Bosch Rexroth PS5000 Commissioning And Operating Instructions
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Bosch Rexroth PS5000 Commissioning And Operating Instructions

Operating and diagnostic terminal
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Industrial
Hydraulics
Rexroth IndraControl VCP 20
Rexroth PS5000 / PS6000
Operating And Diagnostic Terminal
BT 6.190
Commissioning And Operating Instructions
Electric Drives
Linear Motion and
and Controls
Assembly Technologies
Service
Mobile
Pneumatics
Automation
Hydraulics
1070087068
Edition 01

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  • Page 1 Industrial Electric Drives Linear Motion and Service Mobile Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics Rexroth IndraControl VCP 20 Rexroth PS5000 / PS6000 1070087068 Edition 01 Operating And Diagnostic Terminal BT 6.190 Commissioning And Operating Instructions...
  • Page 2 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Title Rexroth PS5000 / PS6000 Operating and Diagnostic Terminal BT 6.190 Commissioning and Operating Instructions Type of Documentation DOK-PS6000-BT6.190****-IB01-EN-P Document Typecode This manual provides information about the Purpose of Documentation D construction, assembly, connection and D operation of the BT 6.190 operating and diagnostics terminal.

  • Page 3: Table Of Contents

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG and Controls Contents Contents Page Safety Instructions ..... . .
  • Page 4 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Firmware version ........

  • Page 5: Safety Instructions

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 1−1 and Controls Safety Instructions Safety Instructions The products described were developed, manufactured and tested in compliance with the fundamental safety requirements of the EU machi- nery directive. These products normally pose no danger to persons or property if used in accordance with the handling stipulations and safety notes prescribed for their configuration, mounting, and proper operation.

  • Page 6: Safety Instructions In This Manual

    1−2 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Safety Instructions Safety Instructions in this Manual DANGEROUS ELECTRICAL VOLTAGE This symbol is used to warn of dangerous electrical voltage. The fail- ure to observe the instructions in this manual in whole or in part may re- sult in personal injury.

  • Page 7: Intended Use

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 1−3 and Controls Safety Instructions Intended Use The product described D serves in connection with a suitable weld timer (spot seam variants of series PS 5000 and PS 6000) to −...

  • Page 8: Qualified Personnel

    1−4 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Safety Instructions Qualified Personnel The requirements as to qualified personnel are based on the require- ment profiles defined by the ZVEI (Zentralverband Elektrotechnik und Elektronikindustrie − German Electrical and Electronic Manufacturers’...
  • Page 9 1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 1−5 and Controls Safety Instructions DANGER! An exception are persons with cardiac pacemakers! The strong magnetic fields occurring in resistance welding may affect the proper functioning of pacemakers. This may be fatal or...

  • Page 10: Installation And Assembly

    1−6 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Safety Instructions Installation and Assembly DANGEROUS ELECTRICAL VOLTAGE Danger of life during installation work while systems are switched Make sure that all plant sections undergoing operations during...

  • Page 11: Electrical Connection

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 1−7 and Controls Safety Instructions Electrical Connection DANGER Danger of life through inappropriate EMERGENCY-STOP facili- ties! EMERGENCY-STOP facilities must be operative in all modes of the system. Releasing the EMERGENCY-STOP facility must by no...

  • Page 12: Operation Of The Product

    1−8 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Safety Instructions Operation of the Product 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.

  • Page 13: Retrofits And Modifications By The User

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 1−9 and Controls Safety Instructions DANGER Danger of bruises through electrode movement! All users, line designers, welding machine manufacturers and welding gun producers are obliged to connect output signals which initiate the electrode movement so that the applicable sa- fety regulations are complied with.

  • Page 14: Maintenance, Repair

    1−10 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Safety Instructions Maintenance, Repair DANGEROUS ELECTRICAL VOLTAGE Prior to any maintenance work − unless described otherwise − the system must always be switched off and sufficiently secured!

  • Page 15: Working Safely

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 1−11 and Controls Safety Instructions 1.10 Working Safely DANGER If the start signal is present on fault reset (acknowledge), the weld timer immediately starts the program sequence! Hazardous ma- chine movements may be the result!

  • Page 16: Ce Mark

    1−12 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Safety Instructions 1.11 CE mark CAUTION The CE certificate for the described device combination is valid for use in an industrial environment For other combinations/applications, the certificate must be deri- ved from the above, or a new certificate must be issued, if neces- sary, by the line designer / user.

  • Page 17: Documentation, Software Release And Trademarks

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 1−13 and Controls Safety Instructions 1.12 Documentation, software release and trademarks Trademarks All trademarks of software installed on Rexroth products upon delivery are the property of the respective manufacturer. Upon delivery, all installed software is copyright-protected. The software may only be reproduced with the approval of Rexroth or in accordance with the license agreement of the respective manufacturer.
  • Page 18 1−14 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Safety Instructions Notes:...

  • Page 19: Overview

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 2−1 and Controls Overview Overview This manual contains information about D the mechanical system, D the electrical connections and D the functions of diagnostic and control terminals − BT 6.190 (rack−mounted model) and...
  • Page 20 2−2 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Overview Notes:...

  • Page 21: Assembly And Connection

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 3−1 and Controls Assembly and Connection Assembly and Connection BT 6.190 built−in unit 3.1.1 Dimensions and assembly Weight: approx. 0.6 kg Installation location: console / hinged frame or switch cabinet; insulated according to IP 65.
  • Page 22 3−2 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Assembly and Connection Required Dimensions of front assembly cutout +1, −0 +1, −0 All dimensions in mm. Front panel thickness: 4 mm Required installation depth: approx. 40 mm Maximmum thickness of mounting wall: 14 mm Dimensions / assembly cutout for built−in unit...
  • Page 23 1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 3−3 and Controls Assembly and Connection Lay out all connection cables in loops and use strength members for all cables. Fasten the BT 6.190 using the 2 supplied fastening clamps: 1.

  • Page 24: Connection

    3−4 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Assembly and Connection 3.1.2 Connection To operate, the BT 6.190 requires not only the power supply to X1 but also communication connection X2 (RS 232 c; connection to X1 of the weld timer).
  • Page 25 1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 3−5 and Controls Assembly and Connection CAUTION Operating an incorrect control type with the BT 6.190 can lead to undesirable welding program modifications and to unpredictable reactions of the control.
  • Page 26 3−6 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Assembly and Connection Communication (X2) Connection: Sub-D socket, 9−pin Type: RS232c, indirectly coupled Cable length: max. 15m Cable type: LiYCY; shielded, position−stranded; Wire cross−section: min. 0.25 mm...

  • Page 27: Bt 6.190 − Hand−Held Terminal (Bt 6.190 Hpg)

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 3−7 and Controls Assembly and Connection BT 6.190 − hand−held terminal (BT 6.190 HPG) Dimensions (WxHxD; in mm): 130 x 201 x 52 Weight: approx. 1.2 kg Housing: polyamide 6, silicon−free Protection class: IP 54 acc.
  • Page 28 3−8 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Assembly and Connection When using the hand−held terminal, also heed the information relevant to operation in the ”Notes Regarding Safety” section. Ensure that the operator has an unobstructed view of moving machine parts within the operational range of the hand−held terminal at all times...
  • Page 29 1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 3−9 and Controls Assembly and Connection CAUTION Operating an incorrect timer type with the BT 6.190 can lead to un- desirable welding program modifications and to unpredictable re- actions of the timer.
  • Page 30 3−10 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Assembly and Connection Operating station PS 5000 / PS 6000 (X1; sub-D, 9-pin) BT 6.190 HPG Plug PS 5000 / PS 6000 (X5) 24 V Socket, 15−pin BT 6.190 HPG (hand−held terminal) connection to operating station...

  • Page 31: Operation

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 4−1 and Controls Operation Operation The BT 6.190 provides you access to user- and control-specific data that are important to the production process (e.g. display/modification of wel- ding parameters, display of current I/O signals).

  • Page 32: Overview Of Bt 6.190 Operating Elements

    4−2 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Operation Overview of BT 6.190 operating elements 1 Display. 4 lines of 20 characters each can be displayed. To adjust the contrast, see page 4−14. 2 Function keys for the direct selection of a main menu entry.
  • Page 33 1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 4−3 and Controls Operation 5 Fault display key. Current errors are indicated by flashing of the integrated LED. When the key is pressed, the display unit switches from any display to the error display and then back to the original display.

  • Page 34: Overview Of Main Menu Items And Their Functions

    4−4 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Operation Overview of main menu items and their functions The BT 6.190 permits the operation and programming of spot seam timers, including all the parameters required for welding.
  • Page 35 1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 4−5 and Controls Operation D Control mode Possibilities: − Display and modify the control operating mode (PHA/KSR). − The desired seam program (0 to 31) is selected in the display line (”Program_”).

  • Page 36: Select Main Menu Items And Navigation In Sublevels

    4−6 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Operation Select main menu items and navigation in sublevels Proceed as follows: 1. Press the key. 2. Use the key to move the cursor to the desired line.

  • Page 37: Quick Mode

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 4−7 and Controls Operation Quick mode Use the direct selection mode to immediately open a certain screen wit- hin any sublevel. Proceed as follows: At any time, you can press key to return to the uppermost menu level, or key to return to the previously displayed menu level.

  • Page 38: List Of Parameter Numbers For Direct Selection Mode

    4−8 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Operation 4.4.1 List of parameter numbers for direct selection mode Affected range Description Parameter number Procedure Basic program (block program 0): 1st derivative−action time Derivative−action time Slope (on/off) Holding time Run inhibit (progr.)
  • Page 39 1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 4−9 and Controls Operation Affected range Description Parameter number Under−current time (input using BOS as 2nd STZ in the program) Pause time (input using BOS as 2nd PSZ in the program)
  • Page 40 4−10 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Operation Affected range Description Parameter number Starting performance Velocity in cm/min (see page 4−19) Current/pause % (see page 4−19) Impulses/cm (see page 4−19) Performance (input using BOS as 2nd STZ in the program) Under−current time (input using BOS as 2nd...
  • Page 41 1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 4−11 and Controls Operation Affected range Description Parameter number Phase angle Block program 2: Reference current Actual current Phase angle Block program 3: Reference current Actual current Phase angle Block program 4:...
  • Page 42 4−12 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Operation Affected range Description Parameter number Setup of SST Display SST type Internal ignition (S) Range of values: ON/OFF Run inhibit (S). Range of values: ON/OFF Clear memory (reset all welding parameters...

  • Page 43: Special Operation Functions

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 4−13 and Controls Operation Special operation functions 4.5.1 Display error messages The BT 6.190 informs you that one or more errors exist using a flashing LED in the key. Press the key to display the current error.

  • Page 44: Setting The Lcd Contrast

    4−14 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Operation To open the language selection screen (steps 1 to 3), you can also use the direct selection mode with parameter number 159. For more information about the direct selection mode, see page 4−7 ff.

  • Page 45: Inhibiting Operating Functions (Changing Codes)

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 4−15 and Controls Operation 4.5.4 Inhibiting operating functions (changing codes) Codes (max. 4 characters) are used to modify parameters or to prevent the display of data. Each existing main menu entry and function ”Change codes” can be pro- tected by separate codes in this way.
  • Page 46 4−16 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Operation 8. If the superordinate code is to be changed, enter this code now and then press Starting at this time, access to the ”Change code” mode is possible only with the superordinate code that was just entered.

  • Page 47: Display Data From The Last Weld

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 4−17 and Controls Operation 4.5.5 Display data from the last weld The BT 6.190 can be used to display: D with which spot seam program thelast weld was carried out D with which reference and actual currents and which phase angle a certain program ran last.

  • Page 48: Display I/O Signals

    4−18 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Operation 4.5.6 Display I/O signals All the input and output signals of the control can be viewed using the BT 6.190. Proceed as follows to display the signals: 1.

  • Page 49: Programming The Welding Current Times

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 4−19 and Controls Operation 4.5.7 Programming the welding current times The BT 6.190 offers two options to program the welding current times: Standard concept: Input D under−current time (ms) and D pause time (ms).
  • Page 50 4−20 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Operation Notes:...

  • Page 51: Maintenance

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 5−1 and Controls Maintenance Maintenance Battery A battery is integrated to buffer the internal data. Battery type: lithium Size: Voltage: 3.6 V If the remaining battery capacity becomes critical, the BT 6.190 issues the error message ”Battery in BT6 empty”.
  • Page 52 5−2 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Maintenance 6. Place the BT 6.190 on a soft, level surface with the front downwards. 7. Loosen the housing screws (1) and threaded bolts of the interfaces (2).

  • Page 53: Fusing

    1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 5−3 and Controls Maintenance Fusing The BT 6.190 is equipped with a self−regenerating semiconductor fuse. As a result, the fuse does not have to be replaced after it has been trigge- red.
  • Page 54 5−4 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Maintenance 5.3.2 Loading the firmware version In rare cases, the BT 6.190 firmware may need to be updated. Firmware updates may be carried out only if instructed to so by us! All codes (see page 4−15) are reset to a value of ”0”...
  • Page 55 1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG 5−5 and Controls Maintenance 7. On the PC, confirm that the bootstrap mode of the BT 6.190 has been activated. The firmware is now loaded into the BT 6.190. A bar shows the current status.
  • Page 56 5−6 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Maintenance Notes:...
  • Page 57 1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG A−1 and Controls Annex Annex Abbreviations General abbreviation for current, can be Transformer-rectifier unit for the PSI in- verter series measured in kA or in SKT (scale values) RA (RO)
  • Page 58 A−2 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Annex Adapter, 3−7, 3−10 Last weld, 4−17 Assembly, 1−6, 3−1 LEERER MERKER, 2−1 Battery exchange, 5−1 Main menu items , 4−4 Maintenance, 1−10, 5−1 Modifications, 1−2 Cables, 1−7, 3−2 Modifications by the user, 1−9...
  • Page 59 1070087068 / 01 BT 6.190 Electric Drives Bosch Rexroth AG A−3 and Controls Annex Ventilation, 3−2 Working safely, 1−11 Weight, 3−1, 3−7 X1, 3−5 Welding splashes, 1−11 X2, 3−6...
  • Page 60 A−4 Bosch Rexroth AG Electric Drives BT 6.190 1070087068 / 01 and Controls Annex Index...
  • Page 61 Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Phone +49 (0)93 52-40-50 60 +49 (0)93 52-40-49 41 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany 1070087068 DOK-PS6000-BT6.190****-IB01-EN-P...

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Rexroth ps6000Rexroth bt 6.190

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