controls
How to …
Perform current calibration

When?
• Whenever an active component (relevant for the current) has

been changed, each electrode (gun) must be calibrated.
How?
• With the electrodes shorted.

Two test welds are performed at different programmed %I
values while measuring the actual currents flowing in each case
(in kA) and entering the current values measured in the timer.
Based on this data, the timer will automatically adjust parameter
"Toroid sensitivity" to the necessary setting.
Conditions:
1. Separate programs whose sequence is not inhibited for

calibrating the electrodes (guns). The respective calibration
program must have been allocated to the electrode to be
calibrated.
The programmed WLD and electrode force should be in the
same range as for the real welding program (weld time may be
selected a little longer than in reality, but not too short). %I data
are not relevant for current calibration.
2. Use the same reference ammeter for all systems to be
calibrated.
3. For calibration and checking the calibration, the setting at the
reference ammeter must be identical and match the relevant
system. The following settings are of special importance:
Type of current: PST: AC current; PSI: DC current.
Fade-out time/trail current: the welding current exhibits a
transient behavior upon making/breaking which is being
accounted for by the timer in parameters "Fade-out time" and
"Trail current". The welding current meter used must be set to
identical values for these parameters.
4. The working range of the welding system must be known
(which %I value is normally used to drive the power unit). The
value last used can be viewed in the “Middle PHA” display field
in windows "Programming: Schedule" or "Programming:
Stepper".
5. The electrode gun and the robot, if any, are in the position
intended for calibration.
and Controls
How to …
Procedure:
1. In the BOS 6000 main window, select the Current calibration

command button in the “Programming” menu, “Electrode” tab.
The “Calibration” window will be displayed.
2. Enter suitable %I values for the 2 test welds into the two %I
fields.The upper %I value should not exceed the working range
of the welding equipment (refer to conditions listed above).
The lower %I value should be in the lower working range of the
welding equipment and should be at least 20 %I lower than the
upper value.
By activating check box “Store values”, you can cause the
timer to present the values input without the need to re-enter
them when calibration is repeated for the relevant electrode.
3. Select a suitable calibration program.
Check whether the appropriate electrode number is displayed!
The next window of the current calibration function will be
shown.
5. Move the sensors of the reference ammeter to the proper
position and check the setting of the reference ammeter.
6. Close the electrode gun.
Possibility of welding schedule start

immediately after hitting “Schedule” button!
DANGER one in the hazard zone when the button is
activated.
and Controls
How to …
7. Hit the Start Wld command button.

A spot is welded with the (upper) %I value specified before.
Read the actual current flown at the reference ammeter and
enter the value into the upper field “Measured current (kA)”.
Accept the value by hitting the Enter button.
Repeat this step 2-3 times. The system will calculate the mean
value of all values entered. The number of inputs already
performed will be displayed to the right of the input field.
8. Hit the Continue command button.

9. Hit the Start Wld command button.
A spot is welded with the (lower) %I value specified before.
Read the actual current flown at the reference ammeter and
enter the value into the lower field “Measured current (kA)”.
Accept the value by hitting the Enter button.
Repeat this step 2-3 times. The system will calculate the mean
value of all values entered. The number of inputs already
performed will be displayed to the right of the input field.
10. Hit the Continue command button.
Now, the timer will calculate the necessary calibration values,
calibration has been completed.
Afterwards, check the calibration with the help of a KSR test
weld.
and Controls
How to …
Perform force calibration

When?
• Whenever an active component (relevant for the generation of

force, e.g., gun, proportionate control valve) has been changed,
each electrode (gun) must be calibrated.
How?
• Two measurements are performed at different programmed

force values (in kN) while measuring the actual forces present
at the electrode and entering the measured values in the timer.
The timer will use this data to automatically adjust the
"Conversion-Factor" and "Zero adjust" parameters to the
necessary settings.
Conditions:
1. Separate programs whose sequence is not inhibited for

calibrating the electrodes (guns). The respective calibration
program must have been allocated to the electrode to be
scaled.
2. Use the same reference force measuring device (e.g.,
pressure pickup) for all systems to be calibrated.
3. The force working range of the welding system must be known
(which kN value is normally used for welding).
4. The electrode gun and the robot, if any, are in the position
intended for calibration.
Procedure:
1. In the BOS 6000 main window, select the Force calibration

command button in the “Programming” menu, “Electrode” tab.
The “Calibration” window will be displayed.
and Controls
How to …
Possibility of damaging guns!

In the course of the calibration process, you
should only use programmed values by which
CAUTION the gun is not mechanically overloaded!
If you do not know the behavior of the
electrode gun, you should initially use low
values when starting the calibration process,
and increase these values in further
calibration cycles until you have reached the
working force.
2. Enter the amount of the desired force-influencing variable (in %

of the hardware-related, maximum possible value of the
influencing variable) into the two % fields for the 2 test
measurements. The upper input value corresponds to the
force-influencing variable that causes the lowest force used
for welding.
The lower input value corresponds to the force-influencing
variable that causes the highest force used for welding.
The two values should differ by at least 20%.
By activating check box “Store values”, you can cause the
timer to present the values input without the need to re-enter
them when force calibration is repeated for the relevant
electrode.
3. Select a suitable calibration program.
Check whether the appropriate electrode number is displayed!
4. Move the reference force measuring device to the proper
position.
Electrode gun closes!

Therefore, please make sure that there is no
unauthorized person in the hazard zone.
DANGER

The next window of the force calibration function will be shown.
Now, the timer will output the previously entered value of the
(lower) influencing variable.
and Controls
How to …
6. Read the force present at the reference force measuring

device and enter the value into the upper “Force” field.
Now, the timer will output the previously entered value of the
(higher) influencing variable.
8. Read the force present at the reference force measuring
device and enter the value into the lower field “Force”.
The timer will use this data to automatically adjust the
"Conversion-Factor" and "Zero adjust" parameters to the
necessary settings, and calibration has been completed.
Note: If the timer proposes to automatically raise parameter

"Maximum pressure", you should answer "No".
Otherwise, a force parameterized there will be replaced
with the force that can be theoretically achieved using
the maximum force-influencing variable and the new,
calculated force characteristic.
and Controls
How to …
and Controls
Fault messages
Fault messages
Please note:
• Due to the large number of different applications, the Help

function can only provide some general clues to possible
causes. Detailed instructions for troubleshooting cannot be
given in all cases for this reason.
• Some messages are type-specific and not available for all timer
types!
• In some cases, the messages can be configured as a fault or a
warning "Setup”, tab “Fault Setup".
• Any active faults will be included in the "Error Table".
• For fault reset, refer to sect. “How to …”, paragraph "Reset
faults".
• For a description of how to add your own fault information, refer
to sect. “How to …”, paragraph "Add fault information".
Stop / No 24V
Possible cause Remedy

No +24V at the stop circuit input Close stop contact
Check +24VDC supply at the stop
circuit terminals
Stop circuit closed

OpenStop circuit was closed again None.
This message only appears in the
log
and Controls
Fault messages
Weld without Command

(Transformer Primary Current without SCR Firing Signal)
Voltage is supplied to the primary
side of the welding transformer
outside the weld time:
Thyristors defective Replace PST or thyristor unit
Welding transformer improperly Check connection
connected
Effects of other welding currents Check: is another timer welding on
the same part at the same time?
Note: This message is not output by the PSI models.
Control stop
Function that is influenced by the Customer-specific application
“Ready” input
Power-Unit not ready

(SCR or PSU Power Supply Fault)
Message of the power unit Check cooling
temperature contact
Check duty cycle/load
Check cables/connectors
For PSU: correct this unit’s fault
message
Note: After a re-installation, you should verify whether the

Thyristor temperature sensor parameter matches the
temperature contact of the power unit.
and Controls
Fault messages
External Over-Temperature
(External Device Over Temperature Fault)
Message of an external temperature
input:
Cable between timer and Check cable/connector
temperature sensor broken
Insufficient cooling Check cooling circuit
Excessive welding %I/duty cycle Reduce welding %I, shorter duty
cycle
Cooling temperature too high

(Over Temperature Fault - Power Unit Heatsink)
Heat sink is too hot (more than Check cooling
70°C) or
Ambient temperature is too high
(more than 70°C):
Check duty cycle/load
Air cooler: If the heat sink
temperature reaches 55°C or more,
the external fan is switched on via
X4/13 (+24V) and X4/14 (GND).
Check the output and the fan by
directly applying 24V to the fan
Check temperature inside switch
cabinet and/or cabinet cooling
Transformer temp too high

(Transformer Over Temperature Fault)
The temperature of the welding Check cooling
transformer is controlled by
thermostatic switches:
Cable between temperature sensor Check cable/connector
and timer broken
Insufficient transformer cooling Check cooling circuit of the welding
transformer
Excessive welding %I/duty cycle Reduce welding %I
and Controls
Fault messages
Battery-Low
The voltage of the timer’s buffer Replace battery
battery has dropped
Note: All data of a weld timer may be deleted if the battery

voltage is low and there is no supply voltage!
Memory deleted
All data has been deleted from this
timer:
New firmware was copied to timer: Copy data
Battery is low or defective Replace battery and copy data
Note: If the error occurs repeatedly, replace timer!
Data download started

(Data Restore to Timer In Process)
Backup data is transmitted from If the Restore/Download function
programming terminal to timer invoked from the GUI is still active,
wait until data transmission is
finished
If the Restore/Download function
invoked from the GUI has been
aborted, cycle power to the timer.
No schedule programmed
Wrong program selected Check program selection
Invalid spot selection Check spot selection
Invalid parameters in selected Check value range of the following
program parameters: power unit number,
electrode number, program number
and Controls
Fault messages
Hardware Fault
(Hardware Fault - Replace Timer / Inverter)
Defective module Replace module or timer
A module is detected during power- Replace module
up which does not match the
firmware:
A firmware was copied to the timer Copy proper firmware to the timer
which is not permitted for the
existing hardware
Additional code for hardware fault:

Bit code: Decimal: Module:
0x0001 1 Damaged flash
0x0002 2 Damaged RAM
0x0004 4 Analog module
0x0008 8 Additional analog module
0x0010 16 Power supply module
0x0020 32 I/O module
0x0040 64 Additional I/O module
0x0080 128 Field bus module missing (missing module
is not a fault!)
0x0100 256 Additional_module_I
0x0200 512 Additional_module_II
If several hardware errors are detected, a group message will be

output.
The following code has the following meaning, e.g.
Fault message 132
Field bus module 128
Analog adapter fault 4
= 132
Note: In the event of a hardware fault, the timer can not be

reset to Ready state by a "Fault reset".
and Controls
Fault messages
I/O-Bus Fault
(Serial I/O Bus Fault)
The serial I/O module has signaled Replace I/O module or timer
a bus error to the timer
Half-Cycle Monitoring
(Transformer Half cycling Fault)
During the welding process, two
subsequent half-cycles with the
same polarity were detected:
Synchronization voltage too low Check synchronization voltage
Thyristor unit defective Check thyristor unit and fuses
Current sensor or connection cable Check current sensor and

defective connection cable
Circuit Breaker Off

(Main Breaker Tripped by Timer)
The timer has energized the main
switch relay: The connected main
circuit breaker tripped
Sync / Power Fault

(Loss of Synchronization Voltage to Timer)
Welding power was switched off, or Switch welding power on, and check
is not in the range of 50 or 60 Hz +- response
5%
Disturbances in welding power Reset fault, check all mains phases
system
Fuse in welding system tripped Check synchronization voltage
and Controls
Fault messages
Fuse in power unit defective Check all fuses of the power unit, or
replace power unit
Synchronization OK
Welding power has been None: This message only appears in
reconnected. the log
Also refer to Sync / Power Fault
Start Inhibited
(Weld scheduled stopped)
The schedule of the selected Enable program at the programming
program was inhibited: terminal (“Start-Inhibit” parameter)
Check program selection, select
proper program
Sequence externally cancelled

The signal at the “Prop. valve Check input, connectors, cable, and
active” input was reset to 0 during proportionate valve
the weld schedule
Program Parity Fault

(Parity error)
The parity bit does not match the Check parity setting at the
selected program: programming terminal (“Parity”
parameter)
Check program selection, select
proper program
and Controls
Fault messages
24V off/to low

The 24V supply for the internal logic
is too low (approx. 19V):
24V supply is too low Check the 24V supply
Connection fault in the area of the Check connections
24V supply
24V supply switched off by
operating process
Note: This message is only output by PSI / PST variants!
Supply Voltage Fault

The 24VDC supply for the internal Check the 24V supply
logic was missing or switched off:
Check connections
Timer switched on
24V supply was reconnected
Control reset was triggered from the
GUI
Power voltage to high

(DC Bus voltage too high - AC input voltage too high)
An excessively high mains voltage
was measured at the DC link level.
The mains voltage was above
approx. 680V for units PSI
6xxx.xxxL1 or above approx. 870V
for the high-voltage version PSI
6xxx.xxxL2:
Mains overvoltage or mains Check mains power supply
transient
and Controls
Fault messages
Note: This message is only output by PSI variants!
Power voltage off/to low

(DC Bus voltage too low - AC input voltage low or off)
The mains voltage is too low or no Check mains power supply
longer available. The mains voltage
is monitored at the DC link level. For
a mains voltage of 380V or more,
the next 10 mains cycles are
measured. If the voltage values
decrease steadily (indicating a
steady discharge of the DC link
electrolyte capacitor), this message
is generated in order to avoid
welding without mains power. A
phase loss will not be detected. The
DC link capacitors store sufficient
energy to bridge the missing phase.
Power voltage off/to low receipt

Acknowledgement of the previous None: This message only appears in
message Power voltage off/to low the log
No Weld external
External weld signal was Check signal at the Weld external
deactivated input
and Controls
Fault messages
Weld external
External weld signal was activated None: This message only appears in
the log
No Weld internal
Weld signal switched off at Check setting at the programming
programming terminal terminal (“Weld/No weld (Global)”
parameter)
Weld internal
Internal weld signal activated None: This message only appears in
the log
With stroke, with weld

Schedule with ignition and with Input “Schedule with stroke, with
solenoid valve (gun closes) weld” is high
No stroke, no weld
Schedule without ignition and Input signal “Schedule with stroke,
without solenoid valve (gun does with weld” is low
not close)
%I too large/Force/Pressure too high/PHA is too high

The programmed %I or pressure
value is too high
and Controls
Fault messages
%I/pressure increase in stepping is Check inputs in %I/pressure stepper

too high (Stepper)
%I limitation /Pressure limit too low Check parameters of the
corresponding limits
Base %I or Base pressure value) Check base %I(programmed current,
too high %I) or base pressure
%I/pressure correction too high Check Correction values
Extend stepping request

The specified electrode has reached
the Extend Electrode Life Near End
of Stepper/Waiting condition:
The counts have exceeded the Replace electrode
programmed end of stepper
Extended electrode life Near End of Stepper

The specified electrode was set to
Extend Electrode Life Near End of
Stepper/Waiting condition:
The counts may exceed the Replace electrode soon, because the
programmed end of stepper by a programmed end of stepper may be
specified number of spots exceeded by a specified number of
spots only
End of stepper
the End of stepper condition
The count value has reached the Replace electrode

programmed wear until end of
stepper
Note: Continued welding may or may not be possible,

depending on the programming of parameter “Stop at
end of stepper”.
and Controls
Fault messages
End of stepper
The weld timer was stopped by End Replace electrode
of stepper
Electrode changed
The electrode change was None: This message only appears in
acknowledged externally the log
Stepper exceed
An external request was made to Replace electrode
exceed the end of stepper
Prewarning reached
the Prewarning condition:
The count value has reached the The electrode will soon reach the
programmed wear until Prewarning End of stepper condition
Dress-Request reached
the Dress-Request condition
The count value has reached the Dress electrode
programmed wear until Dress-
Request
and Controls
Fault messages
Dressing necessary
The specified electrode has
exceeded the Dress-Request
condition
The count value has exceeded the Dress or replace electrode
programmed wear until dress
request
Note: Continued welding may or may not be possible,

depending on the programming of parameter “Stop at
end of stepper”.
Max. number of spots welded before dressing

The weld timer was stopped by Dress electrode
Dressing requirement
Electrode dressed
(Stepper tip dressed)
The electrode tip dress was None: This message only appears in
acknowledged externally the log
Tipdress prewarning
The specified electrode has reached The cutter blade should be replaced
the Tipdress Prewarning condition soon
Electrode life tipdress

The specified electrode has reached Replace cutter blade
the Electrode Life Tipdress
and Controls
Fault messages
condition:
Cutter blade changed

The cutter blade counter was reset None: This message only appears in
the log
Cutter1: Cutter not running

Cyclic signal at “rpm counter 1” Check connectors and cables
input missing
rpm sensor failure Check cutter, cutter motor
Cutter jammed
Cutter1: Dressing process aborted

Inputs “Start cutter 1” or “Close gun Check input signals
1” became low during dressing
operation
Cutter1: Max. mill duration exceeded

The programmed rpm was not Check connectors and cables
reached during max. duty cycle Check cutter, cutter motor
Check programmed duty cycle
Cutter1: Temperature fault

The temperature contact was Check “Cutter temp. contact” input,
opened during dressing connectors and cables
Check cutter motor temperature.
and Controls
Fault messages
Cutter1: Motor protection trip

The motor protection contact was Check “Motor protection trip” input,
Check cutter motor
Cutter1: Emergency-Stop
The stop circuit of the weld timer Check weld timer stop circuit
was opened during dressing Check connectors and cables
Cutter2: Cutter not running

Cyclic signal at “rpm counter 2” Check connectors and cables
input missing
rpm sensor failure Check cutter, cutter motor
Cutter jammed
Cutter2: Dressing process aborted

Inputs “Start cutter 2” or “Close gun Check input signals
2” became low during dressing
operation
Cutter2: Max. mill duration exceeded

The programmed rpm was not Check connectors and cables
reached during max. duty cycle Check cutter, cutter motor
Check programmed duty cycle
and Controls
Fault messages
Cutter2: Temperature fault

The temperature contact was Check “Cutter temp. contact” input,
Check cutter motor temperature.
Cutter2: Motor protection trip

The motor protection contact was Check “Motor protection trip” input,
Check cutter motor
Cutter2: Emergency-Stop
The stop circuit of the weld timer Check weld timer stop circuit
was opened during dressing Check connectors and cables
Phase Angle prewarning reached

The limit set for %I prewarning was Check the phase value setting in “%I
reached/exceeded Prewarning” parameter.
Also refer to Maximum Phase Angle Reached
Maximum Phase Angle Reached

The maximum phase angle setting Check secondary circuit/cables for
was reached wear
Check the phase value setting in “%I
Limitation” parameter.
Mains voltage dip Repeat spot weld
Welding transformer/power unit Use higher next transformer tap
rating too low
and Controls
Fault messages
Note: The current phase value can be viewed under “Middle

PHA”.
Note: The message will be active until the electrode has been
replaced!
Note: Excessively high values achieved by % correction and %

stepping can also trigger this message.
Secondary monitoring circuit is open

(Current measurement circuit open)
Broken sensor cable Replace cable
Detached plug-in connections Check plug-in connections
Incorrect connector assignment Check connector assignment
Defective sensor Replace sensor
Secondary monitoring circuit is shorted

Squeezed-in sensor cable Replace cable
Incorrect connector assignment Check connector assignment
Defective sensor Replace sensor
Termination of Weld / no current

No current was measured at the Check closing mechanisms (robot,
beginning of the weld for 40 ms (the machine)
schedule is aborted)
Check position and pressure of
electrodes
Clean sheets
Check conductivity
Check connector assignment
Replace sensor
and Controls
Fault messages
No voltage 1.HW
No primary voltage was measured Check KUR connectors and cables
in KUR mode
Primary Voltage Measuring Fault - KUR Mode

A primary voltage of more than Check turns ratio of primary voltage
200% or less than 50% of the transformer.
programmed voltage was measured
during KUR mode.
Check the programmed mains
voltage
Reweld By Timer Active

The spot weld was repeated Refer to %I fault signaled
Inhibit Monitoring Mode Active

Schedule for which monitoring Check programming of Inhibit
stopped has been activated Monitoring Mode/Monitoring stopped
(P) and Inhibit Monitoring
Mode/Monitoring stopped (T).
No Weld
Weld signal was switched off during
the schedule
and Controls
Fault messages
Without regulation, without monitoring

Schedule for which monitoring Check programming of Inhibit
stopped and control stopped have Monitoring Mode/Monitoring stopped
been activated (P) and Inhibit Monitoring
Mode/Monitoring stopped (T), control
stopped (P) and control stopped (T).
No current …
Electrodes not closed Check closing mechanisms (robot,
machine)
No electrical contact at the point to Check position and pressure of
be welded electrodes
Contamination of sheets Clean sheets
Sealant used Check conductivity
Low Current …
Current measured is below
tolerance band:
Tolerance band too small Check tolerance band
Programmed value too high, e.g., Check programmed value, stepper
because of stepping values
Contamination of electrodes Repeat weld, clean electrodes
Contamination of sheets Repeat weld, clean sheets
Bad electrode positioning Improve positioning
Welding transformer underrating Change over or replace welding
transformer
Over Current …
Current measured exceeds
tolerance band:
Programmed value step-change to Select broader tolerance band,
lower %I values reduce programmed value step-
changes
Handling of different sheet Use several programs with different
thicknesses or sheet layers parameters
and Controls
Fault messages
Change in electrode pressure Check electrode force system

conditions
Change in resistance conditions Check secondary circuit
(impedance) in secondary circuit,
e.g., shunt circuit
Mains voltage fluctuations Select broader tolerance band,
ensure constant conditions, use NBS
Low Current-series of welds-…

Current measured is below the
limited tolerance band after n
repetitions:
Programmed value step-change to Select broader tolerance band,
higher %I values reduce programmed value step-
changes
Handling of different sheet Use several programs with different
thicknesses or sheet layers parameters
Change in electrode pressure Check electrode force system
conditions
Change in resistance conditions in Ensure constant conditions
secondary circuit
Mains voltage fluctuations Select broader tolerance band,
ensure constant conditions, use NBS
Current measurement range exceeded …

The current measured is above the Select more appropriate measuring
programmed measuring range range
Check current for excessive
fluctuations
Weld time too short …

The permitted time tolerance is not Check setting in Time Monitoring
reached
External termination of weld/No Check signal
current Fault signal
Also refer to Weld time too long

and Controls
Fault messages
Weld time too long …

The permitted time tolerance is Check the "Reference time" and
exceeded "Tolerance" parameters
Note: Changing a weld time presupposes a modification of the

related reference time if time monitoring is active.
Diode Over Current

(Transformer Diode Over Current Fault)
The computational emulation of the
welding diode temperature has
determined a junction temperature
of more than 150°C. This value
corresponds to the power limit
(mainly caused by alternating loads)
of the welding diode, taking into
account a safety margin with
respect to the stationary limit:
Excessive welding %I Reduce welding %I or use longer
welding breaks in order to reduce the
duty cycle
Duty cycle too long Switch off diode monitoring (Loss of
guaranty/warranty!)
Diode defect
(Transformer Diode Defective)
A defective welding diode is
detected in “Measurement:
Secondary” mode due to the
saturation current peaks caused by
the welding transformer that has
been shorted by the defective diode:
and Controls
Fault messages
Welding diode defective Replace transformer (PSG)
Overcurrent or Earth-fault
(Transformer Diode Defective)
The inverter output current is in
excess of 110% of the maximum
current, or there is a major earth
leakage current (no personal
protection):
The transformer supply line or the Replace transformer supply line or
welding transformer has a short- welding transformer
circuit or an earth fault
Output current too high In PHA mode, the current may
become too high. Reduce %I or work
in KSR mode
For weld times above 1s, currents at Change over to “Measurement:
the power limit and ”Measurement: Primary” mode for currents with a
Secondary” mode, the integrator for duration of more than 1s
current measurement may drift off,
pretending a lower actual current to
the inverter, which results in an
overcurrent response due to the
regulation mode
Max. primary current reached

Primary current is cut off by internal Check transformer settings
primary current limit at a value
higher than 25% of the half-cycle
Check: Has the maximum capability
of the system been reached?
Check: Does the system produce
current overshoots ?
and Controls
Fault messages
Driver-Fault
(Transistor Fault or External Short Circuit Fault)
A fault was detected in the IGBT
power transistor control which
indicates a short-circuit or overload.
Defective power transistor inside Replace timer
inverter, or external short-circuit, if
the fault can only be reset by cycling
power to the unit.
if the fault can simply be reset,
please call technical service
No weld contactor enable

Weld contactor enable input signal Check input and wiring
missing
Isolation contactor feedback fault

The feedback signal from the Check input, wiring, and contactor
welding circuit contactor is missing
No Weld Enable or Weld Pressure Input Gun 1

After the Start signal, the feedback Check input, cables and electrode
at input “Weld enable, Pressure gun
contact 1” is missing
No Weld Enable or Weld Pressure Input Gun 2

After the Start signal, the feedback Check input, cables and electrode
at input “Weld enable, Pressure gun
contact 2” is missing
and Controls
Fault messages
No Water Flow Gun 1

After the Start signal, the signal at Check connector, cables and cooling
input “Water flow gun 1” is missing water
No Water Flow Gun 2

After the Start signal, the signal at Check connector, cables and cooling
input “Water flow gun 2” is missing water
Weld Contactor Gun 1 Open

After the Start signal, the main Check connector, cables and main
switch signal at input “Weld switch
contactor 1 closed” is missing
Weld Contactor Gun 2 Open

After the Start signal, the main Check connector, cables and main
switch signal at input “Weld switch
contactor 2 closed” is missing
Weld Contactor Gun 1 Did Not Open

The timer has switched main switch Check output, connectors, cables
1 off via output “Main switch 1”, but and main switch
the signal at input “Weld contactor 1
closed” is still high after 100 ms
Weld Contactor Gun 2 Did Not Open

The timer has switched main switch Check output, connectors, cables
and Controls
Fault messages
2 off via output “Main switch 2”, but and main switch
the signal at input “Weld contactor 2
closed” is still high after 100 ms
Monitor contact open

At the 24V pressure input, the Check connectors, cables and
feedback signal is missing after a pressure/gun switch
waiting time of 5 seconds, which
signals a closed gun or attainment
of the programmed force to the
timer
Mains Power Balance Monitoring Activated

The “ELCB” input signals a fault Check connectors, cables and elcb
Mains Power Balance Monitoring Ok

The “ELCB” input signal is OK None: This message only appears in
the log
Auxiliary contactor monitor

The “Auxiliary contactor monitoring”
input drops from 24V to 0V and the
stop circuit does not follow within 5
seconds
Check auxiliary contactor and time-
delay element
Check inputs
and Controls
Fault messages
Fault-Reset
ALL faults have been reset None: This message only appears in
the log
Welding-Fault Reset
Welding faults have been reset None: This message only appears in
the log
Slave error
Display in master-slave operation Check slave
that the slave inverter is not ready
Read error from slave
Reset error in slave
Current Measurement Range Exceeded

For PSI with third-party control: The Set proper measuring range
current measured is outside the
measuring range
Check: Has the maximum capability
of the system been reached?
Scaling: Communication error

Error in data telegram received from Switch weld current meter on, select
the external weld current meter proper operating mode
Use proper weld current meter
Check display on weld current meter:
are values plausible?
and Controls
Fault messages
Scaling: no valid measuring value received

The weld current meter signals an Repeat scaling
incorrect measurement in the data
telegram transmitted
Scaling: no measuring value received

No signal was received during Connect cable to RS232/V24 port of
communication with the external the timer and the weld current meter
weld current meter.
Use suitable cable. Also refer to V24
in the terminal diagram of the timer
Switch weld current meter on
Install current measuring belt
Check trigger setting on weld current
meter
During pressure calibration, no Check connection and cable for force
voltage was measured by the force sensor: 24V supply and reset signal
measuring outlet: available?
Use force sensor with 1 kN / Volt
Check programmed force values
Check pressure control valve
Check pressure build-up at the gun
Scaling: protocol fault

A fault was detected when changing First connect weld current meter,
from the Bosch protocol to the V24 then reset fault message and repeat
protocol of the reference current scaling.
meter.
Scaling: wrong mode

“Secondary” measuring mode was Set to “primary” measurement
set for current calibration.
Calibration is aborted.
and Controls
Fault messages
Scaling: Sequence aborted

A fault has occurred during a Read the fault from the Error table
program run by which the schedule and correct it.
was aborted (e.g. Emergency-Stop). Fault Reset and repeat calibration
Furthermore, a welding process
fault was signaled with the
additional code “Calibration
aborted”.
Scaling: current out of range

The primary or secondary current Check the sensor on the secondary
measured deviates from the side and its connection
programmed value by more than
30%.
Check transformer selection
Check toroid sensitivity
Scaling: Diff. primary / secondary current too large

During current monitoring, the
difference between the primary
current and the secondary current is
outside the programmed tolerance
band:
Secondary circuit shunted Check secondary circuit
Secondary sensor and connection Repeat scaling
have been changed since scaling
was performed for the last time
Changes in secondary circuit, e.g., Repeat scaling
gun replaced without scaling
Toroid sensitivity or transformer Check welding transformer selection
selection have been changed since and current sensor responsiveness,
last scaling repeat scaling if necessary
The values for fade-out time, trail Check fade-out time, trail current and
current or current measuring range current measuring range, repeat
have been changed scaling
and Controls
Fault messages
Scaling: result invalid

Force scaling and subsequent Check programmed force values
processing of the force values
measured yielded inconsistent
results:
No rising force characteristic can be
calculated between the first and the
second force measuring point
Check connection and cable for force
sensor: 24V supply and reset signal
available?
Force monitoring: time too long

The time for building up force is Check the values for 1.SQZ/PreSqz ,
longer than the pre-squeeze time SQZ and ”Force monitoring before
plus squeeze time less “force end of squeeze time”
monitoring before end of squeeze
time”. That means, the electrode
gun is too slow in building up the
force.
Check programmed pressure value
Worn electrode gun Check electrode gun
Force monitoring: time too short

The time required for building up Check the values for 1.SQZ/PreSqz,
force is shorter than the pre- SQZ and ”Force monitoring before
squeeze time. That means, the end of squeeze time”
electrode gun is too quick in building
up the force.
Check programmed pressure value
Check electrode gun
Force monitoring: Force/Pressure too high

The calculated final force value is Check programmed force value and
above the tolerance band for the tolerance band
and Controls
Fault messages
programmed force value.

Repeat scaling
Check force sensor
Force monitoring: Force/Pressure too low

The calculated final force value is Check programmed force value and
below the tolerance band for the tolerance band
programmed force value.
Repeat scaling
Check force sensor
Replace electrode gun
Error US measurement
Fault in ultrasonic measurement Refer to additional fault message
Note: This fault message signals a fault in the ultrasonic

measurement and occurs together with an additional
fault message. For remedial action, refer to additional
fault message.
Error US control loop

Fault in ultrasonic control: the timer Refer to additional fault message
changed the regulation mode from
USR to KSR during the weld

fault message.
and Controls
Fault messages
PSQ Sequence Cancelled

Ultrasonic measurement/control not Refer to additional fault message
possible

fault message.
USP not calculated

An ultrasonic signal was measured, Check for welding splashes: check
but the ultrasonic point of the pressure, electrodes, and fit
transmission curve cannot be
calculated
USP too high

The transmission curve indicates Checked programmed limit value
too low temperature for weld “Max. USP”
Check weld
USP too low

The transmission curve indicates Checked programmed limit value
too high temperature for weld “Min. USP”
Check weld
spot repetition with US

The spot weld was automatically Check programmable parameter
repeated “spot repetition”
and Controls
Fault messages
The spot weld was automatically Use “Fault Reset with WC”.
repeated after Fault Reset with
Reweld
Note: In this case, it is not possible to record a meaningful

ultrasonic transmission curve. Even if the welding
process fault “Spot repetition” was defined as a warning,
no other faults specific for ultrasonic mode will be output.
Ö Check spot welds!
PSQ hardware fault

Initialization fault when switching the Check firmware version of the US
timer on controller board of the timer
Hardware fault of US controller Cycle power or Reset timer
board
PSQ internal communication error

Communication fault between the Check firmware version of the US
timer and the US controller board controller board of the timer
Cycle power or Reset timer
PSQ temperature too high

Temperature on US regulator board Let unit cool down
is higher than 60°C
USP temperature too high

Temperature inside front-end above Let unit cool down
70°C
and Controls
Fault messages
USP hardware fault

Hardware fault in front-end Replace front-end.
PSQ watchdog fault

Timer detected that US controller Reset Fault
board no longer responds
Cycle power or Reset timer
PSQ not available

US controller board has not yet Extend spot interval to approx. 1
completed the previous schedule second
when next schedule is started
PSQ sequence error

In the beginning of schedule: Front- Check front-end and CAN
end did not perform measuring loop connection
test.
During schedule: no values from
front-end
USP communication error

Communication between the Check voltage supply to front-end
ultrasonic controller board and the and links with front-end
front-end is disturbed during the
schedule
and Controls
Fault messages
US measuring loop fault

The front-end does not receive an Close electrode gun
ultrasonic signal, or a very low
signal, during the measuring loop
test
Electrode caps are not upright
Bad fit of sheet
Check sensors: Transmitter and
receiver
Defective front-end
Check US parameters: gain factor,
sensor spacing, direction of
polarization
Note: Use the “Test measuring channel” function for this

purpose.
PSQ memory deleted

New US controller board installed in Re-program parameters or restore
the timer. parameters with Download function
Different memory structure after
firmware update
PSQ ok
No faults in the ultrasonic system None: This message only appears in
(PSQ) the log
and Controls
Glossary
Glossary
AC
Alternating Current.
Base %I
Programmed current in kA or the phase value in %I for a weld time.
It is defined as 100% and serves as a basis for calculating the %I correction and
%I stepping.
CAN
Controller Area Network.
Data link between the ultrasonic controller board and the front-end
Check box
Square object used to activate/deactivate a function. A group of check boxes is
used for an “m from n” selection.
Configuration tool
Separate program for the administrator that may be used to adjust many features
of BOS 6000 to your specific requirements.
Count
Refer to Counts.
Count factor
Program-specific value that can be configured in “Programming: Stepper”
window.
When a welding program is executed, the counts are incremented by the value of
the count factor.
and Controls
Glossary
Counts
Electrode-specific counter. Indicates the current Counts value of an electrode.
In contrast to the spot counter, the counts are not incremented by the fixed value
of 1 for each spot welded, but rather by an adjustable, program-specific count
factor.In this way, the electrode count can be exactly recorded even when
welding different sheet thicknesses or materials.
CT
Cool time.
DC
Direct Current.
dimmed
The relevant object or a part of it is shown in gray color. In this condition, the
relevant function is blocked or cannot be activated for reasons immanent to the
system.
double click
Move mouse pointer to the desired element, shortly press the left mouse button
twice and release it immediately afterwards.
drag
Move mouse pointer to the desired element, press and hold down the left mouse
button and move the mouse.
The mouse pointer drags the element along as it moves.
Drag the element to the desired location and release the left mouse button.
Dressing counter
Electrode-specific counter. Indicates how often the electrode has already been
dressed (first tip dress not included).
DST
Down-slope time.
ED
Duty cycle.
and Controls
Glossary
First tip dress

Is used to obtain a defined contact area when new electrodes have been
installed.
Front-end
Electronic equipment used in connection with ultrasonic welding.
HLD
Hold time.
HTML
HyperText Markup Language.
%I
Phase value (%I). Programmed %I for PHA mode.
Icon
Small symbols shown by the system instead of windows or entire applications.
In connection with the safety instructions, the icons draw the reader’s attention to
specially important safety issues.
I/O
Input/Output.
IP
Internet Protocol.
IP address
Address of a timer that communicates with BOS 6000 through an Ethernet
network. The address consists of four numbers between 0 and 255 each
separated by dots. Also refer to our documentation on “Programming field buses”,
no. 1070 087005.
kA
kilo-Amps.
and Controls
Glossary
Keyboard control
Operating the BOS 6000 via the keyboard.
Refer to shortcuts.
kN
kilo-Newton.
KSR
KonstantStromRegelung (constant-current regulation).
Drives the power unit so as to ensure that the programmed current is reached in
the secondary circuit.
KUR
Constant-voltage regulation.
Link
Blue, underlined text. A left-click on this text will open a new window or invoke a
function.
List box
List containing options for selection.
Menu
List containing a number of commands/functions for selection.
Menu line
Line containing a number of commands/functions for selection.
Mixed mode
In contrast to Standard mode, the PreWld, WLD, PostWeld are treated
separately for the purpose of monitoring and regulation.
mouse click
Move mouse pointer to the desired element, shortly press the left (unless
specified otherwise) mouse button once and release it immediately afterwards.
and Controls
Glossary
ms
Millisecond.
mV
Millivolts.
NBS
Mains load limitation control.
Function designed to prevent an overload of the welding network caused by
simultaneous welding of several timers.
OFF
Off time.
PHA
Non-regulated timer mode as compared to KSR and KUR.
The welding %I (programmable as %I) is determined by the phase value (of
thyristor power units) or the pulse width (of medium-frequency inverters).
Popup menu
Menu that appears after a right click at the mouse pointer position.
PSI
Weld timer with integrated medium-frequency inverter.
PSQ
Ultrasonic quality assurance system.
PST
Weld timer with integrated thyristor unit.
PSU
Separate medium-frequency inverter unit (without integrated control logic).
and Controls
Glossary
Radio button
Round object used to activate/deactivate a function. A group of radio buttons is
used for a “1 from n” selection.
Scrollbar
A bar at the right and/or bottom margin of an object (e.g., a window or a list box).
By moving it, you can shift the contents of the object (e.g., in order to display
more information).
Shortcuts
Many commands/functions can be invoked by pressing a key or by pressing
several keys simultaneously.
In order to trigger a key combination, you first have to press and hold down one of
the keys Ctrl, Alt or Shift, then press the key indicated after “+”, and finally
release both keys.
Important shortcuts:
Alt+<x> To select menu items via the keyboard. <x>:
Wildcard character for the character underlined
in the relevant menu text.
Alt+Esc Brings the next currently active application into
the foreground.
Alt+F4 Closes the active window
Alt+Space bar Opens the system menu
Alt+Cursor down Opens/closes a list box selected.
Alt+Cursor up
Alt+Tab Selects a currently active application and
brings it into the foreground.
Print Copies the current screen display to the
clipboard
Enter key Executes a command.
End In text/number field: Places the cursor behind
the last character.
In list box: Selects the last entry in the list.
F1 Calls up the Help function
F10 Selects the first item in the menu bar.
Space bar Selects or deselects an element from within the
checkbox
Cursor down Selects an element from a list box, or
Cursor up increments/decrements the numerical value
displayed.
Home In text/number field: Places the cursor in front
of the first character.
In list box: Selects the first entry in the list.
and Controls
Glossary
Ctrl+C Copies selected characters.

Ctrl+V Pastes the last string copied to the clipboard
with Ctrl+X or Ctrl+C to the left of the cursor.
Ctrl+X Deletes selected characters.
Tab Selects the next object/input field.
Shift+End Selects all characters to the right of the cursor
in a text/numerical field.
Shift+Cursor down Selects several consecutive elements from
Shift+Cursor down within a list of choices
Shift+Home Selects all characters to the left of the cursor in
a text/numerical field.
Shift+Tab Selects the previous object/input field.
Slope
Linear %I change in the form of a current slope.
Spot counter
Electrode-specific counter. Indicates the number of spots already welded by the
respective electrode.
In contrast to the counts, the spot counter is incremented by the fixed value of 1
for each spot welded.
The spot counter is only displayed below “spots” in the “Detail-Info” window.
SQZ
Squeeze time.
Standard mode
In contrast to Mixed mode, the PreWld, WLD, PostWeld are treated jointly for the
purpose of monitoring and regulation.
Status line
Is located at the lower margin of the BOS main window and contains the following
information:
Name of the parameter that can be modified in the current input field (containing
the cursor) and its applicable input limits (important for dynamic limit values, e.g.,
due to %I stepping).
Timer communication status:
green: online, blue: offline, red: fault
Date, time and key conditions.
and Controls
Glossary
UST
Up-slope time.
WLD
Weld time. Time in which the power unit is activated. Three different weld times
can be set in the timer:
PreWld Warming-up time. For heating up the parts to be welded.
WLD: Main welding time.
PostWeld: Post-heating weld time. Prevents parts from cooling down too quickly
The duration and %I of all 3 weld times can be configured separately. The PreWld
and PostWeld are optional.
WT
Weld timer.
Other names include, e.g., timer, module, controller module, etc.
Title bar
The horizontal bar on the upper edge of a window or dialog that shows the title of
the window or dialog and the command buttons for maximizing, minimizing or
closing the window, if available.
Is dimmed, for example, for those windows which are not active.
Tool tip
When the mouse pointer remains motionless on an input field/object for a
moment, a relevant explanation appears in a small window.
ÜK
Monitoring contact
US
Ultrasonic.
USR
Ultrasonic control
Waiting/Extended electrode life

Counts range between the end of stepper and the point where no schedule can
be performed any more with this timer.
and Controls
Glossary
WC
Weld complete contact.
Signal that is output by the weld timer after a welding schedule. It normally
causes the robot to move on to the next spot weld.
Whether weld complete is output for faultless welds only or independent of the
welding result can be selected in parameter “WC with error".
and Controls
Glossary
and Controls
Index
Addition (Diagnosis, Timer-Information, Last

Index Weld) 107
Addition (Diagnosis, Timer-Information, Timer)
106
Address mode 115
% After each dressing 65
Autobackup 138
%I after last dressing 69
Auxiliary contactor monitor 216
%I at the end of 1st stepper phase 66
Average/Middle PHA (Programming, Stepper)
%I Correction (Elec.) 119
72
%I Correction (Prg.) 119
%I for new electrode 64
%I Limitation 82 B
%I Prewarning 82 Backup 137
%I too large/Force/Pressure too high/PHA is Base pressure value (Correction, Correction)
too high 200 120
Base pressure value (Programming, Schedule)
< 47
Base pressure value (Programming, Seq. Pg.2)
<LABEL ID=207 REF=YES
56
TOPIC=YES>Para.-Data Import/Export
Basics 23
(Parameter-Restore)</LABEL> 145
Battery-Low 194
Baudrate 115
> Book symbols 12
>%I Step.-Value 64 BOSServ.exe 31
>Monitor Step.-Value 64
>Press. Step.-Value 64 C
Change parameters and transfer to timer 169
1 Change the communication data of logged-in
1. Halfcycle after Pause-Time 45 timers 155
1. Halfcycle limit 82 Choose parity 77
1.CT 48 Circuit Breaker Off 196
Code (Diagnosis, Timer-Information) 106
2 Compare 133
Compare spot reference 172
2. Toroid sensitivity 83 Compare Timer Data 160
2.CT 50 Conditional tolerance band 54
24V off/to low 198 Confirm electrode change 174
Connection set-up 39
3 Contents (structure) 12
Control stop 192
3.CT 50
Control stopped 75
Conversion-Factor 92
A Cooling temperature too high 193
Activating Help 10 Copy 141
Active reference current (Programming, Copy the contents of a numerical input field 165
schedule) 55 Copy Timer Data 157
Active reference current (Programming, Correction 117
Stepper) 72 Correction 118
Actual value (Dressing counter) 70 Corresponding Programs 149
Add fault information 183 Count 65
Count-Factor 71
and Controls
Index
Counts 67 DST 49
Current at 0% I 85
Current at 50% I 85 E
Current calibration 147
Current Measurement Range Exceeded 216 Edit | Autobackup 29
Current measurement range exceeded… 210 Edit | Copy 29
Current measuring/Current supervision 80 Edit | Correction 29
Current monitoring 53 Edit | Export record set 29
Cutter blade changed 204 Edit | Firmware changing 29
Cutter1 Edit | Login 29
Cutter not running 204 Edit | Oscilloscope function 29
Dressing process aborted 204 Edit | Programming 28
Emergency-Stop 205 Edit | Setup 29
Max. mill duration exceeded 204 Edit | Timer change 29
Motor protection trip 205 Electrode changed 202
Temperature fault 204 Electrode dressed 203
Cutter2 Electrode life tipdress 203
Cutter not running 205 Electrode range 84
Dressing process aborted 205 Electrode/Stepper 46
Emergency-Stop 206 End of stepper 201, 202
Max. mill duration exceeded 205 End of Stepper (refer to maximum counts) 68
Motor protection trip 206 End-Slope 52
Temperature fault 206 Enter/change spot references 172
Error table 124
Error US control loop 221
D
Error US measurement 220
Data download started 194 Exit BOS 6000 153
Define access levels for individual objects 163 Export parameter data to ASCII file 175
Delete spot references 173 Export spot reference 171
Delete timers from BOS 6000 154 Export spot reference to an Excel file 171
Deleting topics from the Favorites list 15 Export timer data (backup) 158
Description of the symbols in the menu lines 11 Export Timer Reference 156
Detail Info 151 ext. data change 169
Diagnosis 97 Extend stepping request 201
Diagnostics I/O 98 Extended electrode life Near End of Stepper
Last Weld 107 201
Start Simulation 102 Extended electrode life/Waiting 71
Timer-Information 105 external data change 169
User Diagnostics I/O 101 External Over-Temperature 193
Diode defect 212
Diode Over Current 211 F
Diode temperature 90
DIP switch 116 Fade-out time 78
Display spot comments 173 Fault messages 191
Displaying the topics in the Favorites list 14 Fault-Reset 216
Dress new electrode 71 File | Exit 28
Dressing necessary 203 File | Para. data import/export | Export … 28
Dressing-Curve (Programming, Seq. Pg.2) 59 File | Para. data import/export | Import … 28
Dressing-Curve (Programming, Stepper) 69 Filter tables 166
Dressings 70 Find
Dress-Request 70 Text 13
Dress-Request reached 202 Find keyword 12
Driver-Fault 213 Firmware change 142
and Controls
Index
Force calibration 148 IP Address (Setup, Communication) 114

Force monitoring Isolation contactor feedback fault 213
Force/Pressure too high 220
Force/Pressure too low 220 K
time too long 219
time too short 220 Keyword search 12
Force x.PV 60
FPO (freely programmable output) 60 L
FTP-Upload 135 Language 30
Functions (Setup, Communication) 116 Last weld program chosen 104
Functions | Compare 30 Laufzeitbibliothek 31
Functions | Error table 30 Log in timers to BOS 6000 153
Functions | Network overview 30 Login 32
Functions | Parameter overview 30 Low Current… 209
Functions | Prewarning 30 Low Current-series of welds… 210
Functions | Protocol 30 Lower tolerance band 54
Functions | Rights administration 30
Functions | Spot reference 30
M
Functions | Timer reference 30
Functions in the menu line 28 MAC-Adresse 116
Main weld current 51
G Mains Power Balance Monitoring Activated 215
Mains Power Balance Monitoring Ok 215
Getting to know the BOS 6000 user interface 23 Mains voltage 90
Max repeat welds (max. repetition in series) 76
H Max. %I correction 73
Half-Cycle Monitoring 196 Max. number of spots welded before dressing
Hardware Fault 195 203
Help | About 31 Max. Pressure-Correction 74
Help | Help 31 Max. primary current reached 213
History 9 Max. welding time 75
HLD 51 Maximum count 68
How to … 153 Maximum Phase Angle Reached 206
Maximum pressure 90
Meaning of important icons 26
I
Measuring loop check 80
I% and pressure correction displays 48 Memory deleted 194
I/O Signals 97 Menu line of the Help window 11
I/O-Bus Fault 196 Middle/Average PHA (Programming, schedule)
Ignition Type 96 55
Import parameter data from ASCII file 176 Min. %I correction 74
Import spot reference 171 Min. Pressure-Correction 74
Import Timer Reference 156 Mode 115
Impulse 50 Mode pressure output 78
Including topics in the Favorites list 14 Monitor contact open 215
Influence data comparison at program start 162 Monitor stepper 64
Information concerning the last welding Monitoring 46
schedule performed 97 Monitoring stopped 76
Information concerning the timer 97
Inhibit Monitoring Mode Active 208 N
Inputs / Outputs 100
Interval (Diagnosis, Start Simulation 104 Network overview 126
Interval (Diagnosis, Timer-Information) 106 Next 11
and Controls
Index
No current… 209 Prewarning 122

No schedule programmed 194 Prewarning Count 68
No stroke, no weld 200 Prewarning reached 202
No voltage 1.HW 208 PreWld 48
No Water Flow Gun 1 214 Primary transformer ratio (transformer) 87
No Water Flow Gun 2 214 Primary Voltage Measuring Fault - KUR Mode
No Weld 209 208
No weld contactor enable 213 Print 11
No Weld Enable or Weld Pressure Input Gun 1 Print spot reference 172
214 Print Timer Reference 156
No Weld Enable or Weld Pressure Input Gun 2 Program (Diagnosis, Timer-Information) 106
214 Program (display field in 100
No Weld external 199 Program Parity Fault 197
No Weld internal 200 Programming 42
No. parallel (diodes) 89 General 73
Nominal current (transformer) 87 Schedule 43
Nominal voltage (Thyristor-Unit-Parameter) 94 Seq. Pg.2 56
Number of transformers 86 Stepper 62
Stepper/Electrode 81
O Thyristor-Unit-Parameter 94
Proper use 19
OFF 51 Protocol 128
Off-time 61 Protocol memories 129
On-time 61 PSQ hardware fault 222
Over Current… 210 PSQ internal communication error 223
Overcurrent or Earth-fault 212 PSQ memory deleted 225
Overview of the interface structure 24 PSQ not available 223
PSQ ok 225
P PSQ Sequence Cancelled 221
Para.-Data Import/Export (Parameter-Backup) PSQ sequence error 224
144 PSQ temperature too high 223
Parameter Overview 134 PSQ watchdog fault 223
Perform current calibration 184 Pst Wld kA 52
Perform force calibration 187
Phase Angle prewarning reached 206 Q
ping 36 Qualified personnel 20
Port Number 114
PostWeld 50
R
Power voltage off/to low 199
Power voltage off/to low receipt 199 Range of training courses. 20
Power voltage to high 198 Readme 9
Power-Unit not ready 192 Ref.-Current at end of 1.Stepper-Phase 67
Pre Sqz 48 Reference current 52
Pre Weld kA 51 Reference current for new electrode 65
Pressure after last Dressing 59 Reference current last dressing 70
Pressure at end of 1.Stepper-Phase 58 Reference time 61
Pressure for new electrode 57 Regulation 46
Pressure profile 60 Regulation mode 52
Pressure stepping 57 Renaming the topics in the Favorites list 15
Pressure-Correction (Elec.) 119 Repeat factor 55
Pressure-Correction (Prg.) 119 Replace a defective timer 177
Previous (Back) 11 Reset faults 181
and Controls
Index
Response to data mismatch 40 SQZ 48

Restore 137 Standard gateway 114
Restore Timer data (download) 159 Start Inhibited 197
Reweld By Timer Active 208 Start page (Home) 11
Rights Administration 135 Start with ignition (Diagnosis, Start Simulation
104
S Start without ignition (Diagnosis, Start
Simulation) 104
Safe working practices 21 Start-Inhibit (P) 44
Safety Instructions 17 Start-Inhibit (T) 74
Scaling Start-Slope-Current 51
Communication error 217 Status (Diagnosis, Start Simulation 104
current out of range 218 Status (Diagnosis, Timer-Information, Actual
Difference primary / secondary current too Cycle) 106
large 218 Status (Diagnosis, Timer-Information, Timer)
no measuring value received 217 106
no valid measuring value received 217 Stepper 71
protocol fault 218 Stepper exceed 202
result invalid 219 Stepper-Curve (Programming, Seq. Pg.2) 59
Sequence aborted 218 Stepper-Curve (Programming, Stepper) 66
wrong mode 218 Stepping and dressing 63
Schedule 45 Stop / No 24V 191
Schedule (Diagnosis, Timer-Information) 107 Stop at end of stepper 73
search keyword 12 Stop circuit closed 191
Secondary monitoring circuit is open 207 Subnet mask 114
Secondary monitoring circuit is shorted 207 Supervision (diodes) 88
Sequence externally cancelled 197 Supply Voltage Fault 198
Set Access Level 135 Switch-off temperature (diodes) 89
Set Counter 146 Symbols used 18
Set electrode counter 175 Sync / Power Fault 196
Setup 108 Synchronization OK 197
Communication 113
Fault-Setup 112
T
Stepper curves 109
Tipdress curves 111 Termination of Weld / no current 207
Show (Unhide)/Hide 11 Text search 13
Show / Print / Export logs 167 The available windows 32
Show Contents (structure) 12 The BOS 6000 Help System 9
Show electrode status 173 Thyristor-Unit temperature 95
Show structure 12 Thyristor-Unit-Type 95
Signals 97 Time Monitoring (Programming, Seq. Pg.2) 61
Slave error 216 Time x.PT 60
Slope 49 Time-Monitoring (Programming, Schedule) 47
SMTP Address 114 Timer 36
Software version 9 Timer change 140
Software-Version (Diagnosis, Timer- Timer Reference 33
Information) 106 Timer switched on 198
Software-Version (Thyristor-Unit-Parameter) 96 Timer type (Diagnosis, Timer-Information) 106
Sort tables 166 Timer type (Thyristor-Unit-Parameter) 96
Spot Comment 150 Tipdress prewarning 203
Spot Reference 120 Tolerance standard 61
spot repetition with US 222 Toroid sensitivity 83
Spot-Repetition 47 Trademarks, copyright 22
and Controls
Index
Trail current 79
Transformer temp too high 193
Turns ratio (Thyristor-Unit-Parameter) 95
Type (diodes) 88
Type (transformer) 85
Type of connection (transformer) 86
U
Upgrade the timer firmware 179
Upper current limit 82
Upper tolerance band 54
US measuring loop fault 224
Use favorites 14
USP communication error 224
USP hardware fault 223
USP not calculated 221
USP temperature too high 223
USP too high 222
USP too low 222
UST 49
W
WC (Diagnosis, Start Simulation) 105
WC Period 77
WC Start time 77
WC with error 77
Wear per component 71
Weld Contactor Gun 1 Did Not Open 215
Weld Contactor Gun 1 Open 214
Weld Contactor Gun 2 Did Not Open 215
Weld Contactor Gun 2 Open 214
Weld external 200
Weld internal 200
Weld program chosen 104
Weld time too long… 211
Weld time too short… 211
Weld without Command 192
Weld/No weld (Global) 74
Weld/No Weld (P) 44
Welding-Fault Reset 216
Why 17
Width of a table column 166
With stroke, with weld 200
Without regulation, without monitoring 209
WLD 49
Z
Zero adjust 93
and Controls
Index
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 (0)93 52-40-50 60
Fax +49 (0)93 52-40-49 41
service.svc@boschrexroth.de
www.boschrexroth.com
Printed in Germany
1070087074 DOK-PS6000-BOS6000****-AW01-EN-P

Bosch Manual REXROTH BOS6000 Users Manual

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Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

Rexroth BOS 6000 1070087074

Title Rexroth BOS 6000

Type of Documentation User Manual

Document Typecode DOK-PS6000-BOS6000****-AW01-EN-P

Purpose of Documentation The content of this manual refers to

Record of Revisions Previous editions Release Notes

Copyright © Bosch Rexroth Electric Drives and Controls GmbH, 2006

Published by Bosch Rexroth Electric Drives and Controls GmbH

The BOS 6000 Help System................................................9

Safety Instructions ............................................................ 17

Getting to know the BOS 6000 user interface................. 23

Edit | Timer change..............................................................29

How to ….......................................................................... 153

Fault messages ............................................................... 191

Cutter1: Temperature fault .....................................................204

Scaling: protocol fault .............................................................217

Glossary ........................................................................... 225

Index ................................................................................. 235

The BOS 6000 Help System

The BOS 6000 Help System

Note: For more information on BOS:

The BOS 6000 Help System

Reproduction or distribution by any means subject to our prior

• via Help menu item in a BOS 6000 window

• via Help command button (if available and not dimmed)

• via F1 button if any window of the BOS 6000 interface is active.

Note: In many areas, the Help is “context-sensitive“. That

The Help window displayed is divided into 3 major areas:

• top: Menu line.

• left: Display area for the following functions:

• right: Field for displaying the contents of the subjects.

The BOS 6000 Help System

Description of the symbols in the menu lines

Start page (Home)

The BOS 6000 Help System

Show Contents (structure) view

Note: Book symbols represent a topic with sub-topics. To

Note: To fully extend the structure tree or to close the

The BOS 6000 Help System

The BOS 6000 Help System

Including topics in the Favorites list

Note: Alternative to Add command button:

Displaying the topics in the Favorites list

Note: Alternative to Show (View) command button:

The BOS 6000 Help System

Deleting topics from the Favorites list

Note: Alternative to Remove command button:

Renaming the topics in the Favorites list

Note: Renaming can be canceled by hitting the Esc key.

The BOS 6000 Help System

Why” and “What for”?

Nevertheless, there still is some residual risk!

Ö Please note the information provided in the previous section in

The present information refers to the

Ö You should know and understand the issues at stake before

This symbol is used wherever insufficient or

Note: This symbol is used to draw the user’s attention to

Ö This symbol indicates that you have to do something or have

The BOS 6000 user interface described here serves for

Any other application is deemed improper use!

The consequences of an improper use include

Note: For operating the hardware in residential environments,