Psq6000 Rexroth Manual Datasheet

Contents 1-1
Rexroth PSQ 6000 1070087072

Edition 01
U/I Regulator
Commissioning, Operating Manual

1-2 Contents
Title Rexroth PSQ 6000 U/I Regulator
Class of Documentation Commissioning, Operating Manual
Documentation Type DOK-PS6000-UIR********-IB01-EN-P
Intent of the Documentation

This manual provides information on:
• installation
• functionality, and
• operation
of the U/I regulator XQR modul.
This information supplements the respective manual "PSI 6000 Control

and I/O Level" and the manual “PSI 6000 Medium-Frequency Inverter".
The safety instructions defined in these manuals are applicable.
Follow-Up of Modifications
Previous editions Status Comment
DOK-PS6000-UIR********-IB01-EN-P 08.2006
Note on Industrial Property Rights

© Bosch Rexroth Electric Drives and Control GmbH, 2004−2006
Unless expressly authorized, any copying of this document and utilization
and disclosure of its content is not allowed. Damages will be payable in
case of contravention. 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).
Legal Validity
The data given in this document only intend to describe the product and
must not be understood as guaranteed properties in the legal sense. Any
statement on a specific quality or suitability for a specific application
cannot be derived from the data given in this document. Such data do not
relieve the user from his duty to make his own assessments and tests.
We reserve the right to modify the contents of this Documentation and
the availability of the products.
Editor
Bosch Rexroth Electric Drives and Control GmbH
Postfach 1162
D-64701 Erbach
Berliner Strasse 25
D-64711 Erbach
Phone: +49 (0) 60 62/78-0
Fax: +49 (0) 60 62/78- 728
Dept.: BRC / PAW1
Contents 1-3
1 Contents
1 Contents .................................................................................1-3
2 Safety Instructions.................................................................2-1
2.1 Intended Use........................................................................... 2-2
2.2 Environmental Protection, Return of Material, Reuse ...... 2-2
2.3 Qualified Personnel ............................................................... 2-3
2.4 Dangerous Magnetic Fields .................................................. 2-4
2.5 Installation and Assembly..................................................... 2-5
2.6 Electrical Connection ............................................................ 2-6
2.7 Modifications by the Operator ............................................. 2-7
2.8 Maintenance, Repair ............................................................. 2-7
2.9 Working Safely ...................................................................... 2-8
2.10 Installation and Retrofit........................................................ 2-9
3 System Design......................................................................3-10
3.1 Design of the System as a Whole ........................................ 3-10
3.2 Connection ........................................................................... 3-11
3.3 Weld Timer Integration ...................................................... 3-16
3.4 Field of Application ............................................................. 3-16
3.5 Information on Installation and Assembly........................ 3-16
4 Commissioning with BOS 6000 ..........................................4-17
4.1 First Step .............................................................................. 4-17
4.2 Second Step .......................................................................... 4-17
4.3 Third Step ............................................................................ 4-18
4.4 Forth Step............................................................................. 4-25
5 BOS 6000 with U/I Regulator .............................................5-27
5.1 Requirements ....................................................................... 5-27
5.2 PSQ Status Display.............................................................. 5-27
5.3 Summary of U/I Operator Functions................................. 5-27
5.4 Programming – Sequence ................................................... 5-28
5.5 PSQ Programming – UIR ................................................... 5-29
General: Global UIR Parameters .............................................................5-29
Mode ....................................................................................................5-29
Expulsion Detection.............................................................................5-30
Referring to UIR Program .......................................................................5-30
Measuring ............................................................................................5-30
Regulation............................................................................................5-30
Monitoring ...........................................................................................5-31
Expulsions............................................................................................5-31
5.6 PSQ Programming – UIR Reference ................................. 5-32
Load Curve ..............................................................................................5-32
Å PC ...................................................................................................5-32
1-4 Contents
Reference Sequence Å Timer .............................................................5-32

Actual Curve Å Timer ........................................................................5-32
Write Curve .............................................................................................5-33
Æ PC ...................................................................................................5-33
Reference Sequence Æ Timer .............................................................5-33
Settings ....................................................................................................5-33
Zoom........................................................................................................5-33
Display.....................................................................................................5-33
5.7 Programming – PSQ – UIR Monitoring............................ 5-33
Programming the Monitoring Function ...................................................5-35
Permissible Upper Tolerance Band .....................................................5-36
Permissible Lower Tolerance Band .....................................................5-36
Conditionally Permissible Tolerance Band..........................................5-36
Repetition Factor..................................................................................5-36
Acceptance Repetition Factor ..............................................................5-36
Progress Display ......................................................................................5-37
Welding Sequence Displayed ..............................................................5-38
Update..................................................................................................5-38
Settings ................................................................................................5-38
Zoom....................................................................................................5-38
Actual Æ Desired ................................................................................5-39
Export ..................................................................................................5-39
Y-Zoom................................................................................................5-39
PSQ Status Display..............................................................................5-39
Information on Monitoring ......................................................................5-39
Current .................................................................................................5-40
PHA (Pulse Width) ..............................................................................5-40
Weld Time ...........................................................................................5-41
Energy..................................................................................................5-41
Process Stability PSF ...........................................................................5-41
Process Quality UIP.............................................................................5-42
Tolerances............................................................................................5-42
5.8 Diagnostics – Last Sequence ............................................... 5-43
5.9 Diagnostics – PSQ................................................................ 5-45
Filter.........................................................................................................5-45
Without ................................................................................................5-45
Program................................................................................................5-46
Single/Prog. .........................................................................................5-46
Stop ......................................................................................................5-46
Display.....................................................................................................5-46
Cursor 1 ...............................................................................................5-46
Cursor 2 ...............................................................................................5-46
Min.......................................................................................................5-47
Max. .....................................................................................................5-47
MV.......................................................................................................5-47
Actual Æ Reference.................................................................................5-47
Settings ....................................................................................................5-47
Zoom........................................................................................................5-47
5.10 Setup – UIR Setup ............................................................... 5-48
Recording Mode ......................................................................................5-49
Analysis Mode .........................................................................................5-50
Filter – Program...................................................................................5-50
Filter – Actual Curve ...........................................................................5-50
Delete Actual Curve.............................................................................5-51
Average Curve .....................................................................................5-51
Original Curves....................................................................................5-51
Reference Sequence Æ Timer .............................................................5-52
Æ PC ...................................................................................................5-52
Zoom....................................................................................................5-52
Contents 1-5
5.11 Overview............................................................................... 5-53

Overview – General.................................................................................5-53
Overview – UIR Mode ............................................................................5-53
Overview – PSQ Process Variables.........................................................5-54
Meaning of Table Columns .................................................................5-54
Examples: ............................................................................................5-55
5.12 Process Overview................................................................. 5-57
6 Commissioning with BQR...................................................6-58
6.1 First Step .............................................................................. 6-58
6.2 Second Step .......................................................................... 6-58
6.3 Third Step ............................................................................ 6-59
6.4 Forth Step............................................................................. 6-65
7 BQR User Interface – U/I Regulator..................................7-66
7.1 Installation and Connection................................................ 7-66
Requirements ...........................................................................................7-66
Connection...............................................................................................7-66
Installation ...............................................................................................7-66
7.2 Overview of Operating Functions ...................................... 7-67
7.3 Parameterization of the U/I Regulator .............................. 7-67
Basic Display ...........................................................................................7-68
All Programs ........................................................................................7-68
Mode ....................................................................................................7-68
Expulsion Detection.............................................................................7-69
Selected Program .................................................................................7-69
UIR Parameter .....................................................................................7-70
Supervision Parameters........................................................................7-72
Permissible Upper Tolerance Band .....................................................7-72
Permissible Lower Tolerance Band .....................................................7-73
Conditionally Permissible Tolerance Band..........................................7-73
Repetition Factor..................................................................................7-73
Q Stop ..................................................................................................7-73
Backup/Restore........................................................................................7-74
Display of UI / US Curves (Auto) ...........................................................7-75
All Programs ........................................................................................7-76
Stop ......................................................................................................7-76
Display of Reference Curves (Program)..................................................7-77
Source – From PC................................................................................7-77
Source – Reference Curves from Timer ..............................................7-77
Source – Last Curves from the Timer..................................................7-77
Destination – in PC ..............................................................................7-78
Destination – UIR in Timer .................................................................7-78
Tools, U/I Setup.......................................................................................7-79
Comport ...............................................................................................7-79
Select Language...................................................................................7-79
System Info ..........................................................................................7-79
Initialize Data.......................................................................................7-79
Load Firmware.....................................................................................7-79
U/I setup...............................................................................................7-80
8 Instructions on Commissioning..........................................8-87
8.1 Defining the Basic Welding Parameters ............................ 8-87
8.2 Making the Reference Weld ............................................... 8-88
1-6 Contents
8.3 Commissioning the Suspension Spot Welders with U/I

Regulator......................................................................................... 8-91
8.4 Returning to the CCR Mode............................................... 8-97
9 Comprehending the Resistance characteristics..................9-98
9.1 Normal Curve ...................................................................... 9-98
9.2 Expulsions ............................................................................ 9-99
9.3 Isolating Materials............................................................. 9-100
9.4 Steps to Optimize the Weld............................................... 9-100
General Rules.........................................................................................9-101
Elimination of Expulsions .....................................................................9-101
Early Expulsions ................................................................................9-101
Late Expulsions .................................................................................9-101
Expulsion in the Regulation Mode ....................................................9-102
Optimization in Case of Single-Pulse Welding .....................................9-102
Optimization in Case of Preliminary-Pulse Welding.............................9-103
10 Error Messages ............................................................10-104
11 List of Accessories ........................................................11-105
12 Abbreviations, Terms ...................................................12-106
Safety Instructions 2-1
2 Safety Instructions
The products described in this document have been developed,
manufactured, tested and documented in compliance with the safety
standards specified in the EC Machinery Directive. Provided the handling
rules and technical safety instructions described for project planning,
assembly and intended use are observed, any personal and/or material
risks normally do not arise in connection with the product.
But there are still residual risks!
For that reason, please read this manual carefully before assembling,
connecting or commissioning the products and before programming the
system.
Keep this manual at a place that is accessible to each and any user at
any time.
The contents of this manual refer to

• the mechanical design,
• the electric connection,
• the functionality,
• the steps required for commissioning, and
• programming of the necessary data by means of the
BOS and BQR user interface
of the U/I regulator modul.
There are separate manuals for the respectively existing power

units, weld timer types and welding transformers.
These are a supplement to the present manual !
For that reason, please also observe the following documentation:

• For PSI 6xxx: Medium-Frequency Inverter, Technical
Information (1070 080 059)
• Control and I/O Level, Technical Information (according
to the weld timer type used)
• MF Welding Transformers, Technical Information
(1070 087 063)
In addition, the safety instructions in the manuals “PSI 6000 Control

and I/O Level” and “PSI 6000 Medium-Frequency Inverter” are also
applicable!
2-2 Safety Instructions
2.1 Intended Use

The product described
• when used in connection with a suitable weld timer PS 6000 and a
welding transformer suitable for the integrated power section, is
intended for
- resistance welding of metals,
and
• can be used for operation in an industrial environment (emission
class A, group 2) in accordance with the following regulations:
- EN 50178
- EN 50240
- EN 60204-1
Any use beyond that is no intended use any longer!
DANGER
RF interferences may occur!
This is a class A resistance welding device.
Resistance welding devices of class A are not intended for use in
the public low voltage distribution network supplying f.e. residential
areas, as they may interfere with other devices in the environment.
To utilize class A devices in residential, business and commercial

areas and in small enterprises, you need an individual permit by the
national government or test authority; in Germany, this is the
‘Bundesnetzagentur (BNetzA)’ with its local agencies.
DANGER
Any non-intended use of the devices may cause injury to the user or
third parties, as well as damage to the device, the workpiece to be
machined, or to the environment.
For this reason, be sure only to use our products as intended!
To ensure proper and safe operation, the product must be transported,

stored, set up, mounted, assembled and operated in a proper, correct
and careful manner.
2.2 Environmental Protection, Return of Material, Reuse

Environmental Protection
Our products do not contain any hazardous substances which could be
released when the product is used properly. Under normal conditions, no
negative influences for the environment are to be reckoned with.
Taking back material

The products manufactured by us can be returned for disposal at no
charge. Requirements for this are:
• no buildup of oils, grease or other pollutants
• no included inappropriate foreign substances or foreign
components.
The packaging material consists of paper, wood and styrofoam.
For ecological reasons, a return transport of empty packaging should not
take place. This can be easily put into the recycling bin.
The products must be delivered postpaid to the following address:
Bosch Rexroth Electric Drives and Control GmbH
Bürgermeister−Dr.−Nebel−Strasse 2
D-97816 Lohr am Main
Recycling
Main components of our electronic devices:
- steel, aluminum, copper, plastic materials.
Due to the high proportion of metal, most of our products can be
recycled. To achieve optimum metal recovery, dismantling into individual
components is necessary.
The metals contained in electrical and electronic components can also be
recovered by special separation processes. The resulting plastics can be
thermally recycled.
If batteries or accumulators are contained in the products, these must be
removed before recycling the products and must then be disposed in a
proper and environmentally friendly manner.
2.3 Qualified Personnel

This documentation is designed for especially trained and skilled
personnel having special knowledge in the field of welding technology.
They must have a sound knowledge of the software and hardware
components of the weld timer, the power supply used, and the welding
transformer.
Project engineering, programming, start and operation as well as the
modification of program parameters is reserved to properly trained
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.
Unless described in the Technical Information, any manipulations to the
hardware and software of our products may only be made by technical
personnel of Bosch Rexroth GmbH.
If unqualified manipulations are made to the hardware or software or if
the warnings provided in the Technical Documentation or attached to the
product fail to be observed, this may result in severe personal injury or
serious material damage.
Only skilled technicians who are familiar with the contents of this
documentation are authorized to operate and maintain the products
described.
Such personnel are
• those who, being well trained and experienced in their field

and familiar with the relevant standards, are able to
analyze the work to be carried out and recognize any
hazards.
• those who have acquired the same amount of expert
knowledge through years of experience that would
normally be acquired through formal technical training.
Please also note our comprehensive offer of various training courses. For
latest information on training measures, teachware and training systems,
please refer to www.boschrexroth.com/training. For more detailed
information, please contact our
Training Center Erbach
SAL2
Berliner Strasse 25
D-64711 Erbach
Phone +49 (0) 60 62 78-6 00
Fax +49 (0) 60 62 78-8 33
training.brc@boschrexroth.de
Danger:
Persons wearing cardiac pacemakers do not belong to the group of
persons described above!
The strong magnetic fields developing during resistance welding might
impair the proper functioning of cardiac pacemakers. This may result in
death or considerable injury to the health of the persons affected!
For that reason, such persons must not come near the welding
system.
2.4 Dangerous Magnetic Fields

Danger:
In the environment of resistance welding systems, magnetic field
strengths have to be expected which are above the limit values specified
in VDE 0848 Part 4. Especially if manual guns are used, the limit values
for extremities may be exceeded. In cases of doubt, you should measure
the field strength and take additional measures to ensure safety and
health at work. Please comply with regulation BGV B11 of the German
Berufsgenossenschaft (professional association)
”Unfallverhütungsvorschrift elektromagnetische Felder”.
NOTE
The strong magnetic fields developing during resistance welding might
cause permanent damage to wrist watches, pocket watches, floppy disks
or magnetic strip identity cards (e.g. credit cards). Please do not carry
such objects with you while working in the immediate vicinity of the
welding system.
2.5 Installation and Assembly

DANGEROUS ELECTRIC VOLTAGE
Danger of life during installation work while systems are switched
on!
Make sure that all plant sections undergoing operations during the
installation are de-energized and sufficiently protected against
accidental reclosing!
DANGER
Non-workmanlike installation or mounting may lead to personal
injury or damage to property. Installation or mounting must be
carried out by skilled personnel only.
DANGER
Danger of injury and of damage to property through incorrect
installation!
The products, their wirings and control elements, if any, must be
installed so as to be properly safeguarded against unintentional
operation or contact.
The installation space must be suitable for the degree of protection
specified.
DANGER
Danger of personal injury and damage to property through
inadequate fastening!
The place for installing the modules, and their method of fastening,
must be suitable for their weight!
DANGER
Insufficient degree of protection may be life-threatening or cause
damage to property!
The degree of protection of the products described is IP 20. They
must be installed in switchgear cubicles providing a degree of
protection of no less than IP 54.
2.6 Electrical Connection
DANGER
Bodily injury and material damage is possible if the electrical
installation work is not carried out properly.
Electrical connection work must therefore be carried out by a
professional.
DANGER
Danger of life through inappropriate EMERGENCY-STOP facilities!
EMERGENCY-STOP facilities must be operative in all modes of the
system. Releasing the EMERGENCY-STOP facility must by no
means result in an uncontrolled restart of the system! First check
the EMERGENCY-STOP circuit, then switch the unit on! Please
ensure that you have checked the E-STOP chain!

Danger to life and limb due to insufficient protective earth system!
The devices must be connected to the protective earth (PE) system
of the plant.
The continuous connection of the protective earth system must be
inspected according to EN 60204 Part 1.
CAUTION
Destruction of assemblies!
Do not connect or disconnect any assemblies or connectors while
they are live!
CAUTION
Connecting lines and signal lines must be laid so as to avoid
negative effects on the function of the units through capacitive or
inductive interference!
Interference is frequently coupled and decoupled in long cables.
Therefore, power and control cables must be routed separately. The
influence of interfering cables on cables susceptible to interference
can be minimized by keeping the following distances:
> 100 mm if cables are run in parallel for < 10 m,
> 250 mm if cables are run in parallel for > 10 m.
Please ensure that all contact surfaces are bright, i.e. free from any
paints, plastic coatings and/or dirt/oxidation.
2.7 Modifications by the Operator
DANGER
Modifications to the product may have negative effects on the safety
of the unit!
The possible consequences include death, severe or light injury
(personal injury), damage to property or environmental hazards.
Therefore, please contact us prior to making any modifications. This
is the only way to determine whether changes can be made without
any problems.
2.8 Maintenance, Repair

Prior to any maintenance work – unless described otherwise – the
system must always be switched off and sufficiently secured!
In the event of necessary measurement or test procedures on the
active system, these have to be performed by skilled electrical
personnel.
DANGER
Lithium batteries can cause skin burns or explode in case of
improper handling!
Therefore, do not forcefully open batteries, do not attempt to charge
or heat up batteries over 100 °C!
CAUTION
Please use only spare parts approved by us!
Use only original replacement batteries! In any case, spent
batteries and accumulators should be disposed of as
hazardous waste!
2.9 Working Safely
DANGER
If the start signal is present on fault reset (acknowledge), the weld
timer immediately starts the program sequence! Hazardous
machine movements may be the result!
Therefore, before fault reset, you should make sure that there are no
persons in the danger zone of the welding equipment!
DANGER
During operation of the welding equipment welding splashes are to
be expected! They may cause eye injuries or burns. Therefore:
− wear protective goggles
− wear protective gloves
− wear flame-retardant clothes
Note: Please also observe any safety-relevant information essential for

handling the product. Such information can be found in the appropriate
manuals. If unqualified manipulations are made to the hardware or
software or if any safety instructions and/or warnings fail to be observed,
this may result in severe personal injury or serious material damage.
2.10 Installation and Retrofit
CAUTION
Danger to the module!
All ESD protection measures must be observed when using the
module! Prevent electrostatic discharges!
The following protective measures must be observed for modules and

components sensitive to electrostatic discharge (ESD)!
• Personnel responsible for storage, transport, and handling must

have training in ESD protection.
• ESD-sensitive components must be stored and transported in the
prescribed protective packaging.
• ESD-sensitive components may only be handled at special ESD-
workplaces.
• Personnel, working surfaces, as well as all equipment and tools
which may come into contact with ESD-sensitive components must
have the same potential (e.g. by grounding).
• Wear an approved grounding bracelet. The grounding bracelet must
• be connected with the working surface through a cable with an
integrated 1 MΩ resistor.
• ESD-sensitive components may by no means come into contact with
chargeable objects, including most plastic materials.
3-10 System Design
3 System Design
3.1 Design of the System as a Whole

The U/I regulator is an modul in double Euroformat. It is inserted in the
PSI 6000 weld timer series. Via the internal bus coupling, it is closely
connected to the weld timer for quick exchange of information. A 32 bit
controller computes the control algorithm and handles the communication
to the weld timer and the BQR user interface.
The BQR user interface supplements the BOS 5000 user interface for
operation of the U/I regulator.
The BOS 6000 user interface version 1.17 and higher already contains
operation of the U/I regulator.
The BQR user interface for the U/I regulator is a separate software for
PC installation. The interface to the system is realized via a V24/RS232
link which is connected either to the regulator modul X3C or to the
X1interface on the weld timer. This interface is used to parameterize the
regulator and to display the curve slopes of the weld.
U/I regulator modul
BQR user interface
BOS 5000
BOS 6000
Figure:
BOS user interface of the weld timer at connector X1; user interface of
the U/I regulator BQR at the regulator modul connector X3C
System Design 3-11
3.2 Connection
The electrode voltage cables must be connected as close to the
electrodes as possible. Their contacts can be located at the welding gun
arms and must be installed in such a way that the electrode welding gun
can move freely. The voltage tap must be placed behind the secondary
cables or flexible strips (seen in the direction of the electrodes) to prevent
falsification of the measuring by wear or heating.
Welding transformer
Supply line
Highly flexible cable

The contact between the voltage measuring cable and the welding gun
arm must be achieved by a screwed connection, permanently and with
low impedance. Connection to the welding gun arm can be achieved at
an existing screwed connection by clamping a suitable cable lug.
Since only one core has to be connected to each welding gun arm, the
cable may be placed without shield across a length of about 1 m in this
area, with a cross-section ranging from 0.5 to 1.5mm2. Starting at that
point and before the voltage cable is running together with other lines, the
cable must be provided with a shield across its remaining length. See
cable specification.
A plugged or clamped connection is appropriate at this point, in order to
allow easy replacement of the unshielded section of the voltage cable in
case of wear caused by movements of the welding gun. The shield must
be provided up to the cabinet / welding box and applied to ground
potential only there, however well-conducting and across a large area, so
that any disturbances are discharged well on the outside.
Where the cable is moved by the welding gun, it must be highly flexible.
At such moved spots, the bending radius of the cable must be
maintained. Ensure that strain relief and cable attachment are
appropriate.
3-12 System Design
User interface Control cabinet / welding box Welding gun
(1)
PC PSI X8A
UIR
X3C
USR
X7C
CCR U2 V2
Welding current
Welding
transformer
Current sensor
Welding current
(1): max. length: 100 m
Schematic wiring diagram of the system
Cable Type for Voltage Measuring

Unshielded cable: Single litz wire, type Ölflon FEP from Lapp
Shielded cable: 2 x 0.75 mm2, twisted in pairs,
in correspondence with BOSCH order no. 1070 913494:
2x2x0.75 mm2, LiYCY, 2 twisted pairs of wires for electrode voltage and
current sensor.
The cable length must not significantly exceed a maximum of 100
meters.
Single-sided bonding of the shield to chassis, primarily at the input to the
control cabinet/welding box. We recommend that a shielded cable be
placed inside the cabinet.
Contacting at the welding gun arm:

Solistrand circular welding guns of copper and electrolytically tin-plated,
from Tyco Amp, e.g. type 34124
Note
As the voltage measuring input is dimensioned for low resistance
(approx. 500 ohms), no high-resistance cables, connectors or fuses must
System Design 3-13
be used.
PSQ6000
XQR
Usec 1
1
2 X8A
Usec 2
3 UIR
4
RX
Pin 2
TX X3C
Pin 3
GND RS232
Pin 5
24 V Extern
1 X1S
0V Extern
2 UDM
CAN_L
Pin 2
CAN_GND
Pin 3
0 V Extern X7C
Pin 6
CAN_H CAN-OUT
Pin 7
24 V Extern
Pin 9
Note:
Connector X3C for V24/RS232 of user interface BQR.
Connectors X7C and X1S are used exclusively for the ultrasonic system.
X8A pin assignment:

Pin Signal
1 USEC_1 Electrode voltage, input_1
2 GND Shield
3 USEC_2 Electrode voltage, input_2
4 GND Shield
3-14 System Design
Shield at pin 2 or 4
X3C pin assignment:

Pin Signal
1 DCD
2 RX
3 TX
4 DTR
5 GND
6 DSR
7 RTS
8 CTS
9 n.a.
X1S pin assignment: UDM

Pin Signal
1 24 VDC on
2 0 VDC on
X7C pin assignment:

Pin Signal
1 reserved
2 CAN_L
3 GND_ISO
4 Reserved 24V extern
5 CAN_Shield
6 CAN_GND
7 CAN_H
8 Reserved error line
9 CAN_24VDC
System Design 3-15
LEDs:
Green LED lit:
CAN bus communication to data
processing module is running.
COM Communication
Red LED lit:
No CAN bus communication to
data processing module.
Green LED lit:

Modul working without failure.
RUN Operating state
Red LED lit:
Modul has detected a
malfunction.
3-16 System Design
3.3 Weld Timer Integration

The U/I regulator is adapted to the PSI 6000 series weld timer.
The regulator is thus optimized for use with an inverter.
When implemented in the various available weld timer types, the U/I
regulator requires adjustments in the weld timer firmware and possibly in
the firmware of the regulation modul. Implementations in other weld
timers from our series are carried out upon customer inquiry or for
specific projects.
3.4 Field of Application

The U/I regulator can be used for the following spot welding tasks:
· with and without slope

· single- and multiple-pulse welding with 2nd WLD
· pre-heating time with 1st WLD, post-heating time with 3rd WLD in CCR
mode
· "Repetition" mode is supported.
· "Seam" mode is not supported.
Disturbances
Change of power voltage

Bad fit
Shunt
Change of coating
Bad contacts, adhesive
Bad tips
Third sheet
Other sheet thickness
Power change
Electrode wear
3.5 Information on Installation and Assembly
On delivery, the regulation module is already installed in the weld timer /

inverter unit.
In case of retrofitting, the dummy plate has to be removed and the

regulation module inserted and screwed tight. Before starting this
process, ensure that the supply voltage is switched off!
Retrofitting involves the mechanical installation of the regulation module
in addition to updating the firmware of the timer. The weld timer needs
this new firmware to be able to address the regulation device.
An updated version of the BOS user interface is necessary together with

the new firmware because the weld timer firmware represents a new type
of control unit.
Commissioning with BOS 6000 4-17
4 Commissioning with BOS 6000

Operation of the U/I regulator with BOS 6000 requires fundamental
knowledge of BOS 6000 interface. The online help integrated in BOS
6000 supports you in operating and setting up BOS 6000.
For additional information on commissioning, please refer to Chapter 8.
For operating the weld timer, BOS 6000 must be set up such that all
functions required can be executed, such as
- welding in the CCR mode,
- scaling if necessary, etc.
Thereafter, follow the steps below to start up the system.
4.1 First Step

Commissioning the weld timer / inverter unit in the constant current
regulation mode (CCR).
The functioning of the system in the constant current regulation (CCR)

mode is an essential prerequisite. The U/I regulator uses the same
mechanisms as the CCR. This part of commissioning corresponds to the
known procedures for a PSI 6000 inverter system, so that welding spots
can be produced in the CCR mode.
In this context, see the manuals on the PS 6000 regulation system and
I/O level, medium-frequency inverter, and welding transformer.
This step also comprises any required force and current scaling.
Refer to the corresponding chapters in the manuals.
Note
Scaling must not be performed while the U/I regulator is active.
4.2 Second Step

Prerequisites regarding welding gun and electrodes
The welding gun must be in excellent condition. The electrodes must be

adjusted to ensure that they stand exactly opposite each other and in a
right angle to the sheet.
The electrode tips should be dressed and slightly used (approx.

20 - 25 spots). Dressing corrects the contact surface of the electrode tips.
This results in ambient conditions like those of new tips. However, there
may also be interferences which are caused by dressing. First of all,
dressing can create irregularities on the contact surface (e.g. chatter
marks); secondly, the plane of the contact surface may not coincide as
well with the joining plane as in the used cap condition.
4-18 Commissioning with BOS 6000
Squeeze time and hold time should be long enough to allow the welding
gun to build up the required force.
Force measuring is recommended.
4.3 Third Step

Generating the Reference Curve
Generation of a reference curve requires that welds first be made in the

constant current regulation mode.
Select the welding spots or the programs you wish to use for welding
from the BOS 6000 user interface.
Check or set at the BOS 6000 user interface

Squeeze time Sufficient for this welding job
Hold time Sufficient for this welding job
st
1 weld time Possibly as a pilot pulse in the CCR mode (see
Chapter 9.4)
2nd weld time and Set CCR parameters for this welding job.
current Possibly, upslope in the 2nd weld time
3rd weld time Possibly for post-heating in the CCR mode
CCR mode ON
Repetition sequence OFF
Inhibit monitoring ON
Readjusting Heat values to 100%
Note
If possible, the heat correction should be set to 0% to allow full correction
functionality later in the U/I regulation mode.
PSQ Programming – UIR

Settings for the U/I regulator
General UIR measuring on
UIR regulation on
UIR monitoring on
Referring to UIR program UIR measuring on
UIR regulation off
UIR monitoring off
Data Æ don't forget the Timer (weld timer).
See chapter 5 "BOS 6000 with U/I Regulator" for a detailed

description of the operation.
Setting up the Reference Curve
Under U/I Setup, generation of reference curves is supported.

Advantage: several welding procedures of a program can be used to
generate a reference curve, irrespective of the sequence of the
programs; this even applies to several weld timers that are used at the
same time. In practice, this considerably simplifies the definition of
reference curves.
Start the recording mode for making the first recording.
Select the weld timers in the recording mode by checking the appropriate
checkboxes.
To select a new recording of curves, check the new recording checkbox.
This deletes any curves that have already been recorded.
If you leave the checkbox unchecked, the last recording will be
continued.
To observe the progress of data recording in the right-hand part of the

window, click start recording. If the message recording terminated
appears in the status display, click stop recording to stop recording and
move to the analysis mode, provided you have recorded all welds
necessary for generating the reference curves.
Analysis Mode
Recorded welds of a program
Now, select a program from the filter to view this program's curves. From
actual curve, select one of these curves; this selected curve is indicated
in red for evaluation.
To delete this specific curve, use delete actual curve.
Before calculating the reference curve, you can delete any possible
outliers.
Curves of expulsion welds have to be deleted at any rate.
Expulsions can be recognized from the suddenly falling slope of the

resistance characteristic.
Now, click the average curve button to calculate the reference curve for a
program (on the basis of the curves recorded); the curve is indicated in
red. The black curves show the minimum and maximum resistance
characteristics.
Use original curves to switch back to the original curve screenshot from
the average curve screenshot.
Appyling the Reference Sequence
Click Reference sequence Æ Timer to save the red curve as a reference

sequence in the U/I regulator for this program.
Proceed as described above for the other programs.

Notes
For each combination of sheet thicknesses, we recommend using a

separate program and to determine a separate reference curve.
Advantage: In separate programs, all welding parameters can be set in
an optimal manner for the respective welding job; there is less extension
of weld time caused by different sheet thicknesses.
However, if different sheet thickness combinations must be welded with
one program (manual welding gun), the reference curve is determined by
means of the thinnest sheet combination with the lowest resistance. In
case of coated sheets, it is determined by means of the thinnest sheets
with the thickest coat. Set the force for mean to thick sheet combinations.
Please also refer to Chapter 8.3.
Always make the reference weld without adhesive between the sheets, or
make at suitable sheet strips because adhesive is a disturbance variable.
Welding at the component is possible for determination of reference

curves. If strips are used, please note the following:
- The curve of the first spot on a sheet should not be used as a
reference curve.
- Spots should be welded at a distance of approx. 20 mm (shunt).
If the spot diameter is too small, increase the actual from spot to spot
until the expulsion limit is reached.
If there are expulsions, reduce the actual to the last expulsion-free value
and re-weld. For compensation purposes, it might be necessary to
extend the weld time.
Only after the weld has been made without expulsions and with the spot
diameter required can this curve be applied as reference curve.
Welding quality cannot be determined through interpretation of the

curves. The evaluation of the curves is limited to the following aspects:
- Resistance characteristic: typical course with strong downslope of
resistance at the start (contact is made) and continuous downslope
of resistance towards the end.
- Voltage signal: does a voltage signal exist, and is its curve similar to
the resistance.
Expulsions can also be detected from the suddenly falling slope of the
Please also refer to Chapter 9.
The wear state of the tips should be between 10 and 100 welds.
4.4 Forth Step

Activation of the Regulator for this Program:
Under PSQ programming – UIR
Settings for the U/I regulator

General UIR measuring on
UIR regulation on
UIR monitoring on
Referring to UIR program UIR measuring on
UIR regulation on
UIR monitoring off
Weld time prolongation
Weld time prolongation ON permits the U/I regulator to extend the weld
time for this program. The max. weld time prolongation parameter limits
the weld time prolongation which the U/I regulator needs to compensate
for disturbances. In automated operation, very long weld times may be
undesirable.
When this time limit is exceeded, the error message

“PSQ maximum weld time reached” is displayed.
Steps 2 to 4 must be repeated for each spot which is to be welded with

U/I regulation.
This completes the determination of reference curves.
Note
You can stop the measuring and the regulation for all weld timer
programs in the general field.
Corrections of the reference curve (raise/reduce) can now only be

achieved through the heat correction function of the BOS 6000. Weld
time and current setting cannot be changed any more as they are now
defined by the U/I regulator.
For this reason, when activating PSQ actual monitoring, it is important to
set sufficiently wide tolerance bands for the current to enable the U/I
regulator to react without signaling of errors.
For a description of monitoring with tolerances, please refer to Chapter

5.7.
Use PSQ diagnostics to display the curves of the actual weld.
Visualization of the curve slopes
For a detailed description of operation, please refer to Chapter 5

"BOS 6000 with U/I Regulator".
BOS 6000 with U/I Regulator 5-27
5 BOS 6000 with U/I Regulator
5.1 Requirements
• Operating system: Windows 2000 / XP with a RAM of at least 512
MB,
Windows 2003 server with a RAM of at least
1 GB
• At least 2 GHz Pentium
• At least 5 GB hard disk drive
• Interfaces: Ethernet
RS232/V24 (additionally)
• BOS 6000 user interface, version 1.22.x and higher
Note
The online help integrated in BOS 6000 provides you with basic
information on how to operate and set up the BOS 6000.
5.2 PSQ Status Display
On some screenshots, the PSQ status display provides information on

the state of the U/I regulator and monitor and, if the system has been
expanded appropriately, on the state of the US regulator and monitor.
PSQ
UIR
USR
Regulation Monitoring
Green: active
Yellow: not active
5.3 Summary of U/I Operator Functions
PSQ programming
UIR Parameterization of the U/I regulator
UIR reference Displaying/reading/saving actual and reference
curves
UIR monitoring Monitoring and history values
5-28 BOS 6000 with U/I Regulator
Diagnostics
Last sequence Actual values of the last welding sequence
PSQ Actual curve
Setup
UIR setup Generating reference curves
5.4 Programming – Sequence
The sequence tab allows you to program all basic settings that are
required for a welding program. This is a preparatory step for the U/I
regulation mode.
Note
Provided the U/I regulation and monitoring functions are activated, some
of the parameters/functions provided on the programming – sequence
tab can be dimmed or invisible, since they are required in the mode set.
5.5 PSQ Programming – UIR

Some of the settings can only be made by users with a special
authorization level.
General: Global UIR Parameters
These parameters apply to the overall weld timer, covering all electrodes
and programs.
This is the location of the activation of measuring, regulation, and

monitoring for the UIR of the overall weld timer.
To activate these functions, they must also be activated for the respective
program under referring to UIR program.
See Chapter 5.5“Referring to UIR Program”, Measuring, Regulation and
Monitoring.
Mode
This list box allows optimization of the activated U/I regulator by means of
adjusted regulator parameters, for the robot – manual welding gun – fine
spot aplications.
The mode function mainly affects the weld time prolongation in case of
disturbing variables. For example, the manual welding gun option
considers that it is not possible to calibrate each sheet thickness
combination separately; the robot option takes into account that

excessive weld time prolongation should be avoided. A thicker sheet
requires that the regulator react with the appropriate weld time
prolongation.
Expulsion Detection
Changing current due to expulsion

Use this parameter to define how the regulator reacts to a detected
expulsion. The regulator will change the current at the moment of the
expulsion by the programmed percentage. With a positive sign, the value
can cause an increase of current, and with a negative sign, a reduction of
current.
Expulsion counter
Click Reset to reset the expulsion counter and spots counter for all
programs.
For more information on expulsions, please refer to Program-Related

Parameters, Expulsions, and to Chapter 9.2.
Referring to UIR Program
Measuring
Click measuring to turn the U/I measuring on and off.
As a precondition for voltage measuring, an electrode voltage cable must
be connected to the electrode welding gun. U/I measuring is only
activated if it is also activated under general!
Regulation
Regulation
Turns the U/I regulator for the program selected on and off.
To activate the U/I regulator, the following preconditions must be met:
♦ The measuring must be activated under general and referring to UIR
program.
♦ The U/I regulator must be active under General.
♦ The reference curve of the selected program must be saved, and the
respective parameters must be set.
Beginning of regulation phase II

This value is calculated automatically when the reference curve is
generated.
Max. current raise

The max. current raise permits the U/I regulator to raise the current by a
percentage in relation to the reference current during the balancing of
disturbances.
Max. current reduction

The max. rated current reduction permits the U/I regulator to reduce the
current by a percentage in relation to the reference current during the
balancing of disturbances.
IMPORTANT
Changing these limits may impair the efficiency of the U/I regulator in
dealing with disturbances!
Do not change these values unless absolutely necessary.

time for this program.
The max. weld time prolongation parameter limits the weld time
prolongation which the U/I regulator needs to compensate for
disturbances. In automated operation, very long weld times may be
undesirable.
"PSQ maximum weld time reached” is displayed.
Example:
A weld time prolongation of 100% permits the U/I regulator to double the
programmed weld time if necessary.
Note
In the U/I regulation mode, it is no longer allowed to change the weld time
under programming – sequence – 2nd WLD.
When the U/I regulator is switched off, weld time prolongation is
deactivated as well.
Monitoring
The monitoring field turns the monitoring function fo the program selected
on and off in the U/I regulator. Activation of the monitoring function
requires an activated measuring both under general and referring to UIR
program.
See Chapter 5.7 UIR Monitoring
Expulsions
Spots counter
In the spots counter, the current number of welds (since counter reset)
for the program selected is displayed.
Expulsion counter
When the system detects an expulsion, the expulsion counter is counted
up. This allows to read the frequency of expulsions as compared with the
spots counter.
Use reset to reset the expulsion counter and spots counter for the
program selected.
5.6 PSQ Programming – UIR Reference
Display of the progress of current, voltage and resistance of the selected

curve in a diagram. This option also allows to read and save actual and
reference curves.
Load Curve
Å PC
Downloads a reference curve saved in the PC to the display. Clicking this
button opens a window for selecting the appropriate file.
The extension of these files is rui.
Reference Sequence Å Timer
Downloads the reference curve existing for this program from the weld
timer to the display.
Requirement: For this program, a reference curve had to be saved to the
weld timer.
Actual Curve Å Timer

Downloads the actual curve of the lastsequence from the weld timer to
the display, irrespective of the program that was run previously. The
associated program data, such as number and date/time, is displayed in

the header of the diagram.
Requirement: the U/I measuring is global and has been activated for this
program; the weld timer has completed a sequence.
Write Curve
Æ PC
Saves the displayed curve to the PC. Clicking this button opens a window
for selecting the appropriate directory and file name.
The extension of these files is rui.
Reference Sequence Æ Timer

Saves the curve displayed for this program as a reference curve to the
weld timer.
Any already existing reference curve will be overwritten!
Do not use this functions unless absolutely necessary.
Settings
Clicking this button allows you to set the colors of background, raster,
font, channel and cursor of this window.
Zoom
Zoom function of the x-axis to magnify the displayed curves by a factor of
2, 5, and 10.
You can also move both the x- and the y-axis to view a specific magnified
detail. To achieve this, left-click while the cursor symbol is a hand.
Display
Displays the values of the curve at the movable cursor line:
t moment in the curve
I current at the cursor position
R resistance at the cursor position
U voltage at the cursor position
5.7 Programming – PSQ – UIR Monitoring
To match the welding job and its quality control, the monitoring function
can be activated separately for each of the supervision parameters.
Depending on the welding job, it may be appropriate to monitor different
variables.
The monitoring result is displayed and recorded by the BOS 6000 and
will be available for evaluations, such as for the statistical process control
(SPC).
Note
To record the monitored values, activate (check checkbox) the current
value log function under WT assignment – current value log on starting
the BOS 6000.
The UIR monitoring display comprises two main sections:
1. The monitoring radio button is activated Æ monitoring is programmed
with tolerance bands, etc.
2. The radio button of a monitored variable is activated Æ the curve of the

monitored variable is displayed with tolerance bands.
Programming the Monitoring Function
The monitoring function can be separately turned on and off for each
monitoring variable.
The reference parameters are desired monitoring values for the various
monitoring variables.
The weld timer compares these desired values with the measured actual
values (displayed in the actual fields) and interprets them
• as being “accepted” or “rejected”, based on the tolerance limits of the
permissible upper tolerance band or the permissible lower tolerance
band;
• as continuously “worsening”, based on the conditionally permissible

tolerance band and repetition factor.
Poor actual values initiate an appropriate warning or error message,
provided the relevant monitoring function is activated.
Permissible Upper Tolerance Band

Defines the maximum permissible positive tolerance in a percentage of
the reference value.
Any actual values exceeding this tolerance limit generate the message
type “… too high”.
Permissible Lower Tolerance Band

Defines the maximum permissible negative tolerance in a percentage of
Any actual values falling below this tolerance limit generate the message
type “… too low”.
Conditionally Permissible Tolerance Band

Input value as a percentage of the reference value.
This parameter cooperates with the repetition factor for detecting any
“creeping” errors of the system, resulting in a slow and steady
“worsening” of the actual values.
Repetition Factor
The repetition factor defines the number of successive welding spots may
be within this conditionally permissible tolerance range.
If this value is exceeded, the weld timer emits a message of type
“repetition error …”.
Conditionally permissible tolerance band, repetition factor 3

+ upper tolerance in %
X welding current value

accepted
100% reference current in kA
cond. perm. tolerance

repetition factor=3
- lower tolerance in %
"Repetition error..."
error or warning
Note
The counter for the repetition factor is incremented, irrespective of which
of the monitored variables is within the conditionally permissible tolerance
band. After an accepted weld, the repetition factor counter is reset.
Acceptance Repetition Factor
Defines the number of successive welds within the tolerance band, after
which an exceeded tolerance band is reset. This also affects the display
in summary of PSQ process variables.
Progress Display
This display shows the characteristic of measured values of a supervision

parameter of a program.
Activate one of the radio buttons to select one of the available
supervision parameters. Activate the monitoring radio button to return to
programming of the tolerances.
By default, the diagram shows the last100 welds. If the record memory
contains a higher number of welds, you can scroll up or down through the
display. See welding sequences displayed.
Click zoom to view 200, 500 and 1000 welds in the diagram. See zoom.
The currently applicable reference value and the currently applicable
tolerance bands are displayed as a line.
To view the monitoring values of a specific weld, move the cursor line
while the cursor symbol is a hand. The parameter fields show the desired
and actual values of the weld selected. The name of the welding spot
including date and time are displayed at the upper edge of the diagram.
Display of Desired and actual values in the history values field

♦ Average values of desired current and actual current
♦ Average desired and actual values of the electrode voltage
♦ PHA: average desired and actual values of the pulse width (phase
angle)
♦ Desired and actual values of the weld time
♦ Desired and actual values of the energy
♦ Process stability: desired value always 100%. The actual value is
composed of several variables, providing comprehensive information
about the process by means of a number. Specifies a number for the
current process situation in relation to the stable starting situation.
♦ UIP: desired and actual values of the quality factor. The UIP is
composed of several variables, providing comprehensive information
about the quality by means of a number. It reaches a statement
about the welding quality on the basis of the curves measured.
♦ Desired and actual values of the heat
♦ Average desired and actual values of the resistance
25th weld value
perm. upper
tolerance range
desired =
reference
value
cond. perm.
tol. range
perm. lower
tolerance range
Welding Sequence Displayed

The diagram shows 100 welds by default. If the memory contains a
higher number of welds, you can scroll up or down through the display.
See Zoom.
The number of saved welds is displayed.
Update
Updates the display so that the lastwelds are also shown in the diagram.
Settings
Zoom
The zoom function increases the number of welds displayed in the
diagram to 200, 500 and 1000.
You can also move both the x- and the y-axis to view a specific detail. To
achieve this, left-click while the cursor symbol is shown as a hand.
Actual Æ Desired
Applies the current actual value of the monitoring value selected as the
desired value for monitoring.
Export
The actual values of the monitoring report are saved to a text file. To
achieve this, you can enter a directory including file or select the
“Backup” default directory.
The saved actual values can then be further processed or evaluated by
external parties.
Y-Zoom
Clicking this button magnifies the actual value in the direction of the Y-
axis by a factor of 2, 5 and 10.
PSQ Status Display

In addition to actual values, this display also shows the state of the U/I
regulator and monitor at the time when the weld at the cursor position
was made.
PSQ
UIR
USR
Regulation Monitoring
Green: active
Yellow: not active
Note
This display may change from weld to weld.
Information on Monitoring
We improved the monitoring quality not only by checking individual

physical variables for compliance with the appropriate desired values, but
also by using expressive criteria from the welding process for calculation.
As a result, the process stability PSF and the process quality UIP are
monitored.
In practice, the process is further improved by the fact that each and
every welding spot runs through this quality control.
While moving to the reference point, the regulator uses an acceptable

weld to learn the relation between its measured values and the quality of
the welded joint. While the regulated weld processes are in progress, the
regulator changes the current setting and the weld time, thus
compensating disturbing variables in order to achieve a consistent
welding quality. The integrated monitoring function supplements the
regulation, in order to make a statement about the quality of the joint
immediately after completion of the weld, by using the signal curves in
the production process. The monitoring result is displayed on the user
interface and is additionally saved to the record memory, so that it is
available for statistic evaluations. Using the programmed tolerance
bands, a statement can be made about accepted / rejected welds, with
generation of an error message if necessary.
Expulsion welds are represented as a cross in the monitoring window. To
view the time of expulsion occurrence in the weld time, place the cursor
on this cross. Expulsion welds are represented as a cross in the
monitoring window. To view the time of expulsion occurrence in the weld
time, place the cursor on this cross.
Expuslsion
Current
Here, it is inappropriate to set the tolerance as tight as possible (as is
known from the CCR regulator), since the U/I regulator must change the
current for compensating disturbing variables. When setting the current
tolerances, please keep to the limits of “max. current raise / reduction)”
(Chapter 5.5), which are the limits specified for compensation through the
regulator.
Note
The CCR tolerances programmed on the sequence tab do not have any
effect in the U/I regulation mode. They will be effective only after the CCR
mode is active again. See Chapter 8.4.
PHA (Pulse Width)

Here as well, tolerance limits should not be tight, because the pulse width
is changed in order to achieve a current raise / reduction. The associated
upper tolerance band can be used to implement a system protection
which prevents an excessively high power.
Weld Time
The lower tolerance (weld time too short) can be set within tight limits,
because the weld time will never be shorter than the reference weld time.
An exception here is a premature weld time stop in case of the “no
current” error or an external weld time stop. Depending on the type and
size of disturbances, it might be necessary to extend the weld time. For
that reason, set the upper tolerance value high enough to ensure that the
operational weld time prolongation (e.g. caused by electrode wear) does
not initiate a message yet.
For the weld time, the conditionally permissible tolerance band is
effective in upward direction (contrary to all other monitoring variables).
Energy
Since the weld time is included in the energy balance, the lower tolerance
(energy too low) can be set within tight limits; the energy included will
never be less than that of the reference weld. An exception here is a
premature weld time stop in case of the “no current” error or an external
weld time stop.
Depending on the type and size of disturbances, it might be necessary to
increase the energy. For that reason, set the “upper tolerance” value high
enough to ensure that the operational increase in energy without any
disturbance does not initiate a message yet.
Process Stability PSF

The process stability is a parameter expressing the degree of compliance
of the weld displayed with the reference weld. A process stability value of
100% indicates full compliance with the process of the reference weld
and, thus, a process that remains stable.
For example, a process stability of 70% indicates that the welding
process has changed by 30% as compared with the reference weld. The
welding device has changed, e.g. through wear. Or there was a
disturbing variable which had to be compensated by the U/I regulator.
Disturbing variables, if occurring only once, are characterized by a single
deviation from the 100% line, e.g. in case of an expulsion or an edge
weld.
A continuously increasing deviation indicates wear, mainly of the
electrode tips.
A comparison of the running process with the learned reference provides
a measure for the state and the safety of the welding process and the
welding device (trend analysis).
A change in the process, which is caused by compensation of disturbing
variables through weld time prolongation, is expressed by a worsening
process stability value. At the same time, the “weld time” parameter
assumes a higher value.
If manual welding guns are used, it must be noted that the welding of
different sheet combinations actually is a disturbing variable as well, as
compared with the reference weld. This will also result in deviations of
the process stability if the material used is differing accordingly.
In the CCR/PHA mode, the process stability is displayed only if a

reference curve has been downloaded.
Process Quality UIP

The process quality results from the exact analysis of the resistance
sequence of a weld. Characteristic corner marks and trends of the curve
are used for calculation. To achieve this, the resistance sequence is
subdivided in several sections. Characteristic marks of the resistance
sequence are the start and end resistances as well as the local maximum
and minimum. Slopes and tendencies permitting a statement about the
welding quality are derived from between these points. Depending on the
section concerned, the results of the UIP calculation of the individual
sections are included in the UIP with varying weighting.
Since the dynamics of the resistance sequence is only weak in some

welding jobs, the UIP calculation is additionally compared with the
appropriate sections of the reference sequence and included in the
calculation.
The interpretation of the statement about the quality of manual welding

gun is more difficult if different materials and sheet thicknesses are
processed with one and the same program.
In the CCR/PHA mode, the process quality is displayed only if a
reference curve has been downloaded.
Tolerances
To determine the tolerance bands for monitoring, you should proceed as
follows:
- First apply the actual values of the reference weld as reference

values for monitoring.
- Welds are recorded in the display of a curve of a monitored variable.
This provides a statement about the limits of the monitored variable.
- Set the tolerances around the reference value such that the major
part of the welds are within the accepted range. Any outliers will then
be outside of the tolerance bands.
- Please note that normal manufacturing variations are not outside of
tolerance limits (e.g. caused by electrode wear, dressing).
- The curve display shows the programmed tolerances as lines, thus
illustrating the potential effect of the tolerance bands.
- After having further observed and optimized the variable, activate the
monitoring function for this variable.
- Also verify that the monitoring function is also activated for this
program and in the “general” field.
5.8 Diagnostics – Last Sequence
Clicking the diagnostics – last weld) button will display the measured
values of the last welding sequence. The display will be refreshed
automatically upon each new sequence. In addition, these values are
filed to the record memory so that they can be tracked later on the
Programming – UIR monitoring tab.
This tab provides you with the following information on the relevant weld
timer:
♦ Previously started welding program incl. spot name
♦ Date and time of the last weld
♦ Wear counter reading of the electrode concerned
♦ Dressing counter reading of the electrode concerned
♦ Reference current and actual current, splitted by WLD and averaged
across all WLDs in the Standard line
♦ Reference time and time actually needed
♦ Necessary phase angle, splitted by WLD
PSQ values of the U/I regulator for the 2nd WLD

♦ Reference current and actual current
♦ Reference and actual values of the electrode voltage
♦ Reference and actual values of the pulse width (phase angle)
♦ Reference and actual values of the weld time

♦ Reference and actual values of the heat
♦ Reference and actual values of the energy
♦ Reference and actual values of the resistance
♦ Actual value of the process stability
♦ Reference and actual values of the UIP quality factor
♦ Expulsion time
Note
Minor differences in the values displayed for the average PHA, the
current and the weld time between the 2nd WLD and the 2nd WLD PSQ
result from the fact that the weld time can be measured with or without
overhang.
The reference value is the value specified in the UIR monitoring mode.
The U/I monitor compares this value with the actual value taking the
programmed tolerances into consideration and derives warnings and
error messages from this comparison.
5.9 Diagnostics – PSQ
Clicking the diagnostics – PSQ button will display the measured

values of the last welding sequence. The Filter function supports
generation of the reference curves.
The program data of the curves displayed, such as number and

date/time, is displayed in the header of the diagram.
The course of current, voltage and resistance over time is also displayed.
It is also possible to save the actual curve as a reference curve.
Filter
Without
Downloads the actual curve of the last sequence from the weld timer to
the display, irrespective of the program that was run previously. The
display is refreshed upon each new welding sequence.
Program
If program is activated, you can select a program number. This starts the
data display for this program only. This data display will be refreshed with
each sequence of this program.
This permits to observe a specific program in automatic systems.
Single/Prog.
If single/prog. is activated, you can select a program number. This starts
the data display for this program only. Only one sequence of this program
will be recorded.
To restart the data display, select Stop and then single/prog. again.
In automatic systems, this function prevents the curves displayed from
being overwritten by a new sequence.
Stop
This option stops the data display until it is released by one of the other
filter functions.
In automatic systems, this function prevents the curves displayed from
being overwritten by a new sequence.
For example, this is required when the reference curve is saved with
ACTUAL Æ reference).
Display
Displays the values of the curve at the movable cursor line:
t moment in the curve
I current at the cursor position
U voltage at the cursor position
R resistance at the cursor position
Rref resistance of the reference curve at the cursor position
Cursor 1
Cursor 1 is active by default. That means that the curve values are
displayed at the position of cursor 1.
Cursor 2
To display the curve values at the position of cursor 2, select cursor 2.
Min.
Select this radio button to display the minimum value between the two
cursors.
Max.
Select this radio button to display the maximum value between the two
cursors.
MV
Select this radio button to display the average value between the two
cursors.
Actual Æ Reference
If you intend to use a recorded weld for generating the reference curve,
stop data recording with stop to ensure that the curves displayed will not
be overwritten by a new sequence.
Click the actual Æ reference button to save the curve displayed as the
reference curve to the U/I regulator. To achieve this, enter the program
number and acknowledge the message that appears with OK.
Settings
Zoom
Zoom function (magnification) of the time axis of the displayed curves by
a factor of 2, 5, and 10.
You can also move both the x- and the y-axis to view a specific magnified
detail. To achieve this, left-click while the cursor symbol is shown as a
hand.
5.10 Setup – UIR Setup
Allows for comfortable setting of reference curves, above all in automated

production.
Start the recording mode and select one or more weld timers. From now
on, the resistance characteristics of your welds are recorded and
assigned to the corresponding program. The sequence in which the
programs are executed is not important. It is advisable to weld some
components before completing data recording. Now, you have some
resistance characteristics for each program that has been run. From this
data, a average curve can now be calculated for each program and
saved to the U/I regulator as a reference curve for this program. As a
matter of course, this requires that the welding quality of the curves
recorded is satisfying. To this effect, determine e.g. the spot diameter.
Outliers in the curve slopes caused e.g. by expulsion must be deleted
before calculation.
In practice, this mode considerably simplifies the definition of reference

curves.
Recording Mode
Select the weld timers in the recording mode by checking the appropriate
checkboxes at the beginning of the line. If you check the topmost
checkbox, you can select/deselect all connected weld timers as a whole.
To select a new recording of curves, check the new recording checkbox.
This deletes any curves that have already been recorded.
Recording has been started.
The BOS is now ready to record data and is waiting for the first
sequence.
The welds performed now are displayed as resistance characteristics.

Important: The sequence in which the programs are welded is of no
significance – they can be executed in "any" sequence (e.g. Prg 15, Prg
4, Prg 6, etc.).
The progress of data recording can be viewed in the right-hand section of

the window. If the message recording complete appears in the status
display, click stop recording to stop recording and move to the analysis
mode, provided you have recorded all welds necessary for generating the
reference curves.
Start recording with new recording.
This starts recording of new data. If there are any previously recorded
curves, they are deleted, and the resistance characteristics of the most
recent welding program are saved.
Start recording without new recording (Continue)

Unintentional or intentional exiting of the window does not result in loss of
the recorded data. If you start recording without checking the new
recording checkbox, you can continue recording.
Analysis Mode
Filter – Program
Any previously recorded curve slopes can be viewed in dependence on
the respective program. All recorded curves of this program are
displayed.
Filter – Actual Curve

Use this function to switch between the individual curves of the currently
selected program and to select one curve. The currently selected curve is
shown in red.
Delete Actual Curve

Clicking the delete actual curve button will delete the curve selected.
outliers.

Average Curve
Clicking the Average Curve button will calculate the reference curve for a
program; the curve is indicated in red. The black curves show the
minimum and maximum resistance characteristics of this program.
Original Curves
Clicking the original curves button will switch back to the original curve
screenshot from the average curve screenshot.
Reference Sequence Æ Timer

Click the reference sequence Æ Timer button to save the red curve as
the reference curve to the U/I regulator.
Æ PC
Clicking Æ PC will save the red curve as the reference curve to a
directory of the PC. To do this, a directory must have been selected
beforehand.

achieved through the heat correction function of the BOS 5000/6000.
Weld time and current setting cannot be changed any more as they are
now defined by the U/I regulator. For this reason, when activating PSQ
current monitoring, it is important to set sufficiently wide tolerance bands
to enable the U/I regulator to react without signaling of errors.
Zoom
Zoom function (magnification) of the time axis of the displayed curves by
a factor of 2, 5, and 10.
5.11 Overview
Overview – General
The overview tab allows you to select a parameter from the list. The
current state of this parameter is listed for all programs of the weld timer
selected. This provides a quick overview of the state of the system.
Overview – UIR Mode
Program number
Active = Not active =
Note
The measuring is displayed as being active only if it is global and ON for
this program.
Regulation is displayed as being active only if the measuring is global

and ON for this program, if the regulation is global and ON for this
program and if a valid curve is saved for this program.
Monitoring is displayed as being active only if the measuring is global and

ON for this program, if monitoring is global and ON for this program and if
at least one of the supervision parameters is ON.
Overview – PSQ Process Variables
The PSQ process variables screen of the overview tab allows you to
select the process stability or UIP parameter. The current state of these
supervision parameters is listed for all programs of the weld timer
selected. This provides a quick overview of the state of the quality
control. This requires that tolerances have been specified and monitoring
been activated in programming – UIR monitoring.
Only those programs (Prog.) / spot names are displayed, where n.i.o.
spots are existing.
Meaning of Table Columns
Spot name
If there is no spot name, the message “ no spot name!” will be displayed.
If the spot name is shown on a colored background, there are spots
corresponding with this program. Place the cursor on the spot name to
show a tool tip text which displays the corresponding spots with several
spot names being assigned to one program.
Program number
A program number associated with the above spot name.
Note
Click on the program number to open the UIR monitoring window which
shows the UIP and/or process stability of the program concerned.
N.i.o.
Number of welding spots which are Not OK (n.i.o.), i.e. which have
exceeded the conditionally permissible or the permissible lower tolerance
band.
The number of i.O. (OK) spots can be defined on programming – PSQ –

UIR monitoring screen. This number is defined under acceptance
repetition factor = UIR monitoring limit, which indicates the number of i.O.
(OK) spots have to follow in order to reset an exceeded tolerance.
Total
Display of the totel of all welding spots for this program number that have
been completed since the last time errors were reset on this screen.
Max. status: % display

Percentage value of the rejected (n.i.o.) welds in relation to the total of
welds.
Status bar:
• Green: the programmed number of successive accepted
welds (acceptance repetition factor) has been reached,
i.e. the tolerance band has not been exceeded, and the
percentage value of the n.i.o. welds is below the
percentage specified under Status Max. %.
• Yellow: at least one welding spot was rejected.
• Red: the display range of the bar was exceeded,
depending on the setting under Status Max. %.
Status Max: % Parameter

Allows setting of the display range of the bar to 1%, 2% or 5%. Beyond
this range, the bar will become red.
Update
Destined for reading in of the current data and refreshing of the display.
Whenever the screen is called up, the display is refreshed automatically.
Reset errors
Resets the error display of the process variables.
Counting of n.i.o. spots and total spots is restarted.
This option does not reset any sequence errors!
To sort the columns, just click on the header of the particular column.
Examples:
4 out of 81 welds have exceeded a tolerance band a short time ago. The
bar becomes yellow because the Status max. is set to 5%.
4 out of 71 welds have exceeded a tolerance band. The bar becomes red
because the Status max. of 5% has been exceeded.
3 out of 70 welds have exceeded a tolerance band. The bar, however, is

green because the last welds – set under programming – PSQ – UIR
monitoring – acceptance repetition factor – did not exceed any tolerance
band and the Status max. of 5% has not been exceeded either.
5.12 Process Overview
Clicking the button will provide an overview of the process state

of the connected weld timers.
The following items can be selected:

• Process stability
• UIP
• Q stop (depending on the type of weld timer)
Green bar
Percentage value of all programs enabled for a WT, which did not exceed
any conditionally permissible tolerance band nor any permissible lower
tolerance band.
Yellow bar
Percentage value of all programs enabled for a WT, which exceeded a
conditionally permissible tolerance band or a permissible lower tolerance
band in the last 10 welding spots.
Red bar
Percentage value of all programs enabled for a WT, which initiated a Q-
stop error.
The Q-stop function is not available for all weld timers. Please refer to the
description of the Q-stop function in the WT documentation.
The sequence inhibition of enabled programs is OFF.
The display is sorted such that the worst value is shown at the top.
Update
Click update to refresh the display.
Double-click on a WT to open the overview – PSQ – process variables

window with the appropriate UIR process variable, which provides an
overview of the process state of the various programs of this WT.
6-58 Commissioning with BQR
6 Commissioning with BQR

Following the installation of all components, the system can be
commissioned step by step.
For additional information on commissioning, please refer to Chapter 8.
6.1 First Step

Commissioning the weld timer / inverter unit in the constant current
regulation mode (CCR).
The functioning of the system in the constant current regulation (CCR)

mode is an essential prerequisite. The U/I regulator uses the same
mechanisms as the CCR. This part of commissioning corresponds to the
known procedures for a PSI 6000 inverter system, so that welding spots
can be produced in the CCR mode.
In this context, see the manuals on the PS 6000 regulation system and
I/O level, medium-frequency inverter, and welding transformer.
This step also comprises any required force and current scaling.
Refer to the corresponding chapters in the manuals.
Note
Scaling must not be performed while the U/I regulator is active.
6.2 Second Step

Prerequisites regarding welding gun and electrodes
The welding gun must be in excellent condition. The electrodes must be

adjusted to ensure that they stand exactly opposite each other and in a
right angle to the sheet.
The electrode tips should be dressed and slightly used (approx. 20–25
spots). Dressing corrects the contact surface of the electrode tips. This
results in ambient conditions like those of new tips. However, there may
also be interferences which are caused by dressing. First of all, dressing
can create irregularities on the contact surface (e.g. chatter marks);
secondly, the plane of the contact surface may not coincide as well with
the joining plane as in the used cap condition.
Squeeze time and hold time should be long enough to allow the welding
gun to build up the required force.
Force measuring is recommended.
Commissioning with BQR 6-59
6.3 Third Step

Generating the Reference Curve
Select the desired welding program at the BOS 5000/6000 user interface.
To generate a reference curve, first make some welds in the constant
current regulation mode until you have reached a sufficient spot
diameter.
Check or set at the BOS5000/6000 user interface

Squeeze time sufficient for this welding job
Hold time sufficient for this welding job
st
1 weld time Possibly as a pilot pulse in the CCR mode (see
Chapter 9.4)
2nd weld time and set for this welding job. Possibly, upslope in the
current 2nd weld time
3rd weld time Possibly for post-heating in the CCR mode
CCR mode ON
Repetition sequence OFF
Inhibit monitoring ON
Readjusting Heat values to 100%
Note
If possible, the heat correction should be set to 0% to allow full correction
functionality later in the U/I regulation mode.
Settings at the BQR user interface of the U/I regulator

All programs UIR measuring ON
Selected program UIR measuring on
UIR regulation off
UIR monitoring off
Data Æ don't forget the timer (weld timer).
See chapter 7 "BQR User Interface U/I Regulator" for a detailed

description of the BQR operation.
Setting the reference curve
Under Setting of tools - U/I, generation of reference curves is supported.

Advantage: several welding procedures of a program can be used to
generate a reference curve, irrespective of the sequence of the
programs. In practice, this considerably simplifies the definition of
reference curves.
Press the New key in Data recording to start data recording.
A welding process has been recorded.
All executed welding processes are indicated. View - Program filter

shows the program number of the program executed last, and View -
Actual curve the current number of the last welding process.
If the welding processes which are to be used to generate the reference

curve have been recorded, data recording can be stopped now.
Now, chose a program in View - Program filter to see this program's

curves. In View - Actual curve select one of these curves; this selected
curve is indicated in red for evaluation.
To delete this specific curve, use Delete actual curve.
expulsion
outliers.

Now, click the Average curve button to calculate the reference curve for a
minimum and maximum resistance characteristics.
maximum resistances
Minimum resistances
average curve
Click original curves to switch back to the original curve screenshot from
Confirm reference curve
Use actual curve Æ reference curve to save the red curve as the
reference curve to the U/I regulator.
Notes
For each combination of sheet thicknesses, we recommend using a

separate program and to determine a separate reference curve.
Advantage: In separate programs, all welding parameters can be set in
an optimal manner for the respective welding job; there is less extension
of weld time caused by different sheet thicknesses.
However, if different sheet thickness combinations must be welded with
one program (manual welding gun), the reference curve is determined by
means of the thinnest sheet combination with the lowest resistance. In
case of coated sheets, it is determined by means of the thinnest sheets
with the thickest coat. Set the force for mean to thick sheet combinations.
Please also refer to Chapter 8.3.
Always make the reference weld without adhesive between the sheets, or
make at suitable sheet strips because adhesive is a disturbance variable.
Welding at the component is possible for determination of reference

curves. If strips are used, please note the following:
- The curve of the first spot on a sheet should not be used as a
reference curve.
- Spots should be welded at a distance of approx. 20 mm (shunt).
If the spot diameter is too small, increase the current from spot to spot
until the expulsion limit is reached.
If there are expulsions, reduce the current to the last expulsion-free value
and re-weld. For compensation purposes, it might be necessary to
extend the weld time.
Only after the weld has been made without expulsions and with the spot
diameter required can this curve be applied as reference curve.
Welding quality cannot be determined through interpretation of the

curves. The evaluation of the curves is limited to the following aspects:
- Resistance characteristic: typical course with strong downslope of
resistance at the start (contact is made) and continuous downslope
of resistance towards the end.
- Voltage signal: does a voltage signal exist, and is its curve similar to
the resistance.
Expulsions can also be recognized from the suddenly falling slope of the
Please also refer to Chapter 9.
The wear state of the tips should be between 10 and 100 welds.
6.4 Forth Step

Activation of the Regulator for this Program:
Settings at the BQR user interface of the U/I regulator

All programs UIR regulation ON
Selected program UIR regulation ON
Note
Through all programs, the measuring, monitoring and regulation for all
weld timer programs can be switched off.
Steps 2 to 4 must be repeated for each spot which is to be welded in the

U/I regulation mode.
This completes the determination of reference curves.

Weld time and current setting cannot be changed any more as they are
current monitoring, it is important to set sufficiently wide tolerance bands
Use to indicate the curves of the current welding.
Visualization of the curve slopes
For a detailed description of operation, please refer to Chapter 7

"BQR User Interface – U/I Regulator".
7-66 BQR User Interface – U/I Regulator
7 BQR User Interface – U/I Regulator
The BQR user interface can be used for parameterization and

diagnostics of the U/I regulator on site and for supplementing the BOS
5000. The current versions of the BOS 6000 interface also contain the
functions of the separate BQR user interface. The BQR user interface for
the U/I regulator can only be operated via the V24/RS232 interface on
the regulator modul X3C or the weld timer X1. It automatically adjusts to
one of the two Baud rates of 19,200 Bd or 57,600 Bd. The GUI is
dimensioned for a fixed screen resolution of 1024 * 768 points.
In the same way as in BOS 5000 / BOS 6000, up to 256 welding

programs (0–255) and 32 electrodes (0–31) are supported.
The BQR user interface is only used for commissioning or diagnostics.

After initial setup, the regulator works independently.
7.1 Installation and Connection
Requirements
• Operating system: Windows 2000/NT/XP

• Screen resolution: 1024 x 768
• Serial interface COM1 or COM2 (with at least 57,600 bauds)
• Min. Pentium II 233 MHz
• Min. 1 GB space on the hard disk drive
• Min. 64 MB random access memory
• CD Rom drive
Connection
For connection, a V24/RS232 connection cable is required between the

PC and the regulator modul, e.g. BOSCH order number 1070 066749.
For more information on the connection cable, please refer to the Rexroth
Manual “PSI 6xxx.000 Control and I/O Level”, Technical Information,
index entry “programming unit” or “X1”.
Installation
Depending on your operating system, select one of the following
directories:
• Windows 2000 and NT
• Windows XP
and start the Setup program.
BQR User Interface – U/I Regulator 7-67
7.2 Overview of Operating Functions
Operation of the U/I regulator is subdivided in the areas described in the

following. These areas are reflected in the menu structure.
File View Tools ?

Backup U/I/US curves Comport Help
(auto)
Restore Reference Select Info

curves language
(program)
End Weld timer

identification
PSI settings
Expert mode
Initialize data
Load firmware
Set up U/I
Table: Menu structure of the user interface
7.3 Parameterization of the U/I Regulator
All parameters for U/I regulation are stored in the regulation device. A
distinction is made between parameters for
· "all programs": applicable to all electrodes and all programs

· "selected program": applicable to program numbers 0 to 255
To achieve the desired welding results, all parameters must be set

correctly. To ensure simple application, all parameters are preset with
default values that will generate a functioning welding in most cases.
All parameters are monitored with regard to a permissible entry range, or

the entry is limited to the permissible range. Before a parameter is
loaded, the default vales are indicated.
Basic Display
All Programs
All programs means for the overall weld timer, covering all electrodes and
programs.
This is the location of the activation of measuring, regulation, and
monitoring for UIR.
Mode
This list box allows optimization of the activated U/I regulator by means of
adjusted regulator parameters, for robot – manual welding gun – fine spot
applications.
The “mode” function mainly affects the weld time prolongation in case of
disturbing variables. For example, the manual welding gun option
considers that it is not possible to calibrate each sheet thickness
combination separately; the robot option takes into account that
excessive weld time prolongations should be avoided. A thicker sheet

requires that the regulator react with the appropriate weld time
prolongation.
Expulsion Detection
Current change
Use this parameter to define how the regulator reacts to a detected
expulsion. The regulator will change the current at the moment of the
expulsion by the programmed percentage. With a positive sign, the value
can cause an increase of current, and with a negative sign, a reduction of
current.
Smooth area
Preset with default value. Changes are only allowed as per instruction.
Selected Program
First, select a program with
Here, measuring, regulation and monitoring for a selected program is

activated.
Click measuring on to turn the U/I measuring on and off.

As a precondition for voltage measuring, an electrode voltage cable must
be connected to the welding gun. To activate the U/I measuring, it must
also be activated under "All Programs”!
Click regulation on to turn the U/I regulator on and off.

To activate the U/I regulator, the following preconditions must be met:
a) the U/I regulation mode must be active under "All Programs;
b) the reference curve of the selected program must be stored, and the
respective parameters must be set.
U/I regulation ready
Here, the operating condition of the regulator is indicated:
U/I regulator ready
U/I regulator not ready
A U/I-regulated welding sequence can only be carried out if a valid

reference curve for the selected program has been loaded, and if the U/I
regulator has been activated globally as well as for the selected program.

time for this program.
The maximal parameter limits the weld time prolongation which the U/I
regulator needs to compensate for disturbances. In automated operation,
very long weld times may be undesirable.
“SQ maximum weld time reached" is displayed.
Example:
A weld time prolongation of 100% permits the U/I regulator to double the
programmed weld time if necessary.
Note
In the U/I regulation mode, it is no longer allowed to change the weld time
under programming – sequence – 2nd WLD)
When the U/I regulator is switched off, weld time prolongation is
deactivated as well.
Spots counter
In the spots counter, the current number of welds (since counter reset)
for the program selected is displayed.
Expulsion counter
If the U/I regulator detects an expulsion, the expulsion counter is

incremented. This allows to read the frequency of expulsions as
compared with the spots counter.
Click the reset button to reset the expulsion counter and spots counter for
the program selected.
Click reset all to reset the expulsion counter and spots counter for all
programs.
Copy
Click this button to copy the parameters of the selected program to other
programs.
Note
By double-clicking a parameter field (left mouse button), only the
parameter selected can be copied to several programs.
UIR Parameter
Limit values
The max. current raise permits the U/I regulator to raise the current by a
percentage in relation to the reference current during the balancing of
disturbances.
The max. current reduction permits the U/I regulator to reduce the current
by a percentage in relation to the reference current during the balancing
of disturbances.
IMPORTANT
Changing these limits may impair the efficiency of the U/I regulator in
dealing with disturbances!
Do not change these values unless absolutely necessary.
Period II
This value is calculated automatically when the reference curve is

generated.
Supervision Parameters
To match the welding job and its quality control, the monitoring function
can be activated separately for each of the supervision parameters.
Depending on the welding job, it may be appropriate to monitor different
variables. Please also refer to Chapter 5.7, Information on Monitoring.
The monitoring function can be separately turned on and off for each
monitoring variable (checkbox).
The reference parameters are provided as desired monitoring values for
the various monitoring variables.
The weld timer compares these desired values with the measured actual
values and interprets them
• as being “accepted” or “rejected”, based on the tolerance limits of the
permissible upper tolerance band or the permissible lower tolerance
band;
• as continuously worsening, based on the conditionally permissible

tolerance band and repetition factor.
Poor actual values initiate an appropriate warning or error message,
provided the relevant monitoring function is activated.
Permissible Upper Tolerance Band

Defines the maximum permissible positive tolerance in a percentage of
Any actual values exceeding this tolerance limit generate the message
type “… too high”.
Permissible Lower Tolerance Band

Defines the maximum permissible negative tolerance in a percentage of
Any actual values falling below this tolerance limit generate the message
type “… too low”.
Conditionally Permissible Tolerance Band

Input value as a percentage of the reference value.
This parameter cooperates with the repetition factor) for detecting any
“creeping” errors of the system, resulting in a slow and steady
“worsening” of the actual values.
Repetition Factor
The repetition factor defines the number of successive welding spots that
may be within this conditionally permissible tolerance range.
If this value is exceeded, the weld timer emits the message type
“repetition error …”.
Conditionally permissible tolerance band, repetition factor
+ upper tolerance in %
X welding current value
accepted
100% reference current in kA
cond. perm. tolerance

repetition factor = 3
- lower tolerance in %
"Repetition error..."
error or warning
Note
The counter for the repetition factor is incremented, irrespective of which
of the monitored variables is within the conditionally permissible tolerance
band. After an accepted weld, the repetition factor counter is reset.
Q Stop
This function depends on the type of weld timer and is described in the
associated documentation.
For more information on how to monitor and define tolerance

bands, please refer to Chapter 5.7.
Backup/Restore
The menu item File provides the Backup and Restore functions.
Use the Backup function to store the data of the regulation modul to the
PC (or network).
Having selected the data source "regulator card”, you must determine a
file directory and name. Through actuation of the Start button, the
regulation modul creates a backup of the parameters and reference
curves of the individual programs.
Use the Restore function to transfer saved data back to the regulation
modul.
Having selected "regulator card”, you must determine a file directory and
name. Through actuation of the Start button, the parameters and
reference curves of the individual programs are downloaded from the
backup file to the regulation modul.
Display of UI / US Curves (Auto)
This display shows the curve slops of the last weld.

Program number, date and time of the last sequence are also shown.
In the diagram, the current curve slope is shown:

• Voltage blue
• Current red
• Resistance green
• Reference resistance black
The weld time is plotted on the x axis in milliseconds.
On the curves, individual moments in time (in milliseconds) can be

selected via mouse click. Then, the corresponding measured values of
the selected spot are indicated in the diagram frame.
Use
to select the individual curves.
All Programs
This button in the display field starts the request to the regulator modul;
the signal area turns green.
If a new welding sequence has taken place, current curve slopes are
downloaded and displayed automatically. A new sequence is detected by
the time specification.
Stop
Use Stop to stop data transfer; the signal area turns red.
Display of Reference Curves (Program)
Here, reference and actual curves can be downloaded to the display and
saved as reference curves.
Source – From PC
Downloads a reference curve stored in the PC into the display. To this
end, select the directory (default directory:
C:\EinrichtenUI\Referenzkurven) and the file on the PC.
The reference curve can be saved to one of the targets.
Source – Reference Curves from Timer

Downloads a reference curve from the weld timer to the display. To this
end, a program number must be entered.
The reference curve can be saved to one of the targets.
Source – Last Curves from the Timer

Downloads the actual curve of the most recent weld from the weld timer
to the display. To this end, a program number must be entered.
The curve can be stored in one of the targets.
Destination – in PC
The currently displayed curve is saved as a reference curve to the PC
directory (default directory: C:\EinrichtenUI\Referenzkurven). A file name
must be entered.
Destination – UIR in Timer

The currently displayed curve is saved as a reference curve to the weld
timer. A program number must be entered.
IMPORTANT
Changing the reference curve may impair the function of the U/I
regulator!
Do not use this functions unless absolutely necessary.
Tools, U/I Setup
Comport
Specification of the comport number of the computer where the serial
interface V24/RS232 is connected. Having entered a new port number, a
new initialization of the interface is performed; after successful
completion, the comport number is shown in the left bottom corner and
shaded in green. A red field indicates that the interface is not ready.
Select Language
German and English can be selected here.
System Info
To identify the weld timer and / or the regulation module, the version
identification of the device where the user interface is connected via the
serial interface can be displayed.
When the BQR user interface is connected to the regulator modul X3C,
the version identification of the regulator modul is displayed.
When the BQR user interface is connected to the weld timer (X1
interface), the weld timer type and its version number are displayed
additionally.
Initialize Data
• Delete reference curve: this requires entry of the curve number
= program number.
• Initialize modul parameters: deletes all parameters and resets
the U/I regulator modul to its basic state.
Load Firmware
Use this function to load new firmware to the regulator modul.
– Open file: the extension of the file is "hex".
– Observe the messages on the screen.
The firmware version can be viewed under Tools – System info.
CAUTION
While the firmware download is in progress, no welding sequence can be
performed!
U/I setup
Allows for comfortable setting of reference curves, above all in

automated production.
Start data recording. From now on, the resistance characteristics of all
weldings are recorded and assigned to the corresponding program. The
sequence in which the programs are executed is not important. It is
advisable to weld some components before completing data recording.
Now, you have some resistance characteristics for each program that
has been run. From this data, a average curve can be calculated for each
program and saved to the U/I regulator as a reference curve for this
program. As a matter of course, this requires that the welding quality of
the curves recorded is satisfying. To this effect, determine e.g. the spot
diameter.
Outliers in the curve slopes caused e.g. by expulsions must be deleted
before calculation.
In practice, this mode considerably simplifies the definition of reference
curves.
Start recording with New.
New
This starts a new data recording. Any previously recorded curves will be
deleted. Each welding process performed from now on will be stored in
the BQR and displayed in correspondence with the respective program.
Continue
Unintentional or intentional exiting of the window does not result in loss of
the recorded data. Click Continue to re-start at the point you left the data
recording window.
The recorded curves are filed in the PC under C:\EinrichtenUI\P001,
...\P002, etc.
Program Filter
Any previously recorded curve slopes can be viewed in dependence on
the respective program. Only the curves for the selected program are
shown.
Actual Curve
Use this function to switch between the individual curves of the currently
selected program and to select one curve.
Recording has been started.

The BQR is now ready to record data and is waiting for the first
sequence.
Stop stops the recording.
In the record mode, entries cannot be made in the program filter and
actual curve boxes.
Display - program filter shows the program number of the program

executed last, and display – actual curve the current number of the last
welding process.
Record mode
The welds performed now are displayed as resistance characteristics.

The most recent curve is indicated in red.
Important: The sequence in which the programs are welded is of no
significance – they can be executed in "any" sequence (e.g. Prg 15, Prg
4, Prg 6, etc.).
However, all last curves and the actual curve are always output for the
program welded last.
The actual curve box shows the number of processes executed with the
actual program.
The program number, date and time of the last sequence are shown in
the header.
The footer provides further information on readjustment and electrode
state:
♦ Dressing counter
♦ Wear counter
♦ The current correction factor shows the currently effective power
readjustment in percent of the basic power.
Zoomed curves
Right-click to zoom the curves in their amplitude. Left-click to return the
curves to standard representation.
Recording complete
After termination of recording with Stop, select the curves of the desired
program with program filter. All recorded curves of this program are
displayed.
Use actual curve to switch between the curves of a program and select
the curve desired. The actually selected curve is shown in red.
To delete the curve selected, use delete actual curve.
In the above illustration, Program 3 has been selected with program filter.
10 curves have been recorded; one of these can be selected through
actual curve to have it shown in red. This provides for better
representation and evaluation of the individual curves.
minimum resistances
maximum resistances
Minimum resistances
average curve
Average reference curve
Now, click the average curve button to calculate the reference curve for a
minimum and maximum resistance characteristics of this program.
Click original curves to switch back to the original curve screenshot from
Applying the reference curve
Use actual curve Æ reference curve to save the red curve as the
reference curve to the U/I regulator.
Using In PC, the red curve is saved as the reference curve to the PC
directory C:\EinrichtenUI\Referenzkurven.

Weld time and actual setting cannot be changed any more as they are
actual monitoring, it is important to set sufficiently wide tolerance bands
Instructions on Commissioning 8-87
8 Instructions on Commissioning
Commissioning of the U/I regulator requires a quality weld (= reference

weld) which will form the basis of regulation and monitoring.
There are different cases:
Initial startup (new materials, new systems, new components, etc.)

• As quickly and easily as possible
• Parameters have not been optimized yet
• Wide monitoring limits
• Only certain supervision parameters are reasonable
Optimization (increase in piece numbers, stable bulk production, etc.)

• System optimization (robot positioning, cooling, forces,
scaling, etc.)
• Welding parameter optimization
• Tight monitoring limits
The reference weld must be a problem-free weld of the particular

welding job, with a result that exceeds the minimum requirements. The
spot diameter should be just above the nominal diameter, but below the
expulsion limit. The result must be verified by means of a destructive
test. In addition, the curve slopes should be checked / interpreted, for
example to detect expulsions or edge welds.
The definition of the quality weld as a reference weld requires

compliance with further requirements:
• The electrode tips must be worked in, but not worn too
strongly Æ approx. 20 spots
• The welding gun force must be stable and reproducible:
verify by repeated measurings
• Cooling state okay: check flow volume and cooling tube
8.1 Defining the Basic Welding Parameters

The basic welding parameters for a welding spot to be set up can be
obtained from various sources:
• Apply the welding parameters from a system which is

running in a stable state and performs the same welding
job
• Results of laboratory tests
• DMS table values
8-88 Instructions on Commissioning
• Manufacturer’s specific inhouse standard

• Calculation programs
• Welding parameters database
• Simulation programs
8.2 Making the Reference Weld
Variant 1: Weld a spot on the original component in the production

shop.
• Safest method for regulation and monitoring

• Requires optimized welds
• Requires a low number of expulsions
• Dressing cycle must be incorporated
• Relatively work-intensive as compared with variants 2
and 3
• Results in a relatively large volume of testing scrap
(components)
• Suitable for retrofitting of existing systems
Sequence for each sheet combination (don’t forget special items, such as
adhesives):
• CCR weld with basic parameters on the component with
original welding gun
• Subject components to a destructive test
• If the spot diameter is OK, make several welds on
various components to create defined marginal
conditions
• Define referencing from superimposed curves (see
Chapter 5.10) and save the reference curve
• Make a weld on the component using the U/I regulator
• Copy the reference curve to all spots with the processed
sheet combination and activate the regulator
• Observe the monitoring result
• Weld the component using the U/I regulator
• Destructive test
• Second recursion for optimization
Variant 2: Weld sheet strips at the welding gun in the production shop.
• Less work-intensive than variant 1

• As compared with variant 1, the regulator is involved to a
greater extent, since the individual special features of the
spots on the component are not taken into consideration
• Poorer basis for the process stability and process quality
monitoring variables
Please observe the following:

• Effect of dressing cycle, welding gun replacement,
adhesives, special steels and coatings
• The first welding spot on the sheet strip is of no
relevance
Details on variant 2:
On startup of a new system (new vehicle model)

• Few existing components for setup welding
• Extraordinarily expensive components
• Components fail to be custom-fit
Variations in the welding sequence, which have to be compensated by

the regulator:
• Robot positioning
• Fitting problems
• Shunt
• Wear
• Material variants
Sequence for each sheet combination (don’t forget special items, such as
adhesives):
• CCR weld with basic parameters on the sheet strip with
original welding gun.
• Subject sheet strips to a destructive test
• If the spot diameter is OK, make several welds on
various sheet strips to create defined marginal conditions
• Define referencing from superimposed curves (see
Chapter 5.10) and save the reference curve
• Make a weld on the sheet strip using the U/I regulator
• Copy the reference curve to all spots with the processed
sheet combination and activate the regulator
• Observe the monitoring result
• Weld the component using the U/I regulator
• Destructive test
• Second recursion for optimization
Variant 3: Weld sheet strips in the laboratory.
• Least work-intensive
• The regulator is involved to a very high extent, since
individual special features of the spots and the welding
device are not taken into consideration
• Optimization required for close monitoring
• Suitable for initial parameterization
• Poorer basis for the process stability and process quality
monitoring variables
Details on variant 3:
Problems which may occur on transition from the welding gun in the
laboratory to the welding gun in the production shop:
Which are the differences between the welding guns?
- Resistance of the secondary circuit
- Force development
- Slipping behavior
- Inductive influences
- Electrode tips
Theoretically, the influence exercised by the welding gun can be

eliminated by tapping the voltage directly at the electrode. In other words,
the voltage tap should be placed as near to the electrode as possible, in
order to be able to generalize welding parameters, reference curves and
monitoring limits.
8.3 Commissioning the Suspension Spot Welders with U/I

Regulator
Basic requirements for commissioning the Suspension Spot

Welders with U/I regulator:
• Measuring instruments for scaling of current and

force
• Cap dressing device (or file)
• Sheet strips of all sheet combinations used
• Tools for testing the welding quality of the sheet
strips (e.g. manual ultrasonic device, hammer and
chisel, shear tension machine)
1. Checking / scaling of force and current

Proper scaling of force and current is an important requirement for
optimal functioning of the U/I regulator.
2. Preparing the electrode tips

- Dress the tips initially.
Since there are welding guns which do not allow dressing of the
tips, the necessary working surface of the cap should be
achieved by filing or grinding. Above all, this minimizes slipping of
the welding gun if the tips are applied at an angle.
- Work in the tips (approx. 20 spots).
3. Checking the sheet combinations

- Define the sheet packets, i.e. thinnest / thickest sheet combination
(e.g. for a total sheet thickness ranging from 1.5 mm to 4.5 mm)
- Check the strength of the sheets (e.g. soft, micro alloy, high strength,
ultra-high strength)
- Analyze the coatings of the sheets used (e.g. organic, anodized
or hot-dip galvanized)
- Check critical sheet combinations, 3-sheet weld (e.g. 0.7 mm DC04+ZE
+ 2 mm Usibor + 2 mm H320LA)
4. Defining the welding parameters for the reference curve

(see table: Basic parameters for the U/I regulator)
- Force
The force should be defined for the thicker sheet combinations, with the
strength of the sheets taken into account. The maximum force of the
welding gun also plays an important role. Sometimes, the forces that can
be reached with manual welding guns range only up to 3 kN. In this case,
the force should be set to approx. 2.8 kN, in order to reduce the wear of
the welding gun.
- Current
The current should be set such that the maximum resistance develops in
the 1st third of the weld time. The strength and coating of the sheets
welded with the welding gun must also be taken into consideration. If,
e.g., only hot-dip galvanized sheets are welded, the current for the
reference curve should already be adjusted to galvanizing.
Observe the following recommended values:

• Electrolytic coating and hot-dip galvanization: current increase
of 0.5 to 1.0 kA in addition to the value specified in the table
• Higher-strength steels: current must be reduced by up to
1.0 kA
- Weld time
The weld time should be within the range of the average sheet packet
(e.g. sheets ranging from 1.5 mm to 4.5 mm Æ WLD: ranging from 210
ms to 710 ms according to table Æ WLD: set approx. 450 ms).
We recommend an upslope of 50 ms to 100 ms especially in case of
fitting problems, thicker sheet packets and adhesives.
The squeeze time should be selected such that the programmed force is
completely built up on start of the weld time (see figure force built-up).
The example clearly shows that the maximum force has only been built
up after approx. 300 ms. A squeeze time of at least 1000 ms is
recommended for manual welding guns.
However, the squeeze time should be separately checked for each type
of welding gun. Particularly where large welding guns and high forces are
concerned, an extended squeeze time may improve welding quality.
The hold time may be dependent on the sheet combination.

Tests have shown that the hold time should range from 100 to 200 ms.
Force built-up during the squeeze time:
Force built-up: Lap welding gun with 3,0kN
3500
3000
Resistance characteristic with correct and insufficient squeeze

2500
times:
2000
Force / N
1500 Force / N
1000
500
0
0 100 200 300 400 500 600
Time / ms
Resistance characteristics with correct squeeze time and two short

squeeze time:
Resistance characteristics with different squeeze times
450
Basic parameters for the U/I regulator

R / µOhm
400
If adaptive regulators are used, the welds must be made within
the scope of one current pulse.
350 For soft deep-drawing steels with an additional organic coating,
the basic parameters are as follows if pairs of F16 electrode tips Force 3,0kN
Squeeze: 300ms
are used:
Force 3,0kN
300 Squeeze: 150ms
250
200
0 10 20 30 40 50 60 70 80 90 100
Time / ms
Table: Basic parameters for the U/I regulator

Total sheet Upslope Weld time Current Force
thickness [mm] [ms] [ms] [kA] [kN]
1.2 - 200 9.0 2.0
1.3 - 200 9.0 2.1
1.4 - 200 8.9 2.1
1.5 - 210 8.8 2.1
1.6 - 230 8.7 2.2
1.7 - 240 8.7 2.2
1.8 - 250 8.6 2.2
1.9 - 270 8.6 2.3
2.0 100 350 8.5 2.3
2.1 100 360 8.5 2.4
2.2 100 380 8.4 2.4
2.3 100 390 8.4 2.5
2.4 100 400 8.3 2.5
2.5 100 410 8.3 2.6
2.6 100 430 8.2 2.6
2.7 100 440 8.2 2.7
2.8 100 450 8.2 2.8
2.9 100 470 8.1 2.9
3.0 120 500 8.1 3.0
3.1 120 510 8.1 3.1
3.2 120 530 8.0 3.2
3.3 120 540 8.0 3.3
3.4 120 550 8.0 3.4
3.5 120 560 7.9 3.5
3.6 120 580 7.9 3.6
3.7 120 590 7.9 3.6
3.8 120 600 7.8 3.7
3.9 120 620 7.8 3.7
4.0 120 630 7.8 3.8
4.1 120 640 7.8 3.9
4.2 120 660 7.8 4
4.3 120 670 7.8 4.1
4.4 120 680 7.8 4.2
4.5 150 710 7.8 4.3
4.6 150 730 7.8 4.4
4.7 150 740 7.8 4.5
4.8 150 750 7.8 4.6
4.9 150 770 7.8 4.6
5.0 150 780 7.8 4.7
5.1 150 790 7.8 4.8
5.2 150 800 7.8 4.8
5.3 150 820 7.8 4.9
5.4 150 830 7.8 5
5.5 150 850 7.8 5.1
5.6 150 860 7.8 5.2
5.7 150 870 7.8 5.3
5.8 150 880 7.8 5.4
5,.9 150 900 7.8 5.5
6.0 150 910 7.8 5.5
5. Evaluating the reference curve by means of an example
To generate the reference curve for all optimized welding guns, the
following sheet combination was used in tests:
1.75 mm H320LA + 0.8 mm DC04 OC

=> sheet packet of 2.55 mm
From table: I = 8.3 kA; STZ (WLD) = 410 ms
Example:
Welding gun with Fmax: 3.9 kN
Thinnest sheet combination: sheet packet of 1.54 mm

0.7 mm DC04 ZE + 0.84 mm ZE
Thickest sheet combination: sheet packet of 4.85 mm

1.5 mm H320LA + 2.0 mm Usibor + 1,25 mm Usibor
Æ Welding parameters selected for reference:

Force: 3.5 kN (because of Fmax of the welding gun)
Upslope: 3.0 kA / 100 ms (adhesive is used)
2. STZ (WLD): 7.6 kA (less current because of Usibor) and
450 ms
(The time corresponds approximately to the average value of the
times for the thickest and the thinnest sheets.)
Actual curve:
Course of refernce current
5
I / kA
I_Ref
4
0
0 50 100 150 200 250 300 350 400 450
Time / ms
Resistance characteristic:
Course of refernce resistance
350
300
250
R / µOhm
R_Ref
200
150
100
0 50 100 150 200 250 300 350 400 450
Time / ms
In the resistance characteristic, the maximum should develop relatively

early after the upslope.
6. Checking the welding quality

To check the welding quality, U/I-regulated welds should be made on the
sheet strips, using the critical sheet combinations (thinnest combination,
thickest combination or 3-sheet combination).
If the welding quality proves to be satisfactory, the welding gun can be
used for manufacture.
If there are expulsions or spots that are too small, the welding
parameters should be adjusted by optimizing the actual and weld time
parameters.
8.4 Returning to the CCR Mode
If switching back from the U/I regulation mode to the CCR mode
becomes necessary, it is essential that the CCR parameters have also
been optimized. In this case, the programmed actual value (in kA) will
again become decisive for the welding quality.
The reference actual parameters including tolerances and repetition
factor are effective for CCR (actual) monitoring.
The heat correction function is still effective and can be used to adjust the
value of the current. In most cases, the current in the CCR mode should
be set higher than that in the U/I regulation mode.
In the U/I regulation mode, the heat does not have to be corrected,
because the heat adjustment is programmed to be 100%. Switching back
to the CCR mode, however, might require a heat correction, in order to
compensate for electrode wear.
9-98 Comprehending the Resistance characteristics
9 Comprehending the Resistance characteristics
To execute its regulation task, the U/I regulator utilizes a great deal of
data from the welding process. For calculating the actual and weld time
control variables, the U/I regulator uses various measuring variables at
different times during the welding sequence. In addition to the current, it
also uses the values of energy and resistance. It also includes
information about expulsion events and the time course of the various
variables in its calculation.
To become familiar with the process of a welding job, it is recommended

to comprehend the resistance characteristics. These curves are
visualized on the user interface, together with the actual curves. In the
constant-current (CCR) mode, this visualization allows observation of
changes in the process after welding parameters have been varied, so
that this knowledge can be used for optimization. In the U/I regulator
mode, comprehension of the resistance characteristics helps to
recognize interventions of the regulator and changes in the process
situation.
9.1 Normal Curve

The figure below shows the “normal” course of a curve. At the beginning
of the weld, the values are relatively high; then the resistance decreases
because the sheets are heated and, thus, better abutting. This phase is
called the coupling or heating phase. After a relative minimum, the
resistance again rises to a relative maximum, because the steel starts to
liquefy in the weld spot. Once the maximum value has been reached, the
material in the weld spot is liquid. While the weld time is elapsing, the
resistance value continuously decreases. In this phase, the welding spot
increases until it reaches the spot diameter desired.
normal curve
coupling / fusing phase, spot increases

heating phase
maximum
Stromzeit[ms]
weld time [ms]

Comprehending the Resistance characteristics 9-99
Here, it must be noted that the sequence shown represents an ideal

curve. There may be sheet combinations where the minimum and
maximum positions are expressed only weakly, so that the curve has a
very flat behavior. For example, this applies to very thin sheet
combinations. There may even be cases where the resistance
characteristic starts with a high initial value and then decreases without
any noticeable extreme values until the weld time has elapsed
completely. This can be observed with thin electrolytically galvanized
sheets. The regulator is suitable for such curves, although their
interpretation is more difficult. Dynamic resistance characteristics, i.e.
changes in resistance of approx. 100 µOhms, are usually developing with
thick sheet combinations.
9.2 Expulsions
In the resistance characteristic, an expulsion can be identified by a
sudden change towards lower resistance values. In the example shown
below, the expulsion occurs at 105 ms of the weld time. The measures
for elimination of the expulsion strongly depend on the time of expulsion
occurrence, as will be illustrated in more detail below.
expulsion
expulsion
weld time [ms]
Resistance characteristic with expulsion at 105 ms

9.3 Isolating Materials

Isolating layers between the sheets to be welded are particularly incurred
where adhesives are used in the body assembly shop. If properly
applied, such materials do not impair the weld. However, their isolating
effect must be eliminated before the welding process is started. The
figure below shows the variation in the resistance characteristic. At the
start of the weld time, the resistance remains high until the isolating layer
is displaced or burnt away. The duration of this phase depends on the
material used and the forces at the welding gun and on other factors.
Once the isolation has been eliminated, the welding process will be
running normally with the resistance characteristics being defined by the
sheet combination.
adhesive
adhesive causes delayed start

of the heating phase
Normal course
weld time [ms]
Resistance characteristic in case of welds with adhesive
9.4 Steps to Optimize the Weld
The curves of the process variables visualized by the user interface can
be used to easily optimize the welding parameters.
General Rules
• The special features of the particular welding job must always be

included in optimization (material, coating, adhesives, etc.).
• The welding device and the parts to be joined must always be
checked for being suitable for the welding job (forces, positioning,
cooling, flange width, etc.).
• Any disturbing variables of the welding device must be minimized.
• Using the scales of the graphs, the voltage and resistance conditions
of the machine / welding gun can be checked roughly.
• Before generating the reference weld, defined starting conditions
must be created for the electrode cap (see Chapters 4.2 and 6.2).
• Resistance characteristics should be dynamic with a relatively large
variation in resistance. Such curves indicate a stable process
situation and can be observed easily.
Elimination of Expulsions
At first, the time of expulsion occurrence must be determined.
Early Expulsions
An expulsion occurring before approx. two thirds of the weld time have
elapsed indicates an early expulsion time. When early expulsions are
incurred, it must be expected that the ratio of current to force is not
correct. If a check shows that the force has the proper value, the current
must be reduced.
There are other disturbing variables in the welding process which may be
the cause of expulsions. If the spot position results in an edge weld, it
must be eliminated. Often, fitting problems will cause expulsions. Apart
from eliminating the cause, an improved coupling can be reached by a
current upslope.
Late Expulsions
An expulsion occurring in the last third of the weld time indicates a late
expulsion time. In case of late expulsions, the disturbing variables in the
welding process must be minimized as well. A known problem is a poor
slipping behavior of the welding device.
Expulsions occurring shortly before the weld time has elapsed completely
can often be eliminated by slightly shortening the weld time. This applies
particularly to hot-dip galvanized material.
Expulsion in the Regulation Mode
Although the regulator largely balances disturbances caused by

disturbing variables, welding expulsions may nevertheless occur in the
regulation mode. This can be attributed to the fact that the disturbing
variable is so strong that it cannot be regulated any longer or that several
disturbing variables are effective at the same time.
The response of the regulator to expulsions can be adjusted with regard

to the welding current (see Chapters 7.3 and 5.5). In case of expulsions,
the activated regulator automatically extends the weld time to a certain
degree, in order to compensate for the energy that has been lost with the
material.
The regulator provides the additional possibility of varying the energy

introduced by means of the “heat correction” function. It is also possible
to reduce the energy in order to eliminate expulsions.
Optimization in Case of Single-Pulse Welding
In association with the force, current and weld time must be dimensioned
such that the relative maximum of the resistance characteristic is
positioned before half of the weld time has elapsed. The coupling phase
for hot-dip galvanized material is longer, so that the maximum of the
resistance characteristic may also be positioned in the second third of the
weld time.
Optimization in Case of Preliminary-Pulse Welding
Where preliminary-pulse welding is concerned, the preliminary pulse

must be dimensioned such that there is no fusing yet. This can be
achieved by setting the appropriate current and pulse duration and, if
necessary, the cool time. In the preliminary pulse, the resistance
characteristic must not reach its maximum yet. The falling edge of the
resistance characteristic must be positioned entirely in the main pulse.
preliminary pulse
weld time [ms]
Dimensioning a preliminary pulse

10-104 Error Messages
10 Error Messages
The weld timer will inform you of any events occurring during operation
which are of relevance for it.
Primarily, a distinction is made between
• errors and
• warnings.
In case of an error
• no welding sequence can be started,
• the READY LED at the front of the weld timer turns dark (see
documentation of the weld timer),
• the output signal "Weld Timer Ready" at the PSI 6000 is reset.
In case of a warning
• welding processes are still permissible.
Whether an event is interpreted as error or as warning
depends on the parameterization of the weld timer (BOS; error
assignment).
Errors as well as warnings can be "self-acknowledging".
“Self-acknowledging” means that such events are automatically cleared
by the weld timer after the cause of error or warning has been eliminated.
In this case, a manual “Fehler rücksetzen (error reset)” is not required.
Examples for self-acknowledging errors:

- Stop circuit open /no 24 V
- Supply voltage off / too low
Together with information on error causes and error

elimination, all error and status messages concerning the PS
6000 and the U/I regulator can be found in the “Error List PS
5000 / PS 6000” (No.: 1070 087001).
For the acknowledgement of errors, please refer to the

appropriate weld timer manual.
DANGER
After an error has been reset, the machine might immediately start
the welding procedure!
If an error is reset (acknowledged) while the start signal is present,

the weld timer immediately starts the program run! This may result
in dangerous movements of the machine! For that reason, please
ensure that no-one is staying in the danger zone of the welding
device, before resetting the error!
List of Accessories 11-105
11 List of Accessories
Component Order number

V24/RS232: 9-pin D socket 1070 912981
V24/RS232: protective cover for 9-pin D socket 1070 313723
V24/RS232: cable set, 1.5 m in length 1070 066749
2
Sensor cable: 2 x 2 x 0.75 mm LiYCY 1070 913494
Table: List of accessories including order numbers

12-106 Abbreviations, Terms
12 Abbreviations, Terms
BOS (UIW) User interface welding

BQR User interface U/I regulator
CAN Controller Area Network: data bus
E/A (I/O) Input / output (Eingang / Ausgang)
ED (ON) ON time: ratio of weld time to idle interval
ESZ (EST) End slope time, current ramp at the end of the 2nd WLD
Ext. External, e.g. +24-V voltage for signal elements
(switches) and controlling elements (valves) outside of
the weld timer.
FK (SEC) Step enable contact, completed message contact
kA Kiloamperes (current intensity)
kN Kilonewtons (force)
KSR (CCR) Constant current regulation. Keeps the current in the
secondary circuit constant through regulation.
KUR (CVR) Constant voltage regulation. Balances line fluctuations.
LAN Local Area Network: general network
LT (PU) Power unit (thyristor or inverter)
LST (POW) (G) Current in SKT (scale values/pulse width) or kA
MV (SV) Solenoid valve, activation of the cylinders, for closing the
electrodes.
PG (PU) Programming unit / welding processor.
PHA Phase angle
PSG Transformer-rectifier unit for the PSU/PSI inverter series
PSL PS power unit
PSI Medium frequency power unit (1000 Hz)
PSQ Quality assurance system
PST Thyristor power unit (50/60 Hz)
PSS PS power unit
PSU Welding current inverter (medium frequency)
PSZ (CT) Cool time, time between the current pulses/blocks (1st,
2nd, 3rd CT).
SKT Scale values. Measures of an electric phase angle or
pulse width.
Slope Current tramp from an initial to a final current value
SST Timer (WT) Weld timer, also referred to as timer, or
resistance weld timer.
SSZ (UST) Upslope time, current ramp at the start of the 2nd WLD
Stepper Current stepping for compensation of electrode wear
STZ (WLD) Weld time
nd
2. STZ (2 WLD) Second weld time, main weld time, can form a
block with individual pulses; only this 2nd WLD
can work with current increase and current
decrease (slope)
Temp Temperature
UDM Ultrasonic data processing module (front end)
Abbreviations, Terms 12-107
UIR U/I regulator

US Ultrasonic
USE Ultrasonic sensors
USP Intersecting point between compensating line / x axis
USR USR regulation module
USW NEXUM recording of operating data and statistics
software
ÜK (MC) Monitoring contact.
E.g. for monitoring the pressure inside the cylinder (which
closes the electrodes) or monitoring of the electrode position
(e.g. “welding gun closed”).
VHZ (SQZ) Squeeze time that elapses before the weld time. The
electrodes squeeze together the parts to be welded.
XQR Regulator modul
Zdg. (Weld/No weld) Ignition, firing pulses for triggering the power are
switched on and off
12-108 Abbreviations, Terms

Psq6000 Rexroth Manual Datasheet

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Contents 1-1

Rexroth PSQ 6000 1070087072

Commissioning, Operating Manual

Title Rexroth PSQ 6000 U/I Regulator

Class of Documentation Commissioning, Operating Manual

Documentation Type DOK-PS6000-UIR********-IB01-EN-P

Intent of the Documentation

This information supplements the respective manual "PSI 6000 Control

Note on Industrial Property Rights

Reference Sequence Å Timer .............................................................5-32

5.11 Overview............................................................................... 5-53

8.3 Commissioning the Suspension Spot Welders with U/I

But there are still residual risks!

The contents of this manual refer to

There are separate manuals for the respectively existing power

For that reason, please also observe the following documentation:

In addition, the safety instructions in the manuals “PSI 6000 Control

2.1 Intended Use

To utilize class A devices in residential, business and commercial

To ensure proper and safe operation, the product must be transported,

2.2 Environmental Protection, Return of Material, Reuse

Taking back material

2.3 Qualified Personnel

• those who, being well trained and experienced in their field

2.4 Dangerous Magnetic Fields

2.5 Installation and Assembly

2.6 Electrical Connection

DANGEROUS ELECTRIC VOLTAGE

2.7 Modifications by the Operator

2.8 Maintenance, Repair

DANGEROUS ELECTRIC VOLTAGE

2.9 Working Safely

Note: Please also observe any safety-relevant information essential for

2.10 Installation and Retrofit

The following protective measures must be observed for modules and

• Personnel responsible for storage, transport, and handling must

3.1 Design of the System as a Whole

U/I regulator modul

BQR user interface

Highly flexible cable

User interface Control cabinet / welding box Welding gun

(1): max. length: 100 m

Schematic wiring diagram of the system

Cable Type for Voltage Measuring

Contacting at the welding gun arm:

X8A pin assignment:

1 USEC_1 Electrode voltage, input_1

3 USEC_2 Electrode voltage, input_2

X3C pin assignment:

X1S pin assignment: UDM

X7C pin assignment:

4 Reserved 24V extern

8 Reserved error line

Green LED lit:

3.3 Weld Timer Integration

3.4 Field of Application

· with and without slope

Change of power voltage

3.5 Information on Installation and Assembly

On delivery, the regulation module is already installed in the weld timer /

In case of retrofitting, the dummy plate has to be removed and the

An updated version of the BOS user interface is necessary together with

4 Commissioning with BOS 6000