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Bosch WT PSI 6 Series Technical Information

Bosch WT PSI 6 Series Technical Information

Weld timer
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PSI 6000
Description of Timer and I/O Level
PSI 6XXX.190 W1
Technical Information
101
Edition

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  • Page 1 PSI 6000 Description of Timer and I/O Level PSI 6XXX.190 W1 Technical Information Edition...
  • Page 2 DIN ISO 9001 Reg. no. 16149-01/2 E 2001 This manual is the exclusive property of Robert Bosch GmbH, also in the case of Intellectual Property Right applications. Without their consent it may not be reproduced or given to third parties.

  • Page 4: Table Of Contents

    PSI 6XXX.190 W1 Contents Contents Page Safety instructions and reader’s information Explanation of pictographs and symbols ....Typographic conventions ....... . . Proper use .
  • Page 5 PSI 6XXX.190 W1 Contents Page Installation ..... . Cables ......Suppression of RF noise .
  • Page 6 PSI 6XXX.190 W1 Contents Page Commissioning ....10-1 10.1 Preparations ........10-2 10.2 Testing the welding program...
  • Page 7 PSI 6XXX.190 W1 Contents Your notes: 1070 080 086-101 (01.01) GB...

  • Page 8: Safety Instructions And Reader's Information

    Safety instructions and reader’s information Automationstechnik Safety instructions and reader’s information Please read this documentation before working with the Weld Timer (WT) PSI 6XXX.190 W1 for the first time. Store this manual in a place to which all users have access at all times! The products described have been developed, manufactured, tested and documented in compliance with the fundamental safety requirements of the EU Machinery Directive.
  • Page 9 Safety instructions and reader’s information Automationstechnik There is a certain hierarchy of warnings in this manual. The warnings are printed in bold letters and marked by a warning sign at the margin. The hierarchy of the warnings is as follows: WARNING CAUTION NOTE...

  • Page 10: Typographic Conventions

    Safety instructions and reader’s information Automationstechnik Typographic conventions General listing Example: The message is displayed on the screen. Action Example: Insert floppy Read value Screen displays, Italics Example: Battery-Low messages, displays Tip dress request (Welding) parameters [in brackets] Example: [Weld time], [Schedule].

  • Page 11: Warning Of Magnetic Fields

    Safety instructions and reader’s information Automationstechnik Warning of magnetic fields In the environment of resistance welding systems magnetic field strengths have to be ex- pected which usually are below the limits specified in VDE 0848 Part 4; in cases of doubt, the field strength must be measured.

  • Page 12: Not Permitted For Persons With Cardiac Pacemakers

    Safety instructions and reader’s information Automationstechnik Not permitted for persons with cardiac pacemakers WARNING for persons with cardiac pacemakers! Warning signs should be posted for protecting persons with cardiac pacemakers be- cause the function of these devices may be disturbed (impulse failure, total failure) and a negative influence on the pacemaker programming or even a total program destruction may occur !!! We recommend posting a warning of the type shown below at all entrances to factory...

  • Page 13: Qualified Personnel

    Safety instructions and reader’s information Automationstechnik Qualified personnel This manual is designed for welding technicians and engineers with special training and specific knowledge of the welding technology. They require profound knowledge of the weld timers (WT) MF inverters (PSI) welding transformers and/or welding rectifier-transformers (PSG) The term qualified personnel refers to engineering personnel familiar with the safety standards of the electrical and au- tomation technology.

  • Page 14: Storage And Transport

    Safety instructions and reader’s information Automationstechnik Storage and Transport NOTE Please note the environmental conditions given in the Technical data section to avoid damages. Static discharges may destroy components of the weld timer. Therefore, the original packaging should be used for storage and transport. The equipment must be protected against humidity.

  • Page 15: Installation And Assembly

    (EMC), cf. also section 7 as well as gen- eral information contained in the Bosch EMC manual for resistance welding components. 1070 080 086-101 (01.01) GB...

  • Page 16: Electrical Connection

    Safety instructions and reader’s information Automationstechnik Electrical connection The PSI 6XXX.190 W1 are supplied with 24 V DC. This power supply must provide safety separation in accordance with the Low-Voltage Directive (72/23/EEC, 93/68/EEC and 93/44/EEC). WARNING! Considerable dangers are associated with the mains connection of the power unit! The possible consequences of inappropriate handling include death, severe bodily injury and damage to property.

  • Page 17: Operation

    Danger of bruises through electrode movement! All users, line designers, welding machine manufacturers and welding gun produ- cers are obliged to connect the output signal of the Bosch weld timer which initiates the electrode movement so that the applicable safety regulations are complied with.
  • Page 18 Safety instructions and reader’s information Automationstechnik Simulate start In remote-controlled systems, program execution may begin which may result in dangerous machine movements. Therefore, before remote starting, it must be en- sured that nobody is in the dangerous area of the welding machine! CAUTION! Damage to property through excessive welding current! The maximum welding current of the welding hardware used must not be exceeded.

  • Page 19: Retrofits And Modifications By The User

    Safety instructions and reader’s information Automationstechnik Retrofits and modifications by the user The PSI 6XXX.190 W1 has been designed and manufactured by us as a safe unit. WARNING! Retrofits or modifications may have negative effects on the safety of the unit! The possible consequences include death, severe or light bodily injury (personal injury), damage to property or environmental hazards.

  • Page 20: Maintenance And Repair

    Empty batteries should always be replaced by new ones! CAUTION! The right to perform repair/maintenance work on the PSI 6XXX.190 W1 compo- nents is reserved to the Bosch service department or to repair/maintenance units authorized by Bosch! Only use spare parts/replacement parts approved by Bosch! The applicable regulations on the disposal of empty batteries or accumulators must be observed.
  • Page 21 Safety instructions and reader’s information Automationstechnik Your notes: XVIII 1070 080 086-101 (01.01) GB...

  • Page 22: System

    PSI 6XXX.190 W1 System System General Welding Timers (WT) of the PSI 6XXX.190 W1 series are specifically designed for seam welds. The welding system consists of Welding hardware (welding gun with seam welding device) Timer module PSI 6XXX.190 W1 MF inverter PSI A programming terminal with BOS-5000 software for data entry, operation and monitoring Mains...
  • Page 23 System PSI 6XXX.190 W1 Up to 32 seam welding programs can be programmed and called up. In the basic setup seam operation is preselected. The welding parameters are stored in a RAM memory. The RAM memory has battery backup to prevent loss of data. The condition of the battery and the data is being moni- tored.
  • Page 24 Figure 2: Block diagram of functional principle Welding current The Bosch medium-frequency welding system uses DC current for welding. The duration of the welding current is programmed in milliseconds (ms). The welding process is per- formed more evenly than with 50 Hz welds. The range of good welds is increased.

  • Page 25: Block Diagram Of Timer

    System PSI 6XXX.190 W1 Block diagram of timer On the front panel of the timer is a V24 interface. This can be used for connecting a laptop computer or an operating terminal (BT), for example, for programming as well as operat- ing the timer locally.

  • Page 26: Programming And Operating The Timer

    PSI 6XXX.190 W1 System Programming and operating the timer The following components are required for Operation and Programming of the timer: Programming terminal with one of the following operating systems: Windows 3.1x Windows 95 Windows 98 Windows NT3.x / NT4.0 Software BOS-5000 Technical documentation: Operating and programming instructions, volume 1, part no.
  • Page 27 System PSI 6XXX.190 W1 Your notes: 1070 080 086-101 (01.01) GB...

  • Page 28: Technical Data

    PSI 6XXX.190 W1 Technical data Technical data Welding timers Degree of protection IP20 when installed in power unit Operating voltage +24 VDC +20 %, -15 % with max. ±5% ripple optional internal supply or external supply to logic and I/Os Rated current (w/o I/Os) at 24V approx.
  • Page 29 : 1.6 A Pressure output analog pressure output 0 to + 10 VDC/max. 20 mA Programming via laptop com- via internal V24 / RS232 interface, puter or Bosch BT operating isolated terminal Connection: 9-pin Cannon connector Field bus for programming Profibus-FMS or...

  • Page 30: Power Unit

    PSI 6XXX.190 W1 Technical data Power unit Overview of technical data of power unit PSI 6XXX.190 W1 System voltage 400 V -20 % to 480 V +10 % 3-phase System frequency 50 / 60 Hz Clock frequency 1000 Hz DC link voltage 550 V DC to 680 V DC (nominal voltage) Overvoltage protection...
  • Page 31 Technical data PSI 6XXX.190 W1 Your notes: 1070 080 086-101 (01.01) GB...

  • Page 32: Hardware

    PSI 6XXX.190 W1 Hardware Hardware Structure The PSI 6XXX.190 W1 comprises the following functional units: CPU with centralized control function I/O module parallel inputs and outputs Field bus interface Profibus FMS or optionally Interbus PMS MF inverter (PSI) All settings required for operation can be made at the front side or through a connected programming terminal.
  • Page 33 Hardware PSI 6XXX.190 W1 Module front panel without type-specific I/O system U1 V1 W1 3/PE U2 V2 2/ 2/PE [18] [19] [10] [11] [12] [13] [14] [17] [16] Caution Warning [15] Figure 5: CPU front panel 1070 080 086-101 (01.01) GB...
  • Page 34 PSI 6XXX.190 W1 Hardware Line LED, d.c. link voltage (PSI) is present. Ready LED timer ready, turns off in case of: Internal fault, e.g. dead battery Schedule fault, e.g. no current. Firing LED, Control signal for thyristor unit active Battery fault LED, backup battery voltage too low Reset push button, clears pending fault messages, returns timer to ready state.
  • Page 35 6-pin plug-in terminal (no function). [15] 8-pin plug-in terminal: transformer temperature, floating contact [16] Battery compartment; use only batteries with Bosch P/N 1070 914 446. [17] Blanking plate on slot for field bus module. [18] Elements of type-specific I/O interface. [19] Blanking plate 1070 080 086-101 (01.01) GB...

  • Page 36: Module Front Panel Type-Specific I/Os

    PSI 6XXX.190 W1 Hardware Module front panel type-specific I/Os E0 1 U1 V1 W1 3/PE A0 1 U2 V2 2/ 2/PE Caution Warning Figure 6: Type-specific I/ interface 1070 080 086-101 (01.01) GB...
  • Page 37 Hardware PSI 6XXX.190 W1 Fusing of outputs A0, A1 to A6 : miniature fuse 5 x 20, M 1.6 A A1 to A6 : miniature fuse 5 x 20, M 1.6 A 16-pin plug-in terminal inputs (3.5 mm spacing) 8-pin plug-in terminal inputs (3.5 mm spacing) 14-pin plug-in terminal outputs (3.5 mm spacing) 4-pin plug-in terminal 24 VDC voltage supply (3.5 mm spacing) for types of connection, see sections 7.3.1 and 7.3.2.

  • Page 38: Installation

    Installation PSI 6XXX.190 W1 Installation CAUTION! Danger of life and of damage to property through insufficient protection class! The protection class of the CPU and the I/O module of the PSI 6XXX.190 W1 mo- dules is IP 00. PSI 6XXX.190 W1 modules must be installed in a power unit. Danger of injury and of damage to property through incorrect installation! The units, and especially the operating elements, must be installed so as to be suf- ficiently protected against unintentional operation or contact.
  • Page 39 Installation PSI 6XXX.190 W1 E0 1 U1 V1 W1 3/PE A0 1 U2 V2 2/ 2/PE Caution Warning Figure 7: CPU and I/O module in power unit 1070 080 086-101 (01.01) GB...

  • Page 40: Cables

    PSI 6XXX.190 W1 Cables Cables Cables and cable lengths. Interface Cable Cross section/max. length X1, programming terminal shielded cable min. 0.2 mm up to 20 m (V 24) e.g. 3 x 2 x 0.2 mm LifYCY (Metrofunk) capacitance max. 2.5 nF X2, pressure analog pressure output shielded cable...
  • Page 41 Cables PSI 6XXX.190 W1 Your notes: 1070 080 086-101 (01.01) GB...

  • Page 42: Suppression Of Rf Noise

    Suppression of RF noise PSI 6XXX.190 W1 Suppression of RF noise Means of noise suppression are required to prevent radiation of radio frequency noise. Such noise is caused by transients peaks, which are transmitted by the power supply line. Noise should be neutralized at the source. If this is not practical, the noise suppression devices must be placed as close as possible to the source.
  • Page 43 Suppression of RF noise PSI 6XXX.190 W1 Your notes: 1070 080 086-101 (01.01) GB...

  • Page 44: Electrical Connection

    PSI 6XXX.190 W1 Electrical connection Electrical connection In this section, you will find a description of the CPU ports, various connection options for power supply, and the functions of the parallel I/O interface. WARNING! Working with system voltage may result in death, severe bodily injury or consider- able damage to property unless the appropriate precautionary measures are taken.
  • Page 45 Electrical connection PSI 6XXX.190 W1 <Start> PSI 6200.190 W1 Pin2 <Block selection_1> *1 stop circuit: Pin3 <Block selection_2> floating contact V_24 load: <Block selection_4> Pin5 24 VDC / max. 3A <Program selection_1> +24 VDC I/O <Program selection_2> <Program selection_4> <Program selection_8> <Program selection_16>...

  • Page 46: Interfaces

    PSI 6XXX.190 W1 Electrical connection Interfaces 7.1.1 Programming terminal X1 V24 interface For the cable type and the maximum cable length, please refer to the table “Cables”, see section 5. Both ends of the shield conductor must be connected to the conductive connector shell. The connector should be screwed to the unit to improve the shielding efficiency.

  • Page 47: Pressure X2

    Electrical connection PSI 6XXX.190 W1 7.1.2 Pressure X2 For cable type and maximum cable length, please refer to the table “Cables”, see sec- tion 5. The connection between PSI 6XXX.190 W1 and the pressure control valve consists of a shielded cable. The shield is connected to X2/5 and the shield ground at the pressure control valve.
  • Page 48 PSI 6XXX.190 W1 Electrical connection Pressure control valve +24VDC Valve supply Pressure reached 0V to +10 VDC/max. 20 mA <Pressure input +24 VDC/20 mA> Pressure Figure 11: Connection of pressure control valve with feedback Pressure control valve 0V to +10 VDC/max. 20 mA <Pressure input +24 VDC/20 mA>...

  • Page 49: Transformer Temperature X3

    Electrical connection PSI 6XXX.190 W1 7.1.3 Transformer temperature X3 Temperature monitoring by a floating contact (ncc) in the welding transformer. Transformer temperature too high: [Schedule] is aborted No <Start> is possible. 7.1.4 Power supply X4 see section 7.2 7.1.5 External device X5 +24 V DC are output at interface X5 for supplying an external unit (maximally 2A, depend- ing on the external supply).

  • Page 50: Power Supply

    Electrical connection PSI 6XXX.190 W1 Power supply 7.2.1 Internal power supply Configuration A The power supply to PSI 6XXX.190 W1 is completely provided by the power unit (internal supply). PSI 6XXX.190 W1 is internally supplied with 24 V DC (derived from the mains voltage). Several jumpers have to be positioned to enable the internal power supply.
  • Page 51 Electrical connection PSI 6XXX.190 W1 PSI 6XXX.190 W1 Configuration A: Power supply to weld timer logics, firing, inputs and outputs and the external unit by internal 24 VDC power. *1 stop circuit: floating contact load: +24 V 24 VDC / max. 3A +24 V +24 VDC Jumper + 24VDC int.

  • Page 52: External Power Supply

    Electrical connection PSI 6XXX.190 W1 7.2.2 External power supply Configuration B The power supply to PSI 6XXX.190 W1 is provided by an external unit (external supply). Several jumpers have to be positioned to enable the external power supply. The power supply to the timer is thus independent of the welding network. For configuration B, the external power supply must satisfy the following requirements: Maximum ripple <5 %, tolerance -15 % / +20 %.
  • Page 53 Electrical connection PSI 6XXX.190 W1 PSI 6XXX.190 W1 Configuration B: Power supply to weld timer logics, firing, inputs and outputs and the external unit by an external 24 VDC power supply unit. Power supply unit *1 stop circuit: floating contact load: +24 V 24 VDC / max.
  • Page 54 Electrical connection PSI 6XXX.190 W1 Configuration C The I/O range of the PSI 6XXX.190 W1 is supplied with a voltage of 24 V DC (internal supply, derived from the mains voltage). Several jumpers have to be positioned to enable this configuration. The logic portion is supplied by an external 24 V DC power supply unit (external power supply).
  • Page 55 Electrical connection PSI 6XXX.190 W1 PSI 6XXX.190 W1 Configuration C: Power supply for firing, parallel inputs and outputs by internal 24 VDC power. Power supply to weld timer logics and the external unit by an external power supply unit [1]. *1 stop circuit: floating contact load:...
  • Page 56 Electrical connection PSI 6XXX.190 W1 Configuration D If the external 24 V DC supply to PSI 6XXX.190 W1 cannot be provided by one power supply unit for reasons of potential separation between the timer logic and the I/O supply, the power supply has to be designed in accordance with configuration D. Several jump- ers have to be positioned to enable this configuration.
  • Page 57 Electrical connection PSI 6XXX.190 W1 PSI 6XXX.190 W1 Configuration D: Power supply for firing and parallel inputs and outputs by an external 24 VDC power supply [1]. Power supply to weld timer logics and the external unit by a second external 24 VDC power supply unit [2]. Power supply *1 stop circuit: unit...

  • Page 58: I/O Functions

    PSI 6XXX.190 W1 Electrical connection I/O functions NOTE Electromagnetically activated switching and positioning devices require noise suppres- sion (see section 6). The selection of cables and the cable lengths are subject to the ”Cables” table in section 7.3.1 Parallel inputs Selecting seam programs In the PSI 6XXX.190 W1 the parameters for 32 seam programs can be programmed and selected for the [sequence].
  • Page 59 PSI 6XXX.190 W1 Electrical connection Seam program, assignment of block programs to basic programs: Seam program Basic program Block program 1 to 7 9 to 15 17 to 23 25 to 31 33 to 39 41 to 47 49 to 55 57 to 63 65 to 71 73 to 79...
  • Page 60 PSI 6XXX.190 W1 Electrical connection <Program selection 0 to 31> Basic program The <Program selection> is made by parallel signals with a binary value in the range of 0 to 31. If the <Start> becomes active in connection with the selected program number, the selected basic program is started with the higher-level welding parameters.
  • Page 61 PSI 6XXX.190 W1 Electrical connection <Start> and <Block start> <Start> initiates the [sequence] in the weld timer, and activates the <Solenoid>. By giv- ing the <Start>, the <Program selection> for the basic program is taken over, and the pre-squeeze time [1. SQZ] is started. The <Start> can be cleared and the [sequence] interrupted within the [1.
  • Page 62 PSI 6XXX.190 W1 Electrical connection <Start> <Block start> Sequence 1.SQZ SQZ n x 2.WLD Figure 20: Block start during squeeze times <Start> <Block start> Sequence n x 2.WLD 1.SQZ SQZ Figure 21: Block start after squeeze times 7-19 1070 080 086-101 (01.01) GB...
  • Page 63 PSI 6XXX.190 W1 Electrical connection Response times Changing the <Block selection> within a started basic program can be done without in- terrupting the current. The present current pulse is finished after the programmed weld time. The same applies to the cool time. Afterwards, the new block program will be started with the block delay time [BDT].
  • Page 64 PSI 6XXX.190 W1 Electrical connection <Weld/No weld external> This signal allows to disable the firing of the welding timer as for example during set-up operations ([sequence] without current). In addition to the <Weld/No weld external> signal, the setting of weld/no weld internal for all programs and furthermore the weld/no weld internal setting for an individual program affect the firing.
  • Page 65 PSI 6XXX.190 W1 Electrical connection <Reset fault with weld complete contact> Resetting of a fault is required, whenever a fault prevents any further welding [se- quences] in the timer. Pending faults are reset by software BOS-5000 using the green button on the front panel of the PSI 6XXX.190 W1 or <Reset fault with weld complete contact>...

  • Page 66: Parallel Outputs

    PSI 6XXX.190 W1 Electrical connection 7.3.2 Parallel outputs <Control ready> The <Control ready> signal indicates the ready status of the weld timer. In parallel, the green LED ⇑ on the font panel is lighted. This signal is canceled in the event of a fault, e.g. with: E-STOP circuit open a fault in the [Sequence] or an inadmissible deviation of a monitored value which...
  • Page 67 PSI 6XXX.190 W1 Electrical connection <Weld/No weld> If the sum of all firing settings (logical AND operation, see below) is switched on when a basic program number is selected, the <Weld/No weld> signal is output. <Weld/No weld> signal ON: All firing settings for the selected program of the timer are active. The [Sequence] is performed with welding current.
  • Page 68 PSI 6XXX.190 W1 Electrical connection <Without monitoring> This signal indicates that welding is performed without current monitoring. If current monitoring is switched off, deviations from the tolerance band in current moni- toring are not detected. NOTE When current monitoring has been deactivated, you should always check the quality of your welds.
  • Page 69 PSI 6XXX.190 W1 Electrical connection <Weld complete> (WC) When <Start> has been cleared, the <Weld complete> signal is output for the pro- grammed duration in milliseconds. This signal serves as an acknowledgement for peripheral devices (e.g. robot control). In seam mode the signal reports a faultless weld at the end of the seam. Example: With Start deleted and with operation mode Seam, WC start 1 cycle before HLD end, WC period according to programming Start...
  • Page 70 PSI 6XXX.190 W1 Electrical connection <Welding fault> This signal is output in the event of a fault in the [Sequence] or if the timer recognizes an inadmissible deviation of a monitored value which has been defined as a fault. The ready state of the timer is cleared.
  • Page 71 PSI 6XXX.190 W1 Electrical connection Your notes: 7-28 1070 080 086-101 (01.01) GB...

  • Page 72: Control Diagrams

    Control diagrams PSI 6XXX.190 W1 Control diagrams 1070 080 086-101 (01.01) GB...
  • Page 73 <Start> <Program selection> <Weld external> <Solenoid> É É <Weld complete contact WC> (Start/duration programmable before end of HOLD) <Block selection_1> <Block selection_2> <Block selection_4> <Block start> Pre-squeeze time Squeeze time 1st block delay time 1st block with %I output 1st Slope time 1st weld time 1st cool time 2nd block delay time...
  • Page 74 <Start> <Program selection> <Weld external> <Solenoid> É É <Weld complete contact WC> (Start/duration programmable before end of HOLD) <Block selection_1> <Block selection_2> <Block selection_4> <Block start> Pre-squeeze time Í Í Í Squeeze time Í Í Í 1st block delay time 1st block with %I output 1st Slope time 1st weld time...
  • Page 75 <Start> <Program selection> <Weld external> <Solenoid> É É <Weld complete contact WC> (Start/duration programmable before end of HOLD) <Block selection_1> <Block selection_2> <Block selection_4> <Block start> Pre-squeeze time Squeeze time 1st block delay time 1st block without %I output 1st Slope time 1st weld time 1st cool time 2nd block delay time...
  • Page 76 <Start> no meaning <Program selection> no meaning <Weld external> <Solenoid> <Weld complete contact WC> (Start/duration programmable before end of HOLD) <Block selection_1> <Block selection_2> <Block selection_4> <Block start> Pre-squeeze time Squeeze time 1st block delay time 2nd block without %I output 1st Slope time 1st weld time 1st cool time...
  • Page 77 Control diagrams PSI 6XXX.190 W1 1070 080 086-101 (01.01) GB...

  • Page 78: Bos-5000

    PSI 6XXX.190 W1 BOS-5000 BOS-5000 The seam welding timer PSI 6XXX.190 W1 has 32 seam programs each of which is com- posed of a basic program and 7 related block programs, refer to section 7.3.1. The higher-level welding parameters are to be programmed in the basic programs. The welding parameters for the current blocks, which are required for the [schedule], are pro- grammed in the block programs.
  • Page 79 BOS-5000 PSI 6XXX.190 W1 Sequence Setup Start inhibit Weld/No Weld Max. Welding Time Monitoring stopped Fade-out time Trail current Measurement Circuit Test (Measurement Loop Check) Current measurement fixed on primary side Program-specific start inhibit Electrode number fixed 0 Program-specific weld/no weld Schedule - Welding modes fixed seam Regulation...

  • Page 80: Programming The Welding Parameters

    PSI 6XXX.190 W1 BOS-5000 Programming the Welding Parameters Dividing the Welding Parameters of a seam program between the basic program and the block programs: x: the Welding Parameters are programmed in a basic or block program designated with an x -: the Welding Parameters in the basic or block program are not used.
  • Page 81 BOS-5000 PSI 6XXX.190 W1 Pressure Parameters Basic Block program program Base-Pressure Pressure Profile Pressure values for the pressure profile Other windows in the Welding Parameters menu A seam weld is programmed without the Welding Parameters of the following windows. Programmed Welding Parameters contained in these windows are not used. Stepper Time-Monitoring Monitor-Stepper...

  • Page 82: Input Ranges Of The Welding Parameters

    PSI 6XXX.190 W1 BOS-5000 Input ranges of the Welding Parameters Pre-Squeeze Time 0 to 2000 ms Squeeze Time 16 to 2000 ms 1st to 7th Block delay time to 2000 ms (as Pre-Squeeze Time [1. SQZ] in the block programs) 1st to 7th Current slope time to 2000 ms 1st to 7th Weld time...

  • Page 83: Determining The Actual Values

    BOS-5000 PSI 6XXX.190 W1 Determining the actual values Outside the slope times, an actual value is calculated at the end of each current impulse (WLD + CT). Depending on the fade-out time and mode with/without current monitoring, the aggregate of the current measured is divided by the number of measured half-cycles and regarded as the actual current for this impulse.

  • Page 84: Commissioning

    Commissioning PSI 6XXX.190 W1 Commissioning NOTE For commissioning, please note the safety instructions, the technical data and the electri- cal wiring diagrams. The following sections contain suggestions on how to proceed during commissioning. Acceptance of these suggestions will depend on the specific circumstances and will be the responsibility of the commissioning personnel.

  • Page 85: Preparations

    Commissioning PSI 6XXX.190 W1 10.1 Preparations Connect and turn on the timer according to the wiring diagrams and safety instruc- tions. Deactivate the <Weld external> signal for as long as you do not need any welding current for commissioning. Start the BOS-5000 software and enter your user group and user password. Select Operation.

  • Page 86: Testing The Welding Program

    Commissioning PSI 6XXX.190 W1 10.2 Testing the welding program A welding program can be executed with or without firing (with or without welding cur- rent). For this purpose, weld internal or the weld external function can be turned on or off. In a [Sequence] without welding current, for example, one can first examine the I/O signal exchange with the higher-level control unit and the positioning of robot electrode guns.

  • Page 87: Suggestions For A Welding Test

    Commissioning PSI 6XXX.190 W1 10.2.1 Suggestions for a welding test Check whether the power unit type used has been programmed in Basic-Setup - Thyristor (Power) Unit Setup, and change it if necessary. Perform the first test weld without firing (Weld/No weld internal ”off” or <Weld external>...

  • Page 88: Basic-Setup

    Commissioning PSI 6XXX.190 W1 10.3 Basic-Setup If the timer has already been programmed, the Quick-Programming will give you a good overview of the most important Welding Parameters. Use function key F9 to change from Operation to Programming. Check the Basic-Setup of all programs used. Safe Delete (Delete Memory) Find out whether the protocol memories, Actual values and Welding Param- eters can be deleted.
  • Page 89 Commissioning PSI 6XXX.190 W1 Electrode Setup Check the Electrode Setup or adjust it to the hardware components of your welding equipment. The input concerning the toroid sensitivity and the [Pressure] should be ad- justed to the real conditions later on by performing the Scaling procedure. Sequence Setup Suggestion concerning the settings for all programs: Deactivate Start Inhibit.

  • Page 90: Welding Parameters

    Commissioning PSI 6XXX.190 W1 10.4 Welding Parameters If the timer has already been programmed, the Quick-Programming will give you a good overview of the most important Welding Parameters. Use function key F9 to change from Operation to Programming. Check the Welding Parameters of all programs used. Sequence Check the sequence parameters, in particular, the [Weld Times] and the [%I] values (%I or kA).

  • Page 91: Scaling Process

    Commissioning PSI 6XXX.190 W1 10.5 Scaling process For quality assurance, you should adjust your welding equipment to your real conditions by means of Scaling. The following parameters will be adjusted through Scaling: toroid sensitivity conversion factor for pressure output zero shift for pressure output Select, e.g., Starting Window - Scaling.

  • Page 92: Activating Monitoring

    Commissioning PSI 6XXX.190 W1 10.7 Activating monitoring For quality assurance, Current Monitoring should always be switched on, and the ap- propriate tolerance bands should be entered. The Actual Values are displayed and can be accepted as setpoints. Activating monitoring Select Programming - Basic-Setup - Sequence Setup. Enter Current Monitoring and the tolerance band Select Programming - Welding Parameters - Current Monitoring.

  • Page 93: Saving The Welding Parameters

    Commissioning PSI 6XXX.190 W1 10.9 Saving the Welding Parameters When commissioning has been completed, you should backup your programs with the Upload (Backup) function. Create Upload (Backup): Select Operation - Services - Upload (Backup). NOTE Existing Upload (Backup) files will be replaced. You may enter a new file name for the new Upload (Backup) file using the File Reference function.

  • Page 94: Messages

    PSI 6XXX.190 W1 Messages Messages 11.1 Fault and Status Messages Messages Warnings : The ready status of the timer remains, further [sequences] are not inhibited. Faults : The timer is no longer ready, further [sequences] are inhibited. NOTE Internally the timer works with coded numbers. All messages are output on the program- ming unit in text format.

  • Page 95: Ranges Of Messages

    PSI 6XXX.190 W1 Messages 11.2 Ranges of Messages Messages concerning the connection WT Õ Programming terminal (communication messages) Messages concerning the stepper (electrode) status (Prewarning, End of Stepper reached, etc.). Messages concerning the timer status (battery low, no +24V etc.). Messages from active monitoring (Weld-time exceeded).
  • Page 96 PSI 6XXX.190 W1 Messages 11.2.2 [B] - Electrode (Stepper) Messages Code Explanation Additional code %I (Current) Prewarning Electrode no. Maximum current Electrode no. 11.2.3 [C] - Messages Concerning the Timer Status Code Explanation Additional code Stop Open circuit / no +24V Thyristor unit not ready Battery low Memory deleted = RAM checksum error...

  • Page 97: D] - Messages For Current Monitoring

    PSI 6XXX.190 W1 Messages 11.2.4 [D] - Messages for Current Monitoring Code Explanation 1011 No current (mixed mode) block 1 to 7 1017 1021 Current too low (mixed mode) block 1 to 7 1027 1031 Current too high (mixed mode) block 1 to 7 1037 1051 Current measuring range exceeded (mixed mode) block 1 to 7...

  • Page 98: Maintenance

    CAUTION! The right to perform repair/maintenance work on the timer components is reserved to the Bosch service department or to repair/maintenance units authorized by Bosch! Only use spare parts/replacement parts approved by Bosch! Spent batteries or accumulators must be disposed of as hazardous waste.

  • Page 99: Changing Batteries

    Maintenance PSI 6XXX.190 W1 12.1 Changing batteries NOTE Data buffering is assured for about 30 hours, without internal or external 24 VDC supply voltage and after removing the battery. A 3.6 V Lithium battery is installed in the PSI 6XXX.190 W1 to provide data backup power. This battery supplies the RAM memory and the internal clock in the power down state.

  • Page 100: Ordering

    PSI 6XXX.190 W1 Ordering Ordering Spare parts Designation Part no. PCB I/O level 1070 073 094 Included in shipment (STKK plug-in terminal) Part no. please refer to section 3.2 [10] Power supply, X4: 1070 916 914 STKK 14-pin (3.5 mm) [11] Ext.
  • Page 101 Ordering PSI 6XXX.190 W1 Not included in shipment Part no. please refer to section 3.2 V24, X1: 9-pin female D shell connector 1070 912 981 V24, X1: 9-pin female D shell connector housing 1070 313 723 finished cable V24, X1: for connecting PC to 1070 066 749 timer;...

  • Page 102: A Annex

    PSI 6XXX.190 W1 Annex Annex Abbreviations, Terms 2.WLD 2nd Weld time: main weld time, can consist of a block comprising individual impulses, only the 2.WLD can have upslope and downslope Block delay time, time between block start and first %I impulse Cool time: time between the current pulses/blocks (1., 2., 3.

  • Page 103: Regulation Terms

    Annex PSI 6XXX.190 W1 SING Single spot mode for automatic welding machines and manual systems Slope Current increase (or decrease) from an initial to a final current. Solenoid Activates the cylinders to close the electrodes. valve Squeeze time that elapses before the weld time. The electrodes squeeze the parts to be welded together.

  • Page 104: Index

    Annex PSI 6XXX.190 W1 Index Connection, XIII, 7-1 Control ready, 6-23 Current Monitoring, 9-3, 9-6 Current monitoring, 6-25 Actual current, 9-6 Actual impulse current, 9-6 Actual values, 9-6 Data buffering, 12-2 Assembly, XII DC link voltage, 7-6 Degree of protection, 2-1 Delete Memory.
  • Page 105 Annex PSI 6XXX.190 W1 Global Stepper-Setup, 9-2 Operating mode, 3-3 Operating system, 1-4 Operating voltage, 2-1 Operation, XIV I/O Parameters, 9-1 Outputs, 6-23 Inductive devices, 6-1 Inputs, 6-15 Installation, XII, 4-1 Interfaces, 7-3 Pacemaker, IX Parallel inputs, 6-15 Parallel outputs, 6-23 Part no., 13-1 Light barriers, XIV PE conductor, V...
  • Page 106 Annex PSI 6XXX.190 W1 Rated current, 2-1 Temperature, 2-1 RC element, 6-1 Temperature monitoring, 7-6 Ready LED, 3-3 Test procedures, 12-1 Repair, XVII Thyristor Unit Setup. See Power Unit Setup Repair work, 12-1 Time-Monitoring, 9-4 Replacement parts, 12-1 Timer module, 1-1 Reset Fault with weld complete contact, 6-22 Tipdress curves, 9-2 Reset push button, 3-3...
  • Page 107 Annex PSI 6XXX.190 W1 Your notes: 1070 080 086-101 (01.01) GB...
  • Page 108 1070 080 086-101 (01.01) GB · TB · AT/VWS · Printed in Germany...

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