Bosch Manual REXROTH BOS6000 Users Manual
Short Description
Bosch Manual REXROTH BOS6000 Users Manual...
Description
Electric Drives and Controls
Hydraulics
Linear Motion and Assembly Technologies
Rexroth BOS 6000
Pneumatics
Service
4
dition 01
Bosch Rexroth GmbH | Electric Drives
BOS 6000 | 1070087074 / 01
and Controls
Title Type of Documentation Document Typecode Purpose of Documentation
Rexroth BOS 6000 User Manual DOK-PS6000-BOS6000****-AW01-EN-P The content of this manual refers to the structure and the functionality of the BOS 6000 user interface. •
Record o f Revisions
Previou s editi ons DOK-PS6000-BOS6000****-AW01-EN-P
Copyright
©
Release Date
Notes
06.2006
Bosch Rexroth Electric Drives and Controls GmbH, 2006
Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1).
Validity
Published by
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The given information does not release the user from the obligation of own judgement and verification. It must be remembered that our products are subject to a natural process of wear and aging. Bosch Rexroth Electric Drives and Controls GmbH Postfach 11 62 D-64701 Erbach Berliner Straße 25 D-64711 Erbach Tel.: +49 (0) 60 62/78-0 Fax: +49 (0) 60 62/78-7 28 Abt.: BRC/PAW1
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Contents
Contents The BOS 6000 Help System................................................9 Software version.........................................................................9 Activating Help .........................................................................10 Description of the symbols in the menu lines...........................11 Show (Unhide)/Hide.............................................................11 Previous (Back) ...................................................................11 Next .....................................................................................11 Start page (Home) ...............................................................11 Print .....................................................................................11 Show Contents (structure) view ...............................................12 Keyword search........................................................................12 Text search...............................................................................13 Use favorites ............................................................................14 Including topics in the Favorites list.....................................14 Displaying the topics in the Favorites list.............................14 Deleting topics from the Favorites list..................................15 Renaming the topics in the Favorites list .............................15
Safety Inst ru ct io ns ............................................................17 Why” and “What for”? ...............................................................17 Symbols used...........................................................................18 Proper use................................................................................19 Qualified personnel ..................................................................20 Safe working practices .............................................................21 Trademarks, copyright..............................................................22
Getting to know the BOS 6000 user interface.................23 Basics.......................................................................................23 Overview of the interface structure...........................................24 Meaning of important icons ......................................................26 Functions in the menu line .......................................................28 File | Para. data import/export | Export …............................28 File | Para. data import/export | Import …............................28 File | Exit ..............................................................................28 Edit | Programming..............................................................28 Edit | Diagnosis....................................................................28 Edit | Setup ..........................................................................29 Edit | Correction ...................................................................29 Edit | Oscilloscope function..................................................29 Edit | Export record set ........................................................29 Edit | Autobackup.................................................................29
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Edit | Timer change..............................................................29 Edit | Copy ...........................................................................29 Edit | Firmware changing .....................................................29 Edit | Login...........................................................................29 Language.............................................................................29 Functions | Timer reference.................................................30 Functions | Spot reference...................................................30 Functions | Prewarning ........................................................30 Functions | Error table .........................................................30 Functions | Network overview..............................................30 Functions | Protocol .............................................................30 Functions | Compare ...........................................................30 Functions | Parameter overview ..........................................30 Functions | Rights administration.........................................30 Help | Help ...........................................................................30 Help | About .........................................................................30 The available windows .............................................................31 Login....................................................................................31 Timer Reference..................................................................32 Add/ChangeTimer................................................................35 Connection set-up................................................................38 Programming .......................................................................41 Programming: Schedule ......................................................42 Programming: Seq. Pg.2 .....................................................55 Programming: Stepper.........................................................61 Programming: General ........................................................72 Programming: Electrode......................................................80 Programming: Thyristor-Unit-Parameter..............................93 Diagnosis.............................................................................96 Diagnosis: Diagnostics I/O...................................................97 Diagnosis: Users Diagnostics I/O ......................................100 Diagnosis: Start Simulation................................................101 Diagnosis: Timer-Information.............................................104 Diagnosis: Last Weld.........................................................106 Setup .................................................................................107 Setup: Stepper curves .......................................................108 Setup: Tipdress curves......................................................110 Setup: Fault-Setup.............................................................111 Setup: Communication ......................................................112 Correction ..........................................................................116 Correction: Correction........................................................117 Spot Reference..................................................................119 Prewarning.........................................................................121 Error table..........................................................................123 Network overview ..............................................................125 Protocol..............................................................................127 Compare............................................................................131 Parameter Overview ..........................................................133 Set Access Level ...............................................................134 FTP-Upload .......................................................................134 Backup...............................................................................136 Restore ..............................................................................136 Autobackup........................................................................137
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Contents
Timer change.....................................................................139 Copy ..................................................................................140 Firmware change...............................................................141 Para.-Data Import/Export (Parameter-Backup) .................143 Para.-Data Import/Export (Parameter-Restore).................144 Set Counter........................................................................145 Current calibration .............................................................146 Force calibration ................................................................147 Corresponding Programs...................................................148 Spot Comment...................................................................149 Detail Info...........................................................................150
How to …..................... ..................................................... 153 Exit BOS 6000........................................................................153 Log in timers to BOS 6000 .....................................................153 Delete timers from BOS 6000 ................................................154 Change the communication data of logged-in timers .............155 Export Timer Reference .........................................................156 Import Timer Reference .........................................................156 Print Timer Reference ............................................................156 Copy Timer Data ....................................................................157 Export timer data (backup) .....................................................158 Restore Timer data (download)..............................................159 Compare Timer Data..............................................................160 Influence data comparison at program start...........................162 Define access levels for individual objects.............................163 Copy the contents of a numerical input field ..........................165 Sort tables ..............................................................................166 Filter tables.............................................................................166 Show / Print / Export logs .......................................................167 Change parameters and transfer to timer ..............................169 Export spot reference .............................................................171 Export spot reference to an Excel file.....................................171 Import spot reference .............................................................171 Print spot reference................................................................172 Compare spot reference.........................................................172 Enter/change spot references ................................................172 Display spot comments ..........................................................172 Delete spot references ...........................................................173 Show electrode status ............................................................173 Confirm electrode change ......................................................174 Set electrode counter .............................................................175 Export parameter data to ASCII file........................................175 Import parameter data from ASCII file....................................176 Replace a defective timer.......................................................177 Upgrade the timer firmware....................................................179 Reset faults ............................................................................181 Add fault information ..............................................................183 Perform current calibration.....................................................184 Perform force calibration ........................................................187
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Faul t messages ............................................................... 191 Stop / No 24V.........................................................................191 Stop circuit closed ..................................................................191 Weld without Command .........................................................192 Control stop ............................................................................192 Power-Unit not ready..............................................................192 External Over-Temperature....................................................193 Cooling temperature too high .................................................193 Transformer temp too high .....................................................193 Battery-Low ............................................................................194 Memory deleted......................................................................194 Data download started ...........................................................194 No schedule programmed......................................................194 Hardware Fault.......................................................................195 I/O-Bus Fault ..........................................................................196 Half-Cycle Monitoring.............................................................196 Circuit Breaker Off..................................................................196 Sync / Power Fault .................................................................196 Synchronization OK................................................................197 Start Inhibited .........................................................................197 Sequence externally cancelled...............................................197 Program Parity Fault ..............................................................197 24V off/to low..........................................................................198 Supply Voltage Fault ..............................................................198 Timer switched on ..................................................................198 Power voltage to high.............................................................198 Power voltage off/to low .........................................................199 Power voltage off/to low receipt .............................................199 No Weld external....................................................................199 Weld external .........................................................................200 No Weld internal.....................................................................200 Weld internal ..........................................................................200 With stroke, with weld.............................................................200 No stroke, no weld..................................................................200 %I too large/Force/Pressure too high/PHA is too high ...........200 Extend stepping request.........................................................201 Extended electrode life Near End of Stepper.........................201 End of stepper........................................................................201 End of stepper........................................................................202 Electrode changed .................................................................202 Stepper exceed ......................................................................202 Prewarning reached ...............................................................202 Dress-Request reached .........................................................202 Dressing necessary................................................................203 Max. number of spots welded before dressing.......................203 Electrode dressed ..................................................................203 Tipdress prewarning...............................................................203 Electrode life tipdress.............................................................203 Cutter blade changed.............................................................204 Cutter1: Cutter not running.....................................................204 Cutter1: Dressing process aborted.........................................204 Cutter1: Max. mill duration exceeded.....................................204
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Cutter1: Temperature fault .....................................................204 Cutter1: Motor protection trip..................................................205 Cutter1: Emergency-Stop.......................................................205 Cutter2: Cutter not running.....................................................205 Cutter2: Dressing process aborted.........................................205 Cutter2: Max. mill duration exceeded.....................................205 Cutter2: Temperature fault .....................................................206 Cutter2: Motor protection trip..................................................206 Cutter2: Emergency-Stop.......................................................206 Phase Angle prewarning reached ..........................................206 Maximum Phase Angle Reached...........................................206 Secondary monitoring circuit is open .....................................207 Secondary monitoring circuit is shorted .................................207 Termination of Weld / no current ............................................207 No voltage 1.HW ....................................................................208 Primary Voltage Measuring Fault - KUR Mode ......................208 Reweld By Timer Active .........................................................208 Inhibit Monitoring Mode Active ...............................................208 No Weld..................................................................................208 Without regulation, without monitoring ...................................209 No current …..........................................................................209 Low Current … .......................................................................209 Over Current … ......................................................................209 Low Current-series of welds-… ..............................................210 Current measurement range exceeded … .............................210 Weld time too short …............................................................210 Weld time too long … .............................................................211 Diode Over Current ................................................................211 Diode defect ...........................................................................211 Overcurrent or Earth-fault.......................................................212 Max. primary current reached ................................................212 Driver-Fault.............................................................................213 No weld contactor enable.......................................................213 Isolation contactor feedback fault...........................................213 No Weld Enable or Weld Pressure Input Gun 1.....................213 No Weld Enable or Weld Pressure Input Gun 2.....................213 No Water Flow Gun 1.............................................................214 No Water Flow Gun 2.............................................................214 Weld Contactor Gun 1 Open ..................................................214 Weld Contactor Gun 2 Open ..................................................214 Weld Contactor Gun 1 Did Not Open.....................................214 Weld Contactor Gun 2 Did Not Open.....................................214 Monitor contact open..............................................................215 Mains Power Balance Monitoring Activated ...........................215 Mains Power Balance Monitoring Ok .....................................215 Auxiliary contactor monitor.....................................................215 Fault-Reset.............................................................................216 Welding-Fault Reset...............................................................216 Slave error..............................................................................216 Current Measurement Range Exceeded................................216 Scaling: Communication error ................................................216 Scaling: no valid measuring value received ...........................217 Scaling: no measuring value received....................................217
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Scaling: protocol fault.............................................................217 Scaling: wrong mode..............................................................217 Scaling: Sequence aborted ....................................................218 Scaling: current out of range ..................................................218 Scaling: Diff. primary / secondary current too large ...............218 Scaling: result invalid..............................................................219 Force monitoring: time too long..............................................219 Force monitoring: time too short.............................................219 Force monitoring: Force/Pressure too high ............................219 Force monitoring: Force/Pressure too low .............................220 Error US measurement ..........................................................220 Error US control loop..............................................................220 PSQ Sequence Cancelled......................................................221 USP not calculated.................................................................221 USP too high ..........................................................................221 USP too low............................................................................221 spot repetition with US ...........................................................221 PSQ hardware fault ................................................................222 PSQ internal communication error .........................................222 PSQ temperature too high......................................................222 USP temperature too high......................................................222 USP hardware fault ................................................................223 PSQ watchdog fault................................................................223 PSQ not available...................................................................223 PSQ sequence error...............................................................223 USP communication error ......................................................223 US measuring loop fault.........................................................224 PSQ memory deleted .............................................................224 PSQ ok ...................................................................................224
Glo ssary ........................................................................... 225 Ind ex ................................................................................. 235
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The BOS 6000 Help System
The BOS 6000 Help Sys tem
In this chapter, you will find basic information concerning the BOS 6000 Help system.
Soft ware versio n Help version: Valid as of BOS software version:
Note:
2.0 (10.05.2005) 1.14.5 (20.12.2004)
For more information on BOS: File Readme.chm (Directory "Bosch Rexroth AG"): System requirements, installation, update or removal of the software. File History.htm (English) or file History_GER.htm (German) (Directory "Bosch Rexroth AG"): Modification history of the individual BOS versions. via menu item Help | About…: Part numbers, version data
Copyright 2002-2006. All rights reserved, including applications for protective rights.
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Reproduction or distribution by any means subject to our prior written permission. All information is provided for reference only and is subject to change at any time. No liability is accepted.
Activating Help The Help system can be activated in different ways: •
via Help menu item in a BOS 6000 window
•
via Help command button (if available and not dimmed)
•
via F1 butto n if any window of the BOS 6000 interface is active.
Note:
In many areas, the Help is “context-sensitive“. That means that the current system status (active window, input field below mouse pointer) is detected and a suitable help topic is called up when Help is invoked by pressing F1.
The Help window displayed is divided into 3 major areas: •
top : Menu line. Here, you may choose various Help functions.
•
left : Display area for the following functions: Show Contents (structure), Keyword search, Text search and Use favorites.
•
right : Field for displaying the contents of the subjects.
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The BOS 6000 Help System
Descrip tion of the symbol s in th e menu lines The following functions/icons are offered in the menu line of the Help window:
Show (Unhide)/Hide •
Shows or hides the left window area containing the “Content”, “Index”, “Find” and “Favorites” tabs.
•
While you navigate through the Help topics, the system remembers all topics viewed in the order they have been called. Previous (Back) jumps back one position towards the beginning of the navigation path.
•
If Previous (Back) has been pressed at least once, Next jumps forward one position towards the end of the navigation path.
Previo us (Back)
Next
Start p age (Home) •
Jumps directly to the first Help topic.
Print •
Opens the ”Print help topics” window. You can choose whether you only want to print the current Help topic or its sub-topics as well (if existent). Then you confirm your choice by pressing OK and follow your computer’s print dialog.
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Show Cont ents ( str uct ure) view In the left window area, you can view the structure of all available Help topics. 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Content” tab in the left window area. The available Help topics are shown in a tree structure. By clicking on a Help topic, the system displays the description relating to the contents.
Note:
Book symbols represent a topic with sub-topics. To show/hide sub-topics, you simply have to double-click on the book symbol.
Note:
To fully extend the structure tree or to close the branches except the main topics, move the mouse pointer to the left window area, press the right mouse button and then select “Open all” or “Close all” in the pop-up menu appearing.
Keyword search 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Index” tab in the left window area. All keywords are listed in alpha-numerical order in the keywords list. The description relating to the topic can be displayed by double-clicking on an index entry. 3. For searching, enter the desired term in the “Find keyword“ field. After each character input, the system will select a corresponding keyword from the index list. For this purpose, it compares the string entered to the available index entries. If no exact entry match is found, the system will choose the lower next keyword from the list according to the sort sequence. 4. Click on the Show (View) command button to view the relevant description.
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The BOS 6000 Help System
Text s earc h 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Find” tab in the left window area. 3. For searching, enter the desired term(s) in the “Find term“ field. If necessary, you may use the wildcard character “*” for any possible individual searchNOT terms can be and logically combinedstring. by theThe AND, OR, NEAR, operators the bracket symbols “(“ and “)”. The search itself is not casesensitive, however, the operators have to be written in capital letters. Example : The query “help AND (version NOT 2003)” will find all topics containing both the terms “help” and “version”, but not “2003”. 4. Use the check boxes in the lower left part of the window to define the desired search scope. 5. Click on the List topics command button to list all topics that match the query. Now, the relevant topics can be displayed by double-clicking on a list entry or by clicking on the Show (View) command button after having selected a topic.
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Use favori tes Topics that are frequently needed or especially important can be included in the permanent Favorites list that is listed in alphanumerical order (and can even be given a different name there!). Thus, after closing and re-opening the Help function, the topics of interest are immediately displayed again.
Including topic s in the F avorite s list 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Use the functions "Contents (structure)", "Keyword search", "Text search" or "Use favorites" in order to display the relevant contents. 3. Click on the “Favorites” tab in the left window area. In the lower left display area, the system will enter the name of the topic in the “Current topic” field. 4. If desired, you can change the topic name according to your requirements. The topics displayed can be included in the Favorites list under the name displayed by clicking on the Add command button.
Note:
Alternative to
Add command button:
•
Right mouse click in Favorites list
•
Select menu item ”Add”.
Displa ying t he topics i n the Fa vorites list 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Favorites” tab in the left window area. 3. If there are any entries in the list, you can display the relevant topics by double-clicking on a list entry or by clicking on the Show (View) command button after having selected a topic.
Note:
Alternative to
Show (View) command button:
•
Right-click on the desired topic in the Favorites list
•
Select menu item ”Show (View)”.
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The BOS 6000 Help System
Deleting top ics fr om the F avorites lis t 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Favorites” tab in the left window area. 3. Select the relevant list entry and click on the Remove command button to delete the entry.
Note:
Alternative to
Remove command button:
•
Right-click on the desired topic in the Favorites list
•
Select menu item ”Remove”.
Renaming th e topi cs in t he Favorites lis t 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Favorites” tab in the left window area. 3. Right-click to select the relevant topic and select the “Rename” menu item 4. Enter the new name for the topic. 5. Acknowledge the new topic name with the Enter key.
Note:
Renaming can be canceled by hitting the Esc key.
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Safety Instruction s
Safety Ins tr uc ti on s This section contains important safety-related information.
Why” and “ What for” ? The products described were developed, manufactured and tested in compliance with the fundamental requirements of the EU machinery directive. These productssafety pose no danger to persons or property if they are used in accordance with the handling stipulations and safety notes prescribed for their configuration, mounting, and proper operation.
Nevertheless, there still is som e residual ris k!
Please note the information provided in the previous section in this context!
The present information refers to the •
Functionality of the BOS 6000, the “Welding User Interface”.
Information concerning •
the mechanical construction
•
the electrical connection (24V supply and I/O) and the functionality
•
of the hardware addressable via BOS is described more in detail in the relevant manuals. There, you will also find safety information that is important for product handling. Store this documentation in a place to which all users have access at any time! You should know and understand the issues at stake before installing, connecting or commissioning the products or programming the system. In case of uncertainty, you should always contact your supervisor!
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Symbol s us ed This symbol is used wherever insufficient or lacking compliance with instructions may result in personal injury . DANGER
This symbol is used wherever insufficient or lacking compliance with instructions may result in damage to pro perty . CAUTION
Note:
This symbol is used to draw the user’s attention to special circumstances.
This symbol indicates that you have to do something or have certain conditions. If will a special order hasnumber to be to create the observed, relevant paragraph start with a serial instead of an arrow.
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Safety Instruction s
Prop er use Our weld timers •
serve for resistance welding of metals in connection with a welding transformer and the appropriate power unit, and
•
are suitable for operation in industrial environments in accordance with the following standards: EN 50178, EN 602041, EN 50081-2, EN 50082-2. In residential environments, in trade and commerce as well as small enterprises, class A equipment may only be used if it does not inadmissibly interfere with other equipment.
The BOS 6000 user interface described here serves for •
Operation and
•
Parameter input
of weld timers of the PSS 5000 and PSx 6000 series. Any other application is deemed improper use! The consequences of an improper use include
DANGER
Note:
personal user or of as well as damages damages oftotheproperty – third the parties technical equipment, the workpiece to be processed, or environmental hazards. Therefore, our products should only be used for their intended purpose!
For operating the hardware in residential environments, in trade and commercial applications and small enterprises, an individual permit of the national authority or test institution is required; in Germany, please contact the Regulierungsbehörde für Telekommunikation und Post (RegTP) or its local branch offices.
The faultless, safe functioning of the product requires proper transport, storage, erection and installation as well as careful operation.
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Qualif ied pe rso nnel The present documentation is designed for specifically trained engineers with special knowledge of the welding technology. They must have sound knowledge of the software and hardware components of the weld timers, the power units used, and the welding transformers. Project engineering, programming, start and operation as well as the modification of program parameters is reserved to properly trained personnel! This personnel must be able to judge potential hazards arising from programming, program changes and in general from the mechanical, electrical, or electronic equipment. Such personnel are •
those who, being well trained and experienced in their field and familiar with the relevant norms, are able to analyze the jobs being carried out and recognize any hazards which may have arisen
•
those who have acquired the same amount of expert knowledge through years of experience that would normally be acquired through formal technical training.
Risks for person s with c ardiac pa cemake rs! arising from Due to the strong magnetic fields DANGER
resistance welding, the function of cardiac pacemakers may be disturbed. This may cause the death or considerable health damages! Therefore, these persons should avoid the welding system.
Please note our comprehensive range of training courses. Please refer to http://www.boschrexroth.com for the latest information on training courses, teachware and training systems. Our Erbach Didactic Center will be pleased to provide you with further information, telephone: (+49) (0) 60 62 78 600.
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Safety Instruction s
Safe wor kin g practi ces Program start is immediately possi fault reset! DANGER
ble after
If the start signal is present when a fault is reset (acknowledged), the timer will start its program run immediately! This may result in dangerous machine movements! Therefore, prior to fault reset, make sure that there is no-one in the hazard area of the welding equipment.
Strong magnetic fields! CAUTION
Due to the strong magnetic fields arising from resistance welding, the function of wristwatches, pocket watches or magnetic stripe cards (e.g., EC cards) may be disturbed for ever. Therefore, you should not carry such items on you while working in the immediate vicinity of the welding system.
Loss of data/D amage to fl oppy d isks/CDs! CAUTION
Note:
Never expose floppy disks to the effects of magnetic fields! Therefore, you should not carry any floppy disks on you while working in the immediate vicinity of the welding system. Provide suitable packaging to protect data media against hazardous external influences (such as dust, moisture, heat) or store them in a proper place.
Also note safety information that is important for product handling. For more detailed information, please refer to the relevant manuals: Tampering with the hardware or software and ignoring safety instructions/warnings can result in serious bodily injury or property damage.
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Trademarks, copyright •
All trademarks of software installed on our products upon delivery are the property of the respective manufacturers.
•
Upon delivery, all installed software is copyright–protected. The software may only be reproduced with our approval or in accordance with the license agreement of the respective manufacturer.
•
Reverse engineering of our software/firmware is illegal.
Note:
Interventions in the hardware and software of our products, unless described otherwise in the product documentation, are reserved to specialized personnel.
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Getting to know the BOS 60 00 user interface
Gett in g to k now th e BOS 6000 us er in terf ace In this section, you will be familiarized with important icons and the functions of the menu bar as well as the structure of the user interface and the purpose of the different windows.
Basics The BOS 6000 software (i.e. the welding user interface) can be used for weld timers of the PSS 5000 and PSx 6000 series. While this ensures an identical operating philosophy of all timers, there may be timer-specific differences in terms of scope of functions. Within the user interface, this may result in certain parameters/functions being invisible or dimmed.
Therefore, please always note the documentation relating to your specific timer including the safety instructions provided there!
In order to work with the user interface, you need to have a rough knowledge of the operating system (MS Windows 2000 or higher): • operating the mouse and keyboard •
entering data with the keyboard into input fields, or selecting data from lists.
•
changing the size/position of a window, closing windows
•
changing paths to folders via a dialog box if your settings differ from the default.
Note:
BOS 6000 can be operated using either the mouse or the keyboard.
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Overvie w o f t he interfa ce struct ure The table below shows the following information for all windows within the user interface •
the name of the window, and
its branch structure. In this way, you can find the path leading to a desired window quickly and easily. •
Description of the columns: • Level 1: Contains all windows that can be open at the same time. The table entry “the BOS 6000 main window” represents a menu shown in level 1a. •
Level 1a: Contains all the menus that can be displayed in the BOS 6000 main window.
•
Level 2: Can be called up from level 1.
•
Level 3: Can be called up from level 2.
If the window name is written in brackets ( ) , changing to another open window is not possible unless the relevant window has been closed. Level 1
Level 1a
Level 2
Level 3
() Reference
() () (Timer)
set-up the BOS 6000 main window
Schedule Seq. Pg.2 Stepper
( Counter)
General Electrode
calibration
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Getting to know the BOS 60 00 user interface Timer command button to transfer modified parameters to the timer (refer to sect. "Changing and transmitting parameters to the timer"). Using the Set counter
command button, the Count and the
Dressing-counter of the relevant electrode can be manipulated. Refer to sect. "Set counter".
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Stepping and dressing In order to compensate for negative effects of the electrode wear on the quality of the welded spots, 2 principal strategies can be applied, depending on the objective, which can be separately used during the electrode life, but may also be combined: •
Ensuring a desired welding diameter through periodical preparation of a defined electrode contact surface. This strategy is normally referred to as “Dressing”.
•
Ensuring the current density in the spot weld by gradually increasing the %I and, if necessary, the pressure. This strategy is normally referred to as “Stepping” or “Stepper”.
The “Stepping” function automatically changes the %I value (%I stepping) and the reference current (= monitor stepper) subject to the current program, the wear count and the tip dress counter between two consecutive phases (“start phase and “stepping phase” ). The “dressing” function outputs various signals to ensure that electrodes are mechanically worked on by external devices in configurable time intervals. Both functions are enabled or disabled for the relevant electrode (in parallel to the "Pressure-Stepper ,function") via the "Stepper" parameter. It depends on the other parameter settings whether or not the enabled functions are eventually active:
for %I and moni tor st epper in t he start phase •
%I for new electrode
•
"Reference current for new electrode"
•
"Count"
for %I and moni tor st epper in the stepping phase •
"Stepper-Curve"
•
“Pressure at end of 1.Stepper-Phase”
•
"Ref.-Current at end of 1.Stepper-Phase"
•
"Count"
•
"Maximum Count "
•
"Prewarning Count"
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for activating dressing as well as %I and monitor stepper in the stepping phase with active dressing •
"Dressing-Curve"
•
"Pressure after last dressing"
•
"Reference current last dressing"
•
"Count"
•
"Dressings"
•
"Tip dress request"
%I Step.-Va lue Displays the currently active %I stepping as a percentage of the base %I.
Monitor Step.-Value Displays the currently active stepper value for the Reference current in % of the base reference current (Monitor stepper).
Press. Step.-Valu e Displays the currently active Pressure stepping as a percentage of the base pressure value.
%I for new electrod e Acts electrode-specific in conjunction with the "Stepper" function in the start phase. The parameter defines the %I (in % of the program-specific base %I) to be used for welding at the beginning of the start phase (normally when the relevant electrode has been replaced). During the further development of the start phase, the %I value is linearly changed up to 100% of the program-specific base %I of a weld, depending on the actual count value. The length of the start phase depends on the electrode-specific parameter "Count". If the value 0 has been entered there, no start phase will be used. In this case, you should enter the value 100% as “%I for new electrode.
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Reference current for new ele ctr ode Acts electrode-specific in conjunction with the “Monitor Stepper" function in the start phase. The parameter defines the reference current (in % of the programspecific reference current) to be compared to an actual current at the beginning of the start phase (normally when the relevant electrode has been replaced), taking into account the tolerances. During the further development of the start phase, the reference current is linearly changed up to 100% of the program-specific reference current of a weld. The length of the start phase depends on the electrode-specific parameter "Count". If the value 0 has been entered there, no start phase will be used. In this case, you should enter the value 100% as “Reference current for new electrode.
Count Defines the maximum count at the end of the start phase for the stepper, monitor stepper and pressure stepper function. Within the span indicated here, the individual stepper values will be linearly increased to 100%. The start phase is normally very small (approx. 5 – 50 spot welds) and only has to be programmed for special applications, e.g., galvanized sheets. In combination with tip dressing, the start phase may be used to “run-in” a new electrode.
After each dr essing Note:
This parameter is not available for all timer types.
If activated, the count status of the relevant electrode is reset to “0” after the “Tips have been dressed” input signal has become high. That means that the start phase is carried out after each dressing cycle. Otherwise, the count is set to the value of the "Count" parameter after each dressing cycle. That means that the start phase is carried out a single time when an electrode has been replaced.
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Stepper-Curve (Programming, Stepper) Defines one out of 10 possible curves (0 to 9) for calculating the change characteristic of the base %I and the reference current within the stepping phase. The curve shape (percent change as a function of wear) can be programmed in the "Setup" menu, tab "Stepper curves".
Note:
If parameter "%I at the end of 1st stepper phase" is set to 100 (%), no stepper curve for changing the base %I is active during the stepping phase. If parameter "Ref. current at the end of 1st stepper phase" is set to 100 (%), no stepper curve for changing the reference current is active during the stepping phase.
Note:
If parameter "%I after last dressing" is set to a value other than 100 (%), a Dressing-Curve additionally influences the %I values during the stepping phase. If parameter "Ref.-Curr. last Dressing" is set to a value other than 100 (%), a Dressing-Curve additionally influences the reference current during the stepping phase.
%I at th e end o f 1st s tepper phase Acts electrode-specific in conjunction with the "Stepper" function in the stepping phase. In the course of the stepping phase, the %I value is increased up to the value entered for this parameter (in % of the programspecific base %I) subject to the current count value, starting from 100% of the program-specific base %I. The course of this change (during the stepping phase) can be influenced by parameter "Stepper-Curve". The length of the stepping phase depends on the electrodespecific parameter "Count". Its end is defined by the electrode-specific parameter "Maximum Count".
Note:
If parameter “%I at the end of 1st stepper phase“ is set to 100 (%), no Stepper-Curve influences the %I value during the stepping phase.
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Note:
If parameter "%I after last dressing" is set to a value other than 100 (%), a Dressing-Curve additionally influences the %I values during the stepping phase.
Ref.-Cur rent at end of 1.Stepper-Phase Acts electrode-specific in conjunction with the “Monitor Stepper" function in the stepping phase. The parameter defines the reference current (in % of the programspecific reference current) to be compared to an actual current at the end of the stepping phase (immediately before a dressing cycle or before replacing the relevant electrode), taking into account the tolerances. In the course of the stepping phase, the reference current is increased up to the value entered for this parameter (in % of the program-specific reference current), starting from 100% of the program-specific reference current. The course of this change (during the stepping phase) can be influenced by parameter "Stepper-Curve". The beginning of the stepping phase depends on the electrodespecific parameter "Count". Its end is defined by the electrode-specific parameter "Maximum Count".
Note:
If parameter “Reference current at the end of 1st stepper phase“ is set to 100 (%), no Stepper-Curve influences the monitoring during the stepping phase.
Note:
If parameter "Ref.-Curr. last Dressing" is set to a value other than 100 (%), a Dressing-Curve additionally influences the reference current during the stepping phase.
Counts Indicates the current Counts of the relevant electrode. New electrodes always start with a Count of 0. The actual count is incremented by the program-specific Count-Factor after each spot welded.
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Maximum count Effect when dr essing has b een deactivated (for activation/deactivation, refer to parameter Dressings"): Defines the End of Stepper of the relevant electrode. Within the span indicated here, the individual stepper, monitor stepper and pressure stepper values will be increased from 100% to the relevant target values. When the maximum count has been reached, the “Prewarning” signal will be reset, and “End of Stepper” will become high. Increasing the Count further will not change the stepping values.
Effect when dressing has bee n activated (for activation/deactivation, refer to parameter Dressings"): Defines the maximum permitted counts of the relevant electrode between 2 subsequent dressing cycles. Within this span, a programmed Stepper Curve will be processed. When the maximum count has been reached, the timer will output the “Dressing” signal (increasing the count further will not change the stepping values). The “Tips have been dressed” input signal causes the timer to set the count of the relevant electrode to the value programmed in parameter "Count". With some timer types, it is also possible to program a reset to “0” (set parameter "After each dressing" “ON”). The desired number of these cycles is defined by the expression: Dressings + 1. This results in the following End of Stepper: maximum count * Dressings + 1. Within the “maximum count * Dressings" span, a programmed Dressing-Curve is processed. During the last cycle, the timer resets the “Prewarning” signal when the maximum count has been reached and outputs the “End of stepper” signal. Increasing the Count further will not change the stepping values. The “Electrodes have been replaced” input signal resets the count and the Dressing counter of the electrode in question (to “0”).
Prewarning Coun t Defines the number of counts prior to the End of Stepper for which the “Prewarning” signal is to be output for the relevant electrode.
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Dressi ng-Curve (P rog ramming , Stepper) Defines one out of 10 possible curves (0 to 9) for calculating the change characteristic of the base %I and the reference current after a dressing cycle. The change will be performed after each dressing cycle and will remain constant until the next dressing cycle (stepper function). It will act in addition to a change generated by the Stepper-Curve The curve shape (percent change as a function of the product of dressings x count) can be programmed in the "Setup" menu, tab "Dressing-curves".
Note:
If parameter “%I after last dressing“ is set to 100 (%), no Dressing-Curve is active for changing the base %I. If parameter “Reference current last dressing“ is set to 100 (%), no Dressing-Curve is active for changing the reference current.
%I after last d ressin g Acts program-specific in conjunction with the "Stepper" function in the stepping phase. The parameter serves for automatically calculating any %I changes to be activated after a dressing cycle. It initially determines the complete %I change desired in the course of all dressing cycles until the last dressing (in % of the program-specific base %I). The course of this change (i.e. the %I change after dressing) can be influenced by parameter "Dressing-Curve". A %I change will be performed after each dressing cycle and will remain constant until the next dressing cycle (stepper function). It will act in addition to a %I change generated within the stepping phase by the Stepper-Curve.
Note:
If parameter “%I after last dressing“ is set to 100 (%), no Dressing-Curve is active for %I stepping.
Note:
If parameter "%I at the end of 1st stepper phase" is set to a value other than 100 a Stepper-Curve additionally influences the(%), %I values during the stepping phase.
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Reference current last dr essing Acts program-specific in conjunction with the “Monitor Stepper" function in the stepping phase. The parameter serves for automatically calculating any reference current changes to be activated after a dressing cycle. It initially defines the reference current (in % of the program-specific reference current) to be compared to an actual current after the last dressing, taking into account the tolerances. The course of this change (i.e. the reference current change after dressing) can be influenced by parameter "Dressing-Curve". A reference current change will be performed after each dressing cycle and will remain constant until the next dressing cycle (stepper function). It will act in addition to a reference current change generated within the stepping phase by the StepperCurve.
Note:
If parameter “Reference current last dressing“ is set to 100 (%), no Dressing-Curve is active for monitor stepper.
Note:
If parameter "Reference current at the end of 1st stepper phase" is set to a value other the thanmonitoring 100 (%), avalues StepperCurve additionally influences during the stepping phase.
Actual value (Dressing counter) Indicates how often the relevant electrode has already been dressed.
Dressings Indicates how often the relevant electrode should be dressed in the course of its life cycle (including first tip dress. Refer to "Dress new electrode").
Dress-Request
Defines the number of counts prior to the "Maximum Count" for which the “Tip dress request” signal is to be output for the relevant electrode.
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Stepper If activated, the “Stepper”, “Dressing” and “Dress new electrode” functions have been enabled for the electrode in question and operate according to their parameter settings. Only when activated will electrode-specific signals (“End of Stepper”, “Prewarning”, etc.) be generated or checked by the timer.
Count-Factor
Program-specific definition of the amount by which the count of an electrode is incremented after each spot welded. The count factor is an experimental value that may be adjusted to the individual welding task. When set properly, the electrode can be automatically used under optimum conditions even when welding different sheet thicknesses or materials. If only count factors of 1.0 are used, the counts correspond to the spot count.
Wear per com ponent Defines the wear experienced by an electrode when manufacturing a part with the electrode in question. From this value, the timer calculates the number of remaining parts that can still be manufactured using the relevant electrode (refer to "Prewarning" window).
Dress n ew electrod e Note:
This function is not available for all timer types.
Turns the “first tip dress” function on or off. “First tip dress” is used to ensure a defined condition (diameter, shape, etc.) of a new electrode.
Extended e lectrod e life Note:
This function is not available for all timer types.
Indicates the number of wear counts that will be accepted before the timer is inhibited when the relevant electrode has reached its End of Stepper. Also refer to parameter “ Stop at end of Stepper.
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Acti ve reference cur rent (Programm ing, Stepper) The fields for the prewld to pstwld show the actual rms current values (in kA) measured in the individual heat blocks. The “Standard” field shows the mean actual rms current during all 3 heat blocks.
Average/Middle PHA (Programming, Stepper) Indicates the mean command value obtained in KSR mode for driving the power unit (in %I) for the prewld to pstwld. The “Standard” field indicates the mean command value of all 3 heat blocks for driving the power unit (in %I). In PHA (and KUR) mode, the values displayed exactly correspond to the programmed %I values.
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Programmin g: General Note:
First you have to select the relevant timer - indirectly via the “Spot-Name” field, or - directly via the “Timer” field.
Use the Data ----> Timer command button to transfer modified parameters to the timer (refer to sect. "Changing and transmitting parameters to the timer").
Stop at end of st epper If assigned the value “ON”, another welding schedule is no longer possible using the relevant electrode if this electrode has reached its end of stepper condition. Exceptions can be programmed via the "Extended electrode life" function).
Max. %I corr ectio n Defines the maximum %I correction (increase ) of the relevant timer (refer to "Correction" menu, tab "Correction", parameter "%I correction (x)").
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Min. % I corr ection Defines the maximum %I correction d( ecrease ) of the relevant timer (refer to "Correction" menu, tab "Correction", parameter "%I correction (x)").
Max. Pressure-Correction Defines the maximum pressure correction (increase ) of the relevant timer (refer to "Correction" menu, tab "Correction", parameter "Pressure correction (x)").
Min. Pressure-C orr ection Defines the minimum pressure correction (decrease ) of the relevant timer (refer to "Correction" menu, tab "Correction", parameter "Pressure correction (x)").
Start-Inhibit (T) If programmed as “ON”, starting any program of the selected timer will initiate the error message “Start inhibited". Also refer to parameter “Start-Inhibit (P)”.
Weld /No weld (Glob al) Defines whether the power can generally be energized running any programs of theunit selected timer (parameter value when “On”) or whether it is not energized (parameter value “Off”). Also refer to parameter “Weld/No Weld (P)“.
Note:
The power unit will not be energized unless the following conditions are met: Parameter “Weld/No weld (P)” = “On” and Parameter “Weld/No weld (Global)” = “On” and (if existent) the “Weld external” input signal has been set.
Machine movements are also possi ble if Weld/No weld is deactivated DANGER
If the WCrun, contact is output at the end of the program machine movements may be initiated even if “No weld” has been specified. Therefore, please make sure that there is noone in the hazard zone when the welding program is started.
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Max. welding ti me Limits the maximum weld times that can be programmed for the prewld, WLD and postweld for the relevant timer.
Control stopp ed If programmed as “On“, this function will inhibit KSR mode (refer to parameter "Regulation mode") for all programs of the relevant timer. This condition will be symbolized by a red frame surrounding the timer symbol in question in the Network overview. If the current sensor or the connection cable is defective, Control stopped may be activated, e.g., for emergency operation.
Possibility of incor rect welds CAUTION
When control has been stopped, the current in the secondary circuit is no longer regulated with respect to the programmed value. Therefore, changes in resistance in the secondary circuit (since the last weld of a program with operative regulation) will directly affect the quality of the spot weld! You should never activate Control stopped without good reason! Make sure that all spot welds are checked if Control stopped has been activated.
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Monitoring stopped If programmed as “On“, this function will prevent a response of Current monitoring for all programs of the relevant timer. This condition will be symbolized by a red frame surrounding the timer symbol in question in the Network overview. If the current sensor or the connection cable is defective, Monitoring stopped may be activated, e.g., for emergency operation.
Possibility of incor rect welds CAUTION
If current monitoring is inhibited, the current in the secondary circuit will not longer be compared to the programmed Reference current. Actual currents outside the programmed tolerance bands will no longer be signaled in this condition. Possible consequences include direct effects on the quality of the spot weld! You should never activate Monitoring stopped without good reason! Make sure that all spot welds are checked if Monitoring stopped has been activated.
Max r epeat welds (max. repe titi on i n s eries) In order to prevent the Spot repetition from responding all the time (in the event of “creeping“ system faults), this parameter may be used to specify the number of directly consecutive welding programs for which the spot repetition may respond.
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Choose parity Note:
This function is not available for all timer types.
To select the type of parity check. If the parity check has been activated, the timer can verify, through the additional “Parity” input signal, whether or transmitted. not the “Program selection xx” input signals have been properly Possible settings: •
Off: no parity check.
•
Even: Parity check on. The number of active input signals “Program selection xx” must be even if the “Parity” input signal is not high.
•
Odd: Parity check on. The number of active input signals “Program selection xx” must be odd if the “Parity” input signal is high.
WC with error Defines whether the “WC” signal is to be output after the end of a welding schedule for “good” welds only, or after any welds. In connection with the WC signal, also refer to parameters "WC Period" and "WC Start time".
WC Period If the start signal is no longer present in “Single spot“ Mode at the end of a welding schedule, the WC will be automatically reset after the period of time defined in this parameter..
WC Start ti me Influences the time when the WC is output. •
Input = 0: The positive edge of the WC will be simultaneously output at the end of HLD.
•
Input > 0: The positive edge of the WC is delayed by max. 1000 ms with respect to the end of HLD. Input < 0: The positive edge of the WC will be output before the end of HLD. This allows you to reduce constant delays in the subsequent handling sequence. Although 1000 ms can be maximally programmed as the time period for accelerating the WC, this time must always be shorter than the currently programmed HLD.
•
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Mode pressure output Note:
This parameter is not available for all timer types.
Defines the physical influencing variable for generating the electrode force at the timer’s pressure output. •
0...20mA: The desired electrode force can be output as a current value within the absolute of 0500 to 20 mA. Maximum permittedlimits burden: Ohm
•
0...10V: The desired electrode force can be output as a voltage within the absolute limits of 0 to 10 V. Maximum output current: 20 mA
•
4...20mA: The desired electrode force can be output as a current value within the absolute limits of 4 to 20 mA. Maximum permitted burden: 500 Ohm
Note:
The characteristic for converting the electrode force into the relevant manipulating variable is influenced via the "Conversion-Factor" and "Zero adjust" parameters.
Note:
This parameter is not available for all timer types.
Fade-out time
Time span immediately after current activation by which measurement of the rms value of the actual current is to be delayed. Using this function, you can prevent the current rise from influencing the rms measurement of the actual current.
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For other possiblities of influencing the rms value measurement, refer to parameter “ Trail current".
Note:
The programmed fade out time is identical for all weld times and for all welding programs! Therefore, you should make sure that the fade out time is always shorter than the shortest programmed weld time.
Note:
The fade out time must match the corresponding settings of the external current meter for comparative measurements (current calibration).
Note:
This parameter is not available for all timer types.
Trail current
Defines whether the current drop caused by the very operating principle at the end of a weld time is to be included in the rms value measurement of the actual current. If defined as “Off”, rms value measurement of the actual current will stop exactly at the end of a weld time. Using this function, you can prevent the current drop from influencing the rms measurement of the actual current.
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For other possibilities of influencing the rms value measurement, refer to parameter “ Fade out time".
Note:
This setting is identical for all weld times and for all welding programs.
Note:
The fade out time must match the corresponding settings of the external current meter for comparative measurements (current calibration).
Measuring loop check If defined as “On”, the external current sensor circuit will be checked before a weld time is started. If this check reveals an inadmissible volume resistance, the timer will cancel the running program and generate an error message.
Note:
If no external current sensor is used, the measuring loop check must be deactivated.
Possibility of incor rect welds CAUTION
If the measuring loopcurrent check is deactivated although an external sensor is used, the system will not be able to detect any errors in the sensor loop. Possible consequences include direct effects on the quality of the spot weld! Therefore, you should activate the measuring loop check if you use external current sensing equipment.
Curre nt su pervision Note:
This parameter is not available for all timer types.
Defines the type of current measurement for the relevant timer: • primary: Actual currents are determined by a current sensor integrated in the primary circuit, but transformed into secondary current values for further processing (e.g. for display in BOS). This option is cost-effective, easy to implement, and suitable for weld times longer than 1 second as well as seam operation. Compared to the “secondary” option, it has higher tolerances for
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the boundary regions of the output current range. Calibration should also be performed for primary current measurement. •
secondary: Actual currents are directly determined in the secondary circuit using an external current sensor. In connection with current calibration, this option ensures highly precise secondary currents yet is not suitable for weld times longer than 1 second or for seam operation. An external current sensorin(e.g. integrated intothe thesecondary welding transformer) is necessary order to measure current .
Progra mming: Electrode Note:
First you have to select the relevant electrode - indirectly via the “Spot-Name” field, or - directly via the “Electrode” field.
Use the Data ----> Timer command button to transfer modified parameters to the timer (refer to sect. "Changing and transmitting parameters to the timer"). Click on the Current calibration "Current calibration" window. Click on the Force calibration "Force calibration" window.
command button to open the command button to open the
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%I Limitatio n Limits the maximum permissible %I values for the electrode in question.
Note:
%I Prewarni ng
The value input must not be lower than the value of parameter “%I Prewarning ”.
Defines the current in %I for the relevant electrode which is to trigger a %I Prewarning.
Note:
The value input is limited by the value of parameter “%I Limitation”.
1. Halfcycl e limit Limits the phase angle of the 1st halfcycle within the welding schedule (= transformer inrush current) to the value input for the relevant electrode. This parameter is relevant and displayed for equipment with thyristor power units only.
Note:
The program-specific transformer inrush current can also be limited using parameter "1. Halfcycle after Pause-Time".
Upper cu rrent limit Limits the maximum configurable %I values for the electrode in question. In order to determine the maximum configurable %I values, the system may strip out any %I compensation from the value input.
Example: Input value: 16.8 kA Maximum %I stepping: 120% In input fields for %I values, inputs greater than 14.00 kA are not possible.
Toroid sensitivity Specifies the toroid sensitivity (in mV/kA) of the current sensor for the relevant electrode (gun).
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The sensitivity of our sensors is 150 mV/kA. When using third-party sensors, the appropriate sensitivity can be programmed using this parameter.
Note:
As the accuracy of current measurement is subject to this value, you should in any case use the "Current calibration" function!
Possibility of incor rect welds! The value is automatically adjusted by the timer in the course of current calibration. CAUTION
Making arbitrary changes to the toroid sensitivity will render current calibration useless. The accuracy of current measurement is no longer guaranteed. Therefore, you should never make any arbitrary changes to the value displayed!
2. Toroid sensitivity Note:
This parameter is not available for all timer types.
With some timer types, an external sensor can be used to check the plausibility of the current measured by primary current measurement (refer to "Programming" menu, tab "General", "Current supervision") parameter. In these cases, it is necessary to manually enter the toroid sensitivity (in mV/kA) of the relevant current sensor with respect to the electrode (gun) in question. The sensitivity of our sensors is 150 mV/kA. When using third-party sensors, manually enter the appropriate sensitivity in this parameter.
Possibility of error messages! Arbitrary changes of the 2nd toroid sensitivity may result in recurring error messages! CAUTION
Therefore, you should never make any arbitrary changes to the value displayed!
Electro de range Note:
This parameter is not available for all timer types.
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The electrode range depends on the welding transformer used and on the current sensor, therefore, this value may be programmed separately for each electrode (gun). Timers offering automatic measuring range changeover display the currently active measuring range in this parameter. For timers with a programmable measuring range, the electrode range must be manually entered here, depending on the toroid sensitivity.
Electro de ranges with PS 5000 and AC power unit: Electrode range
measurable currents in kA with given toroid s 50 mV/kA
100 mV/kA
ensitivity
150 mV/kA
500 mV/kA
1000 mV/kA
1500 mV/kA 0.0 – 0.5
0
1.5 – 15.0
0.7 – 7.5
0.5 – 5.0
0.1 – 1.5
0.0 – 0.7
1
7.5 – 75.0
3.7 – 37.0
2.5 – 25.0
0.7 – 7.5
0.5 – 3.7
0.3 – 2.5
2
30.0 – 300
15.0 – 150
10.0 – 100
3.0 – 30.0
1.5 – 15.0
1.0 – 10.0
3
75.0 - 750
37.0 - 375
25.0 - 250
8.0 – 75.0
3.7 – 37.0
2.5 – 25.0
Electrode ranges with PS 5000 and medium-frequency inverter: Electrode range
measurable currents in kA with given toroid s 50 mV/kA
100 mV/kA
150 mV/kA
ensitivity
500 mV/kA
1000 mV/kA
1500 mV/kA 0.0 – 0.8
0
2.4 – 24.0
1.2 –12.0
0.8 – 8.0
0.2 – 2.4
0.0 – 1.2
1
12.0 – 120
6.0 – 60.0
4.0 – 40.0
1.2 – 12.0
0.6 – 6.0
0.4 – 4.0
2
48.0 – 480
24.0 – 240
16.0 – 160
4.8 – 48.0
2.4 – 24.0
1.6 – 16.0
3
120 - 999
60.0 - 600
40.0 - 400
12.0 – 120
6.0 – 60.0
4.0 – 40.0
Electrode ranges with PS 6000: Electrode range 10
measurable currents in kA with given toroid s
ensitivity
150 mV/kA 0.25* – 2.5 *
11
0.5 – 5.0
12
1.0* – 10.0
13
2.0* – 20.0
14
4.0* – 40.0
15
8.0 – 80.0
16
16.0* – 160
*
* Lower values are displayed with an undefined accuracy.
Curr ent at 0% I Note:
This parameter is not available for all timer types.
Input of the appropriate current value that is generated by the inverter (PSU) at 0 %I with a linear current control characteristic.
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Curr ent at 50% I Note:
This parameter is not available for all timer types.
Input of the appropriate current value that is generated by the inverter (PSU) at 50 %I with a linear current control characteristic.
Type (transfo rmer) Note:
This parameter is not available for all timer types.
Serves to select the welding transformer for the electrode (gun) in question. The necessary information is shown on the nameplate of the welding transformer (e.g. “PSG 3100.00”). If the proper transformer type cannot be selected from a list box, you have to select the “Other transformers” option. In this case, the following information must be additionally entered: Transformer ratio Nominal current Type of diode and No. of parallel Diodes
Possibility of damaging the transformer! CAUTION
The timer derives additional important information from the transformer type specified here that is necessary for safe operation. Therefore, you should never make any arbitrary changes to the input value!
Type of connection (tra nsformer) Note:
This parameter will not be displayed unless values greater than “1“ have been entered in "Number of transformers".
You specify whether the transformers on the primary side are connected in parallel or in series.
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Possibility of damaging the transformers! CAUTION
The timer derives additional important information from this parameter that is necessary for safe operation. Therefore, you should never make any arbitrary changes to the input value!
Number (of transformers) Note:
This parameter is only relevant for weld timers of the PSI 6000 series.
Number of welding transformers connected. If several welding transformers are connected, the electrical characteristics of these transformers must be identical. Use connection leads of the same conductor area and length for all transformers in question.
Possibility of damaging the transformers! CAUTION
The timer from derives information this additional parameter important that is necessary for safe operation. Therefore, you should never make any arbitrary changes to the input value!
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Prima ry transformer r atio (transforme r) Note:
This parameter will not be displayed in conjunction with PSI 6000 unless “Other transformers“ has been selected in Transformer-Type.
Transformer ratio of the primary transformer used. This information is normally shown on the nameplate of the welding transformer. The timer needs the transformer ratio information for converting the primary current into the secondary current (for primary current measurement, refer to "Programming" menu, tab "General", "Current supervision" parameter).
Possibility of damaging the transformers! CAUTION
The timer derives additional important information from this parameter that is necessary for safe operation. Therefore, you should never make any arbitrary changes to the input value!
Nomina l current (tra nsformer) Note:
This parameter will not be displayed unless “Other transformers“ has been selected in Transformer-Type.
Nominal current of the welding transformer in kA. This information is normally shown on the nameplate of the welding transformer. The timer limits the maximum welding current to the value specified in this parameter in order to protect the transformer.
Possibility of damaging the transformers! The CAUTION
timer
derives
additional
important
information this parameter that is necessary forfrom safe operation. Therefore, you should never make any arbitrary changes to the input value!
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Supe rvision (diode s) If activated, the high-current diodes in the transformer’s secondary circuit will be monitored for excessive junction temperatures. For this purpose, the system checks - with reference to a cooling water temperature of 30 degrees Centigrade - whether the (internally calculated) junction temperature of the diodes (value displayed in field "Diode temperature") exceeds the "Switch-off temperature" configured. If yes, the welding sequence is immediately aborted.
Possibility of damaging the transformers! CAUTION
If diode supervision is deactivated, the diodes may be destroyed in the event of overload. Therefore, we strongly recommend to leave diode supervision active at all times!
Type ( dio des) Note:
This parameter will not be displayed unless “Other transformers“ has been selected in Transformer-Type and "Diode supervision" is active.
Diode type used for the welding transformer.
Possibility of damaging the transformers! CAUTION
The timer derives additional important information from this parameter that is necessary for safe operation. Therefore, you should never make any arbitrary changes to the input value!
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No. para llel (dio des) Note:
This parameter will not be displayed unless “Other transformers“ has been selected in Transformer-Type and "Diode supervision" is active.
Number of diodes used for each secondary branch.
Possibility of damaging the transformers! CAUTION
The timer derives additional important information from this parameter that is necessary for safe operation. Therefore, you should never make any arbitrary changes to the input value!
Switch-off temperature (diodes) Note:
This parameter will not be displayed unless “Other transformers“ has been selected in Transformer-Type.
Refer to parameter Supervision (diodes).
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Possibility of damaging the transformers! CAUTION
The timer derives additional important information from this parameter that is necessary for safe operation. Therefore, you should never make any arbitrary changes to the input value!
Diode tempera tur e Displays the calculated junction temperature of the high-current diodes during the last weld performed with the relevant electrode (gun).
Mains v oltage Displays the mains voltage during the last weld performed with the relevant electrode (gun).
Maximum pressure Limits the maximum permissible electrode force values for the electrode (gun) in question.
In order to determine the maximum configurable values, the system strips the Final values of active stepper data configured or the maximum permissible pressure correction data out from the input value.
Example: Input value: Maximum pressure stepping: Max. pressure correction (+):
3.9 kN 120% 10%
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No input greater than 3.00 kN can be made afterwards in the relevant input fields.
Possibility of damaging guns! CAUTION
Before pressure calibration has been properly carried out, there is no defined correlation between the programmed force and the resulting force at the electrode gun! For thisthe reason, the value input cannot protect gun unless pressure calibration has been properly completed. You should never make any arbitrary changes to the value displayed!
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Conversion-Factor Determines the slope of a linear characteristic that defines the resulting gun force as a function of the force influencing variable (refer to "Programming" menu, tab "General, Parameter"Mode Pressure Output") parameter. The following relationship applies in general: F(St) = x St + where F is the resulting force in kN and St the force-influencing variable.
Possibili ty of damage s to guns and/or incorrect welds! CAUTION
The value is automatically determined by the timer in the course of pressure calibration and entered in this parameter. By making arbitrary changes of the parameter value the defined correlation between the value input and the resulting force at the electrode gun will be lost! Therefore, you should never make any arbitrary changes to the value displayed!
Examples: Input value “1”: the timer converts a programmed force into the force-influencing variable at a 1:1 ratio using a 45 degrees characteristic.
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Note:
Also refer to parameter Zero adjust".
Zero adju st Determines the offset by which the linear characteristic (refer to parameter "Conversion-Factor") intersects with the force axis (F).
Possibili welds! ty of damage s to guns and/or incorrect CAUTION
The value is automatically determined by the timer in the course of pressure calibration and entered in this parameter. By making arbitrary changes of the parameter value the defined correlation between the value input and the resulting force at the electrode gun will be lost! Therefore, you should never make any arbitrary changes to the value displayed!
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Programmin g: Thyrist or-Unit-P arameter Note:
First you have to select the relevant welding program - indirectly via the “Spot-Name” field, or - directly via the “Thyr.” field.
Note:
Entries in the “Thyr.” field are only possible if the timer is capable of driving several power units in parallel.
Use the Data ----> Timer command button to transfer modified parameters to the timer (refer to sect. "Changing and transmitting parameters to the timer").
Nominal vol tage (T hyr isto r-Unit-P arame ter) Note:
This parameter is only shown in Regulation mode "KUR" (refer to "Programming" menu, tab "Schedule").
Input the nominal voltage of the power unit.
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Turns ratio (Thyr isto r-Unit-Pa ramete r) Note:
This parameter is only shown in Regulation mode "KUR" (refer to "Programming" menu, tab "Schedule").
A feedback transformer is used for voltage measurement with the KUR regulation mode. Enter the turns ratio of this transformer in this parameter. Example: 380 V : 24 V = 15.833. If your transformer is designed for a higher voltage, you should nevertheless enter the calculated turns ratio.
Thyristor-Unit-Type Note:
This parameter is not available for all timer types.
Adjusts the timer to the power unit connected.
Possibili ty of derives damage sadditional to the plant!important The timer CAUTION
information from this parameter that is necessary for safe operation. Therefore, you should never make any arbitrary changes to the input value!
Thyristor-Unit temperature Note:
This parameter is only available for timers with an external power unit.
Indicates the type of temperature contact at the power unit. On : Contact is closed if overtemperature is present Off: Contact is opened if overtemperature is present.
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Possibili ty of damage s to the plant! CAUTION
The timer derives additional important information from this parameter that is necessary for safe operation. Therefore, you should never make any arbitrary changes to the input value!
Ignition Type Note:
This parameter is only relevant for connection of CNOMO power units.
It is needed to set the control method for the AC power unit. Standard (Burst): Default CNOMO (Pulse): Special case
Possibili ty of damage s to the plant! The timer derives additional important information from this parameter that is CAUTION
necessary safeshould operation. Therefore, foryou never make any arbitrary changes to the input value!
Timer t ype (Thyri stor -Unit-Pa ramete r) Returns the exact timer type.
Software- Versio n (Thyri stor -Unit-Pa ramete r) Displays the firmware version.
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Diagnosis Within the BOS 6000 main window, the “Diagnosis“ menu (which is called up by the
icon) offers the following choices:
•
Selection of “Spot-Name” or “Timer” to change over to the desired timer.
•
Selection of the "Diagnostics I/O" tab to display the condition of all I/O signals.
•
Selection of the "Users-Diagnostics I/O" tab to display the condition of all I/O signals. In contrast to the other tabs, customized names (set by the configuration tool) are used for the signals in this case.
•
Selection of the "Start Simulation" tab in order to start any desired welding program with/without ignition, or in order to output the WC contact. If the timer is in an error condition, a “Fault reset” can be performed before.
•
Selection of the "Timer - Information" tab in order to display various types of information concerning the timer status.
•
Selection of the "Last Weld" tab in order to display various types of information concerning the last welding schedule performed.
Note:
The “Diagnosis” menu can only be activated for online timers.
Note:
For information concerning the Status line, refer to “Explanations“ section.
Note:
In some cases, the settings/functions are only possible at a certain user level.
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Diagno sis: Diagnos tics I/O Note:
First you have to select the relevant timer - indirectly via the “Spot-Name” field, or - directly via the “Timer” field.
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Using the New or Standard command buttons, you can switch between the alternative types of display for the input/output signals.
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Note:
The signals displayed are timer-specific and may be different for your relevant timer.
Progra m (display field in “ Diagnosis” menu) Shows the program number currently active at the digital inputs as a decimal number.
Inputs / O utpu ts Returns the current status of these signals. For this purpose, all signals are cyclically updated and displayed either in binary format (line by line from left to right, starting with the lowest signal number) or one below the other (in table format), depending on the type of display selected. Signal status: 0: Signal is low 1: Signal is high
(white background) (green background)
•
If the signals are shown in binary format , you can click on a bit field in order to display the signal number, signal type and signal name in line “Description”. transmitted via the field bus “discrete”: present at a hardware input/output ”internal”: is influenced/generated within the timer
•
If the signals are displayed in table format , the following applies to the identification of the signal types: E: Signal is present at a hardware input A: Signal is present at a hardware output S: signal is transmitted via the field bus I: Signal is influenced/generated within the timer
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Diagno sis : Users Diagnost ics I/O Note:
First you have to select the relevant timer - indirectly via the “Spot-Name” field, or - directly via the “Timer” field.
Note:
In contrast to the other tabs, customized names (set by the configuration tool) are used for the signals in this case.
Click on the Timer-Information command button to call up the data available on the "-Information" tab in a separate window. Click on the Last Weld command button to call up the data available on the "" tab in aseparate window. The information contained in the tables corresponds to the description in the previous section, "Inputs / Outputs".
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Diagno sis: Start S imul ation Note:
First you have to select the relevant timer - indirectly via the “Spot-Name” field, or - directly via the “Timer” field.
Machine movements are also possi ble if Weld/No weld is deactivated DANGER
If the WC contact is output at the end of the program run, machine movements may be initiated even if “No weld” has been specified. Therefore, please make sure that there is noone in the hazard zone when the welding program is started or the WC contact is deliberately output.
Possibili ty of imm ediate welding sc hedule start afte r “ Fault reset with rewe ld” ! DANGER
If the start signal is present when a fault is reset with reweld, the timer will immediately start repeating its program run! Welding will be repeated! Therefore, please make sure that there is noone in the hazard zone when fault reset with reweld is started.
Possibili ty of imm ediate machine movements after “ Fault Rese t with WC” ! DANGER
If the start signal is still present at “Fault reset with WC”, the timer will set the “WC” output signal as soon as the fault has been reset! This may result in machine movements. Therefore, please make sure that there is noone in the hazard zone when Fault reset with WC is initiated.
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Possibility of delayed welding! DANGER
Under certain conditions, the timer will automatically extend the SQZ before proceeding to WLD (waiting for pressure contact or pressure feedback). Therefore, you should ensure that no-one enters the hazard zone for as long as the messages “No Schedule” (“Interval” field) or “OK” field) are not displayed in the “Actual(“Status” Cycle” area.
The timer can be reset to “Ready” state and the WC contact can be output by hitting the Reset w ith WC command button. When hitting Reset with Reweld , the timer will be reset to “Ready” state after a current fault of the type “Low current” or “no weld current …”, isand faulty welding schedule will be restarted if the start signal stillthe present.
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Interval (D iagnosi s, Sta rt Simulation Indicates the section of the welding schedule that is currently being processed by the timer (schedule display).
Status (Diagnos is, Start Simulation Additional information concerning the active interval. Indicates the current condition (e.g. “Waiting for press.cont. 1/2", “WC on”, “No schedule”).
Last weld program cho sen Display of the program no. of the program that was started last in the relevant timer.
Weld pro gram chos en Input of the program number of the program to be influenced via the "Start with ignition" or "Start without ignition" radio buttons.
Start wi th ign itio n (Diagnosi s, Start Simulation
Please note the safety instructions in the beginning of section "Diagnosis: Start Simulation"!
•
Radio button “On” : chosen program starts with ignition
•
Radio button “Off” : a start signal previously given by the “On” radio button is removed.
Start without ignition (Diagnosis, Start Simulation)
Please note the safety instructions in the beginning of section "Diagnosis: Start Simulation"!
•
Radio button “On” : chosen program starts without ignition
•
Radio button “Off” : a start signal previously given by the “On” radio button is removed.
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WC (Diagnos is, Start Simu lation)
Please note the safety instructions in the beginning of section "Diagnosis: Start Simulation"!
•
Radio button “On” : WC contact is output.
Radio button “Off” : a WC signal previously given by the “On” radio button is removed. For the WC parameters, also refer to "WC with error", "WC Start time" and " Period" in the "Programming" menu, tab "General". •
Diagnosis: Timer-Information Note:
First you have to select the relevant timer - indirectly via the “Spot-Name” field, or - directly via the “Timer” field.
The timer can be reset to “Ready” state and the WC contact can be output by hitting the Reset w ith WC command button. When hitting Reset with Reweld , the timer will be reset to “Ready” state after a current fault of the type “Low current” or “no weld
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current …”, and the faulty welding schedule will be restarted if the start signal is still present.
Timer type (Dia gnos is, Timer-I nfor mation) Display of the exact timer type of the relevant timer.
Software- Versi on (Diagnosi s, Timer-I nfor mation) Displays the firmware version of the relevant timer.
Status (Diagnosi s, Timer-I nfor mation, Timer) Displays the active type of message: •
Ok (no message is active)
•
Warning
•
General fault
•
Welding fault
Code (D iagnosi s, Timer-I nfor mation) Display of the message text.
Addi ti on (Diagnosis, Timer-Inf mation, concerning Timer) the timer message displayed. Additionalorinformation Displays either the program number, electrode number, or an additional message text.
Interval (D iagnosi s, Timer-I nfor mation) Indicates the section of the welding schedule that is currently being processed by the timer (schedule display).
Status (Diagnosi s, Timer- Information , Actual Cycle) Additional information concerning the active interval. Indicates the current condition (e.g. “Waiting for press.cont. 1/2", “WC on”, “No schedule”).
Program (Dia gno sis, Timer-I nfor mation) Number of the program that was last started in the relevant timer. Schedule (D iagnosi s, Timer- Information ) Active schedule status of the program that was last started (e.g. “finished”).
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Addi ti on (Diagnosis, Timer-Inf or mation, Last Weld) Additional information concerning the last weld (e.g. “Welding fault” or “OK”).
Diagno sis : Last We ld Note:
First you have to select the relevant timer - indirectly via the “Spot-Name” field, or - directly via the “Timer” field.
The following information will be displayed for the relevant weld timer: •
welding program that was started last and spot name
•
Time of the last weld
•
Wear counter status of the electrode in question
•
Reference currentvalue and actual current, separately for each WLD, or as an average for all WLD (“Standard” line).
Reference time and time actually needed •
the necessary/programmed phase value, separately for each WLD
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Setup Within the BOS 6000 main window, the “Setup“ menu (which is called up by the
icon) offers the following choices::
•
Selection of “Spot-Name” or “Timer” to change over to the desired timer.
•
Selection of the "Stepper curves" tab in order to define up to 10 different stepper curves (0 to 9)..
•
Selection of the "Tipdress curves" tab in order to define up to 10 different tipdress curves (0 to 9).
•
Selection of the "Fault-Setup" tab in order to define messages as faults or warnings.
•
Selection of the "Communication" tab in order to display various communication parameters of the Ethernet interface.
Note:
For information concerning the Status line, refer to “Explanations“ section.
Note:
In some cases, the settings/functions are only possible at a certain user level.
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Setup: Stepper c urv es Note:
First you have to select the relevant timer - indirectly via the “Spot-Name” field, or - directly via the “Timer” field.
You can transfer all stepper curves to the timer by hitting the Appl y command button. Each curve (0 to 9) influences the %I, reference current and pressure and defines the desired change of all these quantities subject to the electrode count during the stepping phase. Select the desired curve in the “Curve number field. You may enter remarks concerning the curve in the input field to the right of the curve number. •
The starting point (%I change of 0% with a count of 0%) refers to the respective base value of the %I, Reference current and Pressure.
•
The final point (%I change of 100% with a count of 100%) refers to parameter "Pressure at end of 1.Stepper-Phase" for the pressure, to parameter "%I at end of 1.Stepper-Phase" for %I, and to parameter "Reference current at end of 1.StepperPhase" for the reference current.
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The starting point and the end point of a curve (white points) are always fixed. A total of 8 intermediate points are available between the starting point and the end point for influencing the curve characteristic. For this purpose, you must drag the black points with the mouse to the desired position, or enter the corresponding values right below the “%I change” and the “Count Value” parameters. For reasons of plausibility, count values can only be entered in ascending order into the input fields from left to right. Linear interpolation will be carried out between any 2 intermediate points.
In a first approximation, these curves approximately resemble the shape of an e-curve, rising sharply in the beginning and becoming flatter afterwards. The actual shape of a %I stepping curve is an experimental value. Normally, it does not really depend on the actual heat value, or the electrode shape used by a welding program, but rather the electrode alloy and the parts to be welded. Therefore, two curves – one for sheet steel and one for galvanized sheets – are normally sufficient.
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Setup: Tipdr ess curv es Note:
First you have to select the relevant timer - indirectly via the “Spot-Name” field, or - directly via the “Timer” field.
Input window as in "Setup: Stepper curves". You can transfer all data displayed to the timer by hitting the Appl y command button. Each curve (0 to 9) influences the %I, reference current and pressure. Based on the curve, the timer defines the change of all quantities specified after a dressing cycle subject to the electrode count. The change will remain constant until the next dressing cycle (stepper function). It will act in addition to a change generated by the Stepper-Curve Select the desired curve in the “Curve number field. You may enter remarks concerning the curve in the input field to the right of the curve number. •
The starting point (%I change of 0% with a count of 0%) refers to the respective base value of the %I, Reference current and Pressure.
•
The final point (%I change of 100% with a count of 100%) refers to parameter "Pressure after last dressing" for the pressure, to parameter "%I after last dressing" for %I, and to parameter "Reference current last dressing" for the reference current.
•
The starting point and the end point of a curve (white points) are always fixed. A total of 8 intermediate points are available between the starting point and the end point for influencing the curve characteristic. For this purpose, you must drag the black points with the mouse to the desired position, or enter the corresponding values right below the “%I change” and the “Count Value” parameters. For reasons of plausibility, count values can only be entered in ascending order into the input fields from left to right. Linear interpolation will be carried out between any 2 intermediate points.
The purpose of a dressing curve is to provide shape compensation for the many shape changes of an electrode due to repeated tip
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dressing. Again, the optimum curve shape is an experimental value which depends on the type of electrode maintenance concept. A linear adjustment (ramp) may be used as an initial approximate value.
Setup: Fault-Setup Note:
First you have to select the relevant timer - indirectly via the “Spot-Name” field, or - directly via the “Timer” field.
Use the Data ----> Timer command button to transfer modified parameters to the timer (refer to sect. "Changing and transmitting parameters to the timer"). For each message shown, a type can be defined. •
Checkbox “Fault” is active: The message will be signaled as a fault. In contrast to a Warning, timer state will not accept a start “How signalto..“, until"Reset it has been restored tothe Ready (refer to section Fault" paragraph).
•
Checkbox “Warning” is active: The message will be signaled as a warning. The timer will continue working. Any schedule-specific warnings will be cleared by the next start.
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Possibility of downt imes and misinterpretation of welding results on the system! CAUTION
Arbitrary changes to a message type may lead to undesirable downtimes and to a misinterpretation of welding results on the system! Therefore, you should make sure that changes notsystem! affect the intended, proper behavior do of the
Setup: Communication Note:
First you have to select the relevant timer - indirectly via the “Spot-Name” field, or - directly via the “Timer” field.
Note:
The information displayed is not relevant for all timer types.
Displays information concerning the Ethernet interface.
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IP Addr ess (S etup, C ommu nic ation) IP address stored in the flash memory of the Ethernet adapter. For more information concerning Ethernet, please refer to our documentation on “Programming field buses”:
Subnet mask Subnet mask stored in the flash memory of the Ethernet adapter. For more information concerning Ethernet, please refer to our documentation on “Programming field buses”:
Standard gateway IP address of the standard gateway stored in the flash memory of the Ethernet adapter. For more information concerning Ethernet, please refer to our documentation on “Programming field buses”:
SMTP Addr ess SMTP address stored in the flash memory of the Ethernet adapter. For more information concerning Ethernet, please refer to our documentation on “Programming field buses”:
Port Number
Port number stored in the flash memory of the Ethernet adapter. For more information concerning Ethernet, please refer to our documentation on “Programming field buses”:
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Addr ess mode Addr ess mode DEF_IP_SWITCH
ALL_IP_SWITCH
Comment If Anybus switch bank == 0: IP, subnet and gateway from flash If Anybus switch bank != 0: Low-Byte IP from Anybus switch bank, High-IP from Basic address switch, Subnet and GATEWAY from object If Basic switch banks == 0: as LOW_AB_IP_SWITCH. If Basic switch banks != 0: IP = Basic switch banks, subnet and gateway from object
NO_IP_SWITCH
always: IP, subnet and gateway from object
LOW_AB_IP_SWITCH
If Anybus switch bank == 0: IP, subnet and gateway from flash If Anybus switch bank != 0: Low-byte IP from Anybus switch bank: High-IP == 192.168.0.X Subnet == 255.255.255.0 GATEWAY == 0.0.0.0
LOW_CPU_IP_SWITCH
immer: Low-Byte IP from CPU switch bank, High-IP, Subnet and GATEWAY from object
MIX_IP_SWITCH
always: Low-Byte IP from CPU switch bank, High-IP from Basic address switch, Subnet and GATEWAY from object
Baudrate Baudrate Automatic Fixed 10 MBd Fixed 100 MBd
For more information concerning Ethernet, please refer to our documentation on “Programming field buses”:
Mode Mode Automatic Fixed, simplex Fixed, duplex
For more information concerning Ethernet, please refer to our documentation on “Programming field buses”:
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Functions (Setup, Communication) Informs in binary format about the status of various server services of the timer. •
Bit x is high: Service/function is active
Bit 0 WEBServer
Bit 1 Modbus/TCP-
Bit 2
Bit 3
FTP-Server TELNETServer
Bit 4 Ethernet
Bit 5 SMTP
Server
MAC-Adress Display of the worldwide unique MAC address of the Ethernet adapter. For more information concerning Ethernet, please refer to our documentation on “Programming field buses”:
DIP switch Displays the setting of the IP-ADR switch bank (on the front side of the Ethernet adapter) in decimal format.
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Correction Within the BOS 6000 main window, the “Correction“ menu (which is called up by the
icon) offers the following choices::
•
Selection of “Spot-Name” or “Timer” or “Program”.
•
Selection of the %I "Correction" in order to make process-related and forcetab changes quickly andtemporary, without altering the individual base values.
Note:
For information concerning the Status line, refer to “Explanations“ section.
Note:
In some cases, the settings/functions are only possible at a certain user level.
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Corre ction: Correction Purpose: •
Program- and electrode specific %I correction within permitted limit values (in %).
•
Program- and electrode specific electrode force correction within permitted limit values (in %).
Note:
As this window is used to program not only programspecific correction data, but also any electrode-specific corrections, you should first select the relevant welding program (via field “Spot-Name“ or via fields “Timer“ and “Program"). The electrode-specific correction data displayed always belongs to the electrode that was parameterized in the welding program selected (display in field “Electrode”).
Use the Data ----> Timer command button to transfer modified parameters to the timer (refer to sect. "Changing and transmitting parameters to the timer").
Note:
The current parameter settings will be displayed in the "Programming" menu, tab "Schedule".
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%I Correction (Prg.) Corrects the demanded %I of the relevant program by the percentage indicated. The permissible correction value also depends on parameters "Max %I-Correction" and "Min %I-Correction" within the "Programming" menu, tab "General "". The %I correction (Prg.) and the %I correction (Elec.) act in addition to each other.
%I Corr ectio n (Elec.) Corrects the demanded %I of all programs using the electrode displayed by the percentage indicated. The permissible correction value also depends on parameters "Max %I-Correction" and "Min %I-Correction" within the "Programming" menu, tab "General "". In order to enter correction values for other electrodes, you must select a spot/a program that has been assigned to the desired electrode as described above. The %I correction (Prg.) and the %I correction (Elec.) act in addition to each other.
Pressu re-Corr ection (Prg.) Corrects the electrode force (“base pressure value” parameter) of the relevant program by the percentage indicated. The permissible correction value also depends on parameters "Max Pressure-Correction" and "Min Pressure-Correction" within the "Programming" menu, tab "General "". The Pressure correction (Prg.) and the Pressure correction (Elec.) act in addition to each other.
Pressu re-Corr ection (Elec.) Corrects the electrode force (“base pressure value” parameter) of all programs using the electrode displayed by the percentage indicated. The permissible correction value also depends on parameters "Max Pressure-Correction" and "Min Pressure-Correction" within the "Programming" menu, tab "General "". In order to enter correction values for other electrodes, you must select a spot/a program that has been assigned to the desired electrode as described above. The Pressure correction (Prg.) and the Pressure correction (Elec.) act in addition to each other.
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Base pressure value ( Correction , Corr ection) Defines the electrode force (in kN) used for welding by the relevant program.
Note:
The electrode force specified is only effective after proper Force calibration or a proper input in parameters "Conversion-Factor" and "Zero-adjust" (refer to "Programming" menu in tab "Electrode") ! Otherwise, there is no defined correlation between the value input and the resulting force at the electrode gun!
Spot Reference Purpose: To Add, change and delete spot names. •
To transfer the spot names from the spot reference table of BOS 6000 to the relevant timer (without comments!) using the Spot-Table --> WT command button. This function is absolutely necessary in order to use spot addressing and must be performed for all online timers whenever the spot reference has been changed.
•
To transfer the spot names from a timer to the spot reference table of BOS 6000 using theSpot-Table 0.0): indicates the maximum permitted electrode count between 2 dressing cycles. Can be configured in window"Programming: Stepper".
Dressings Indicates how often the electrode may be dressed until the end of stepper. Can be configured in window"Programming: Stepper".
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Meaning of command buttons: Electro de changed Acknowledges an electrode change for the electrode displayed. The counts, spot and dressing counters of the electrode in question are set to 0.
CAUTION
Possibility of incor rect Arbitrary changes of welds! the counters of an electrode may result in incorrect welds, defective workpieces and the cooling water leaks at the electrodes! Therefore, you should make sure that an electrode change is not acknowledged unless the electrodes have actually been replaced!
Set counter Sets the counts and dressing counter of the electrode displayed.
Possibility of incor rect welds! Arbitrary changes of the counters of an CAUTION
electrode workpieces may result and in the incorrect defective coolingwelds, water leaks at the electrodes! You should never make any arbitrary changes to the counts or the dressing counter values!
Cancel Close “Detail Info” window.
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How to … In this section, you will learn how to carry out important activities within BOS 6000. The descriptions are focused on the handling and operation of the software.
Exit BOS 6000 Note:
To exit the application, you must have the appropriate user privileges. The setting can be modified by an Administrator currently logged in using the “Set Access Level” window.
Note:
Logging of the plant condition (faults, changes, etc.) is also terminated by exiting BOS.
1. In the title bar of the BOS 6000 main window, click on or select the File | Exit menu item in the menu bar of the BOS main window. 2. Then confirm the query "Are you sure" by hitting OK . The BOS 6000 user interface and the BOS 6000 server application (BOSServ.exe) running in the background are closed.
Log in tim ers to BOS 6000 Note:
This function can only be invoked in the course of program start.
1. Close BOS 6000 and restart it. 2. In the “ Timer Reference” window, click on the Add command button. The “ Add/Change Timer” window will be displayed.
Note:
As an alternative to the Add command button, you may also right-click and then select the “Add” menu option.
3. Enter the relevant data. 4. Accept the data in the window by hitting OK .
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5. Close the “ Add/Change Timer window by hitting the Cancel command button. The new timer will be displayed in the “ Timer Reference window as a new line in the table. The field in column “Software-Version” initially has a red background. This shows you that the corresponding record has not yet been generated in the internal database. 6. Hit the Continue command button to start establishing the connection. The system creates a new record for the new timer in the internal database. For online timers, Connection setup will be started next. In the event of a data mismatch between the database and the online timer, a data comparison will be carried out.
Note:
The system behavior in the event of data mismatch can be selected in the “Direction” list box of the “ Add/Change Timer window.
Delete ti mers fr om BOS 6000 Note:
This function program start.can only be invoked in the course of
Note:
BOS 6000 can no longer access a timer that has been deleted. Parameter input, diagnosis and logging are not possible for deleted timers!
Do not delete any timers from BOS 6000 which you will still need for programming or diagnosis, or for which continuous logging is necessary!
1. Close BOS 6000 and restart it. 2. In the “ Timer Reference window, select the timers to be deleted. Use the check boxes at the left line margin for this purpose. 3. Right-click with the mouse in the “ Timer Reference” window and select the “Delete” menu item. 4. Confirm the query “Are you sure” by hitting OK to delete the selected timers. 5. Click on Continue in the “ Timer Reference window to start the connection setup.
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Change the commu nication data of l ogged- in timers Note:
This function can only be invoked in the course of program start.
1. Close BOS 6000 and restart it. 2. In the “ Timer Reference window, select the timer whose communication data is to be changed. Use the cursor keys for this purpose. You may also leftCursorUp/CursorDown click on the relevant line. The currently selected timer is shown as a line with a blue background. 3. Right-click with the mouse in the “ Timer Reference window and select the “Change” menu item. The “ Add/Change Timer” window will be displayed.
4. Change the relevant data. 5. Accept the data in the window by hitting OK . 6. Click on Continue in the “ Timer Reference" window to start the connection setup. For online timers, Connection setup will be started next. In the event of a data mismatch between the database and the online timer, a data comparison will be carried out.
Note:
The system behavior in the event of data mismatch can be selected in the “Direction” list box of the “ Add/Change Timer" window.
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Export Timer Reference Create a backup copy of the table shown in the“ Timer Reference" window. 1. In the “ Timer Reference" window, select File | Export Timer Reference . 2. Enter the directory and the filename under which the timer reference is to be stored and confirm your entries by hitting the Save command button. The current timer reference will be stored as an ASCII file with the filename extension *.txt. Never change this file manually. Otherwise, experience problems when restoring the data!
you may
Import Timer Reference Note:
This function can only be invoked in the course of program start.
A previously exported timer reference is reimported into BOS 6000.
Please note that the current timer reference is completely deleted by this process!
1. In the “ Timer Reference" window, select File | Import Timer Reference . 2. Confirm the query by hitting Yes and select the directory and the name containing the timer reference to be imported. Confirm your entries by hitting Open. The selected timer reference is imported.
Print Timer Reference 1. In the “ Timer Reference" window, select File | Prin t .
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Copy Tim er Data You may copy data both within one and the same timer (e.g. program or electrode data) or from one timer to another. 1. In the BOS 6000 main window, select the Edit | Copy menu item from the menu bar. The “ Copy” window will be displayed.
2. First mark the data to be copied using the radio buttons provided. 3. Select the “Source” from which timer the data is taken from the list box. 4. Select the “Destination” to which timer the data is to be copied from the list box. 5. If program or electrode data is to be copied, specify the program or electrode data to be copied in the left numerical input field (“Program” or “Electrode/Stepper”). Here, you must enter the relevant program/electrode/stepper number. 6. If program or electrode data is to be copied, specify the destination program or electrode data in the right input display field (“Program” or “Electrode/Stepper”). Here, you may also enter more than one program/electrode/stepper number(s). Use the “-“ and/or “,” signs to define contiguous number ranges or separate numbers. Example : to copy the data of a program to programs 10 to 21, 41 and 52, you would write: 10-21,41,52 7. Confirm your entries by hitting OK. The ”Data --> Timer” dialog is opened. You may specify the reason for copying in the “Comment” field. The text entered here will be shown in addition to the change event in the data change log.
Note:
At this point, the data has not been copied yet!
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8. Start the copying process by hitting OK. Wait for the BOS 6000 message that the process has been completed and confirm the message by hitting OK . 9. If no more data is to be copied, close the “ Copy" window by hitting the Cancel command button.
Expo rt t imer data (backup ) All settingsall of relevant one/several saved database in a backup file.parameter By this process, datatimers of theare internal is stored in separate compressed files (*.zip) for each selected timer.
Note:
This function does not affect any active welding processes.
1. In the “ Timer Reference" window, click on the Export Record set command button. The “ Upload" window will be displayed.
2. Select the timers the data of which should be included in the backup. Use the check boxes at the left line margin for this purpose. Checking the uppermost check box will select/deselect all check boxes in the list. 3. The backup path may be changed, or a new backup directory may be created, using the … command button.
Note:
As a standard, backup files can be stored on any available drive ofproper the BOS 6000privileges. computer, provided that the user has the access As an alternative, however, they may also be stored on any FTP server because BOS 6000 already includes a suitable FTP client. This function can be activated and configured via the configuration tool.
4. Hit the OK command button to start the backup procedure.
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Resto re Timer data ( dow nlo ad) Note:
This function can only be invoked in the course of program start.
The complete timer data contained in a backup file (*.zip) is restored to the internal database of BOS 6000. 1. In the “ Timer Reference" window, click on the Import Record set command button. The “ Download” window will be displayed.
2. First, select the relevant zip file using the … command button and confirm your selection by hitting Open . 3. From the right list box, you select the timer whose data record in the internal database is to be replaced with the contents of the zip file and confirm your selection by hitting OK . In the “Import Record Set Comparison” window, the system displays important information concerning the backup selected and the specified target timer record set. 4. Hit the OK command button to start the restore procedure. For more details, refer to window “ Connection setup".
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Comp are Tim er Data 1. In the BOS 6000 main window, select the Functions | Compare menu item or click on the symbol . The “ Compare" window will be displayed.
2. Select the timers to be compared. Use the “Timer 1” and “Timer 2" list boxes for this purpose. 3. Hit the Compare command button. The differences between the two timers will be determined.
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4. In the “Detail view” tab, you will see the details of the differences. Sort the table according to your needs.
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Influence da ta com pariso n at pro gram start In the course of the program start, the system will compare the data of a timer and its corresponding record set in the internal database (refer to "Connection setup") window. You can predefine the desired system behavior in the event that differences are detected.
Note:
This setting can only be made in the course of program start.
1. Close BOS 6000 and restart it. 2. In the “ Timer Reference" window, select the timer whose communication data is to be changed. Use the cursor keys CursorUp/CursorDown for this purpose. You may also leftclick on the relevant line. The currently selected timer is shown as a line with a blue background. 3. Right-click with the mouse in the “ Timer Reference" window and select the “Change” menu item. The “ Add/Change Timer” window will be displayed.
4. Change the “Direction” field according to your requirements. The effects of the possible list box entries have been described in section “ Add/Change Timer". 5. Accept the data in the window by hitting OK . 6. Click on Continue in the “ Timer Reference window to start the connection setup. Connection setup will be started next. In the For online timers, event of a data mismatch between the database and the online timer, a data comparison will be carried out.
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Define acce ss leve ls for indi vidual o bjects Note: This
function is administrators.
only
available
to
logged-in
For many objects/functions of the user interface (menu items, command buttons etc.), access rights can be defined. Based on these access attributes, the system decides whether or not a logged-in user is entitled to read or write access for a certain object. The access attributes may be assigned “Access levels” from 1 to 9, with access level 9 corresponding to the highest security level. Only administrators may access objects for which access level 9 has been defined.
Note:
Each user can be assigned an access level in the user administration of the configuration tool. A user may access those objects/functions only for which at least the same or a lower access level has been defined.
Definin g access leve ls of num erical input fields: 1. Log in to BOS 6000 as administrator (refer to sect. "Login"). 2. Move the mouse and right-click on it.pointer to the desired numerical input field 3. Select “Set read level” or “Set write level” as well as the desired level in the pop-up menu. Only those users whose access level is identical to or higher than the access level just assigned will be able to access the object accordingly in the future.
Definin g access leve ls of menu items and command but tons: 1. Log in to BOS 6000 as administrator (refer to sect. "Login").
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2. In the BOS 6000 main window, select the Functions | Rights Administ ration menu item or click on the symbol . The “ Set Access Level" window will be displayed.
Note:
At some points within BOS 6000, the window "Set Access Level" can also be called up via a link (e.g., in the window "Timer Reference").
3. Use the tabs to select whether the access level of a menu item (“Menu” tab) or a command button (“Button” tab) is to be modified in the calling window. The “Table” tab is only available in conjunction with a pop-up menu which can be activated by right-clicking in the calling window. 4. Select the line containing the relevant object and click on select the desired access level. If
to
is not displayed, press
the Cursor-right key. Only those users whose access level is identical to or higher than the access level just assigned will be able to access the object accordingly in the future. 5. Repeat the last two steps in order to assign all relevant objects the desired access levels. 6. Confirm the current settings by hitting the Update button.
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Copy t he contents of a numerica l in put f ield 1. Move the mouse pointer to the desired numerical input field and right-click on it. If the copy function is available at this point, a pop-up menu will be displayed. 2. Select “Copy” from the pop-up menu In the upper area of the next dialog window, the system will display information concerning the parameter to be copied. Example:
3. First select the destination to which the parameter contents are to be copied: All pro grams: copy to all programs. Electrode: Copy to programs working with the electrode displayed. Program/Electrode : copy to certain programs/electrodes. 4. If program or electrode data is to be copied, specify the destination program or electrode data in the next input field. Here, you may also enter more than one program/electrode/stepper number(s). Use the “-“ and/or “,” signs to define contiguous number ranges or separate numbers. Example : to copy the value to programs 1 to 3, and 8, you would write: 1-3,8 5. The copying process is immediately started by hitting OK.
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Sort tables Most tables can be sorted according to any criteria. •
Numerical columns will be sorted in numerical order by the system.
•
Columns containing strings will be sorted in alpha-numerical order.
1. Click on the heading of the column containing the sortkey for sorting the table. By clicking on the same column heading again, you can invert the sorting direction. If permitted by the column width, a symbolic arrowhead will inform you of the current sort direction:
ascending:
Note:
descending:
In order to change width of a table column , move the mouse pointer to the line that separates two adjacent column headings. the mouse pointer is on a separation line, its When appearance will change. Then keep the left mouse button depressed while dragging the line to the desired new position and then release the mouse button.
Filter tables Some tables (in which the Show filter command button is offered, e.g., in some logging tables) can be conveniently filtered according to topics. When filtering is active, only those table lines are displayed/printed/exported that meet the filter criteria selected. The filter topics are dynamic, i.e., all entries in a column are automatically included in a list box by the system which also avoids redundant entries. Filters are activated by selecting an entry from one or several list boxes. 1. Select the Show filter command button. Instead of the column headings, list box items will be displayed where activated. The command button text changes to Hide filter .
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2. In the relevant column, click on to display the available topics and select a topic. The filter becomes immediately active. 3. Repeat the previous step for all columns that require a filter. All active filters act as a logic AND operator. The currently active filters can be inferred from the text color of the entries in the individual list boxes: black: Filter off blue: Filter active. Select the uppermost list box entry (“…(*)”) to deactivate the filter for the respective column . To deactivate all filters, select the “Update ” menu item. 4. If necessary, you can now export or print the filtered table.
To exit the filter function, click on the Hide filter command button. Instead of the list box items the column headings will reappear. All active filters are deactivated.
Show / Prin t / Expo rt l ogs 1. In the BOS 6000 main window, select the Functions |
Protocol menu item or click on the
icon. The “ Protocol” window will be displayed.
2. Select the desired protocol using tabs “”Error Protocol”, “Weld Fault Protocol”, “Data Change Protocol”, or “Weld current Protocol”. 3. Use the “Start” and “End” date input fields to limit the scope of the protocol data to be shown/printed to a certain period of time. 4. Use the Show filter command button to limit the protocol data to be shown/printed/exported to certain topics. In addition, in order to print the protocol displayed:
Select the “Print” menu item. In the next dialog window, you may either preview the printed protocol (Preview button) or define the print parameters (Print button).
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In addition, in order to export the protocol displayed: Select the “Export” menu item. In the next dialog window, you may enter the destination path and file name (“Store values” tab) or select the separator (“Setup” tab). Enter the path and the filename and confirm your entries by hitting the OK button. The protocol data will be stored in an ASCII file.
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Change parame ters and t ransfer to ti mer Ar bitr ary parameter changes may lead to dangerous conditions at the system! DANGER
Using BOS 6000, you may access all parameters, and thus the fundamental behavior of the connected timers. Do not change any parameters without reason. Do not change any parameters without knowing the consequences. In case of uncertainty, you should always contact your supervisor!
To change parameters, you may proceed as follows: •
Change a single parameter and then accept the new setting to the timer.
•
Change several parameters and then accept the new settings to the timer.
Note:
We recommend accepting single parameter changes to a timerstatus only. at Inany thistime. way, you can ensure a defined control
Note:
If a timer can be addressed by several programming terminals (with BOS 6000 running on each of them), you can automatically visualize all data changes made by any other programming terminal in a table. For this purpose, the “Ext. data change”function must have been activated in the relevant programming terminals using the configuration tool.
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Procedure 1. Change the desired parameter(s). 2. Press the Enter key or click on the Data --> Timer button. The ”Data --> Timer” dialog screen is displayed (Example): ... if a single parameter has been changed:
... if several parameters have been changed one after the other:
At this point, it is still possible to define the change to be actually transferred to the timer by selecting the check box on the left margin of the table. 3. Enter the reason for the parameter change in the ”Comment” field. The text input will be displayed in the data change protocol in addition to the change itself.
Note:
In the configuration tool, you can define whether and how many characters must be entered at minimum in the comment field.
4. Hit the OK command button to transmit the changed data to the timer. The new data made will become effective in the system upon the next program selection.
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Export spot reference To create a backup copy of the table shown in the“ Spot Reference" window. 1. In the “ Spot Reference" window, select File | Export… . . 2. Select the directory and the filename under which the spot reference is to bebutton. stored and confirm your entries by hitting the Save command The current spot reference will be stored as an ASCII file with the filename extension *.txt. Never change this file manually. Otherwise, experience problems when restoring the data!
you may
Expo rt sp ot r eference to a n Exce l fi le 1. In the “ Spot Reference" window, select File | Export --> Excel Tab . . 2. Select the directory and the filename under which the spot reference is to be stored and confirm your entries by hitting the Save command button. The current spot reference will be stored as an Excel file with the filename extension *.xls.
Note:
Saving a spot reference to an Excel file cannot replace regular backups of the spot reference. A spot reference that has been saved in an Excel file cannot be retrieved to BOS 6000!
Import spot reference A spot reference previously exported to an ASCII file is reimported into BOS 6000.
Please note that the current spot reference of BOS 6000 is completely deleted by this process!
1. In the “ Spot Reference" window, select File | I mport … . . 2. Confirm the query by hitting Yes and select the directory and the name containing the spot reference to be imported. Confirm your entries by hitting Open. The selected spot reference is imported.
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Print spot reference 1. In the “ Spot Reference" window, select File | Print .
Compare spo t refere nce Shows the differences between the internal spot reference tables of the individual online timers and the BOS 6000 spot reference table. 1. In the “ Spot Reference" window, select File | Compare S pot reference from the menu bar.
Enter/change sp ot references 1. In the “ Spot Reference" window, click on the Add button to create a new spot reference or in the “ Spot Reference" window, select the spot reference to be changed and select the “Change” menu item. The “Add/Change spot” window appears:
Note:
As an alternative to the Add command button, you may also right-click and then select the “Add” menu option.
2. Enter the relevant data. 3. Accept the data in the window by hitting OK . The new or changed spot reference is accepted to the spot reference table. 4. Close the “Add/Change Spot” window by hitting the Cancel command button if you do not want to add/change any other spot references. To add/change more spot references, first click on the Delete command button and then continue as described under point 2 above.
Displ ay spot comments 1. In the BOS 6000 main window, select the desired spot from the “Spot-Name” list box.
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2. Click on the icon . The “ Spot comment" window will be displayed.
Note:
The icon cannot be selected unless at least one comment has been assigned to a spot (for assignment of comments: refer to “ Spot reference" window.
Delete spo t referenc es 1. In the “ Spot Reference” window, select the spot reference to be deleted, right-click and select the “Delete” menu item. 2. Confirm the query “Are you sure” by hitting OK to delete the selected spot reference from the table.
Show electr ode status 1. In the BOS 6000 main window, select the Functions | Prewarning menu item or press key F2 or Click on the icon. The “Prewarning” window will be displayed.
Note:
If the “Prewarning” window had already been displayed before, you may use the Update command button. By this, you ensure that the BOS displays the most current condition without a time delay.
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Confi rm electrode change Possibility of incor rect welds! CAUTION
Arbitrary changes of the counters of an electrode may result in incorrect welds, defective workpieces and the cooling water leaks at the electrodes! Therefore, you should make sure that an electrode change is not acknowledged unless the electrodes have actually been replaced!
1. In the BOS 6000 main window, select the Functions | Prewarning menu item or press key F2 or click on the icon . The “ Prewarning” window will be displayed. 2. Use the check boxes on the left line margin to select the electrodes you have changed. 3. Hit the Electro de changed command button. The counts, spot and dressing counters of the electrodes in question are set to 0.
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Set electro de coun ter Possibility of incor rect welds! CAUTION
Arbitrary changes of the counters of an electrode may result in incorrect welds, defective workpieces and the cooling water leaks at the electrodes! You should never make any arbitrary changes to the counts or the dressing counter values!
1. In the BOS 6000 main window, select the Functions | Prewarning menu item or press key F2 or click on the icon . The “ Prewarning” window will be displayed. 2. Use the check boxes on the left line margin to select the electrodes you want to manipulate. 3. Hit the Detail-Info command button. The “ Detail-Info” window will be displayed. 4. Hit the Set co unter command button. The “ Set counter” window will be displayed. 5. The counts of the electrode displayed can be set to a desired value in the “Count” input field, and the “Dressings” input field serves to specify a dressing counter value. 6. Hit the OK command button to activate the new values input.
Expor t parameter data to ASC II fi le 1. In the BOS 6000 main window, select the File | Para.-Data Import/Export | Export menu item. The “ Para.-Data Import/Export” window will be displayed. 2. Select the timer containing the source data from the list box (top left). 3. In the input field (top right), you should change the file name to which the ASCII data is to be saved, if necessary. As a default, the file name is taken from the timer name. To change the default destination path, use the … command button. . 4. Use the “Program” or “Electrode/Stepper” tabs to select whether you want to export program or electrode data.
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5. Make your selection more specific via the radio button. If you select the “Program” or “Electrode/Stepper” button, enter the desired numbers. Here, you may also enter more than one program/electrode/stepper number(s). Use the “-“ and/or “,” signs to define contiguous number ranges or separate numbers. Example : to export the parameters of programs 1 to 3, and 8, you would write: 1-3,8 6. Hit the OK command button to save the data.
Note:
If a file with the same name already exists in the destination folder specified, the system will query whether or not the existing file should be replaced.
Import parameter d ata from ASCII fil e 1. Select the timer to which the data is to be imported in the “Timer” list box of the BOS 6000 main window. 2. In the BOS 6000 main window, select the File | Para.-Data Import/Export | Import menu item. The “ Para.-Data Import/Export” window will be displayed. 3. Enter the name of the ASCII file to be imported in the input field. As a default, the file name is taken from the selected timer name (refer to step 1). To change the default source path, use the … command button. . 4. Hit the OK command button to import the data.
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How to …
Repl ace a defect iv e timer In addition to the possibility of importing an existing (Backup) from the previous timer into the new one (Restore), you may use the “Timer change” function for this purpose. In contrast to Backup/Restore, the “Timer change” procedures include a transfer of the currently active parameter settings and current electrode dataTherefore, (e.g. counter and other actual all values to the new timer. it is statuses) not necessary to replace electrodes immediately after a timer change.
Note:
In order to use the “Timer change” function, communication with the timer to be replaced must still be operative (“Status” field in “Timer change” window must be green). If no communication is possible via the currently selected communication port, you should try and find out whether communication still works using another interface (e.g., V24 at X1).
1. In the BOS 6000 main window, select the Edit | Timer Change menu item. The “ Timer change” window will be displayed.
2. Select the desired timer by clicking on the relevant line. 3. Click on OK command button. The system will retrieve all current counter statuses and actual values from the relevant timer and update the BOS 6000 internal database with this data. Since the BOS 6000 internal database always a data synchronous data map of all connected timers,shows no other has to be obtained from the relevant timer. The BOS 6000 internal database now contains all data that is required for the timer change. The BOS 6000 indicates this status by the message “Change timer” in the “Description” field and waits for the communication to be interrupted (“Status” field becomes gray, text of the OK button changes to Timer change ).
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Dangerous mains voltage is pr esent! DANGER
Possibility of electric shock through inadvertent and inappropriate handling of the inverter/power unit! Therefore, you must ensure that units are always replaced by properly qualified staff only!
Possibili ty of welding sequence a nd machine movements! DANGER
At this point, welding sequences and machine movements are possible if the timer to be replaced is in READY condition. Therefore, please make sure that the personnel is not at risk at any time when accessing or staying in the hazard zone!
4. Switch the defective unit off, safely isolate it from supply, and replace it. 5. Make the necessary switch settings on the new unit (e.g. ADR switch, NEXT/END switch for Interbus network). 6. Turn 24V logic supply on the unit on. 7. Select the Timer Change command button from the “Timer change” window.The complete timer-specific record set will now be automatically copied from the BOS 6000 internal database to the timer. Wait for the status messages at the end of the data transmission (“Function was finished successfully.”). 8. Repeat force and current calibration.
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How to …
Upgrade the timer fir mware The firmware of a timer normally need not be changed. However, if recommended by the service technician, a firmware update may be necessary to correct errors.
Conditions f or the firmw are update: •
the firmware file (*.hex) must be available, stored on an accessible data medium and match the hardware in question.
•
the functionality of the new firmware must be compatible with the existing application.
Procedure: 1. In the BOS 6000 main window, select the Edit | Firmw are Changing menu item. The “ Firmware Changing" window will be displayed:
2. Check the information in column “Timer type (memory)”. The correct firmware must be displayed there for the timers in question. If this is the case, proceed with step 6. 3. Otherwise, first you have to load the firmware to the RAM of the corresponding timers. Select the desired timers by clicking on the relevant check boxes. 4. Select the firmware file(s). For this purpose, you should click into the corresponding field in the “File” column for all desired timers, confirm the command button … displayed there, and select the proper firmware file (*.hex). Check whether the entries for all selected timers in column “File” are now correct! 5. Hit the Load FW command button. The firmware is now loaded into the RAM of the selected timers. Welding can be continued during the firmware load. A status bar in the “Status” column shows the progress. When the complete firmware has been loaded (“Status” column: 100%), the name and version number of the firmware loaded will appear in the “Timer type (memory)” column.
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6. Save actual values and counter statuses. Select the desired timers by clicking on the relevant check boxes. 7. Hit the Save actual values command button. The actual values and counter statuses of the selected timers will now be transferred to the BOS 6000 internal database. Welding can be continued during this process. In column “Status”, you will receive the message “Actual values have been saved” when the function has been completed. 8. Initiate the firmware change. Select the desired timers by clicking on the relevant check boxes. 9. Hit the Change command button. The system will request you to restart the BOS 6000. At this point, welding is still possible. 10. Make sure that the relevant timers are no longer involved in a welding process and confirm by hittingYes . The firmware previously loaded into the RAM will be copied to the flash memory. Now, the new firmware will be permanently stored in the relevant timer (even after a loss of RAM power supply/backup power). The will restartdisplayed the relevant timers and BOS 6000. will In thesystem timer reference after the login, the system temporarily set the timer-relevant fields in column “Direction” to “FW-MODE”.
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11. In the “ Timer Reference" window, click on the Continue/Next command button. The Connection setup will be started. If there is a difference between the data in the timer and the internal database, all relevant data including counter statuses and actual values will be loaded from the database to the relevant timer.
Reset faults Note:
As an alternative to the method described here, the errors that occurred last can also be reset in the “Diagnosis“ menu, tabs “Start Simulation" or "Timer Info".
1. In the BOS 6000 main window, select the Functions | Error table menu item or press key F3, provided that window “Error table" is not yet active.
2. Select the line that contains the relevant fault (left click or cursor keys “up”/”down”). 3. Call up the Detail infor mation (double click or “Enter” key). Functions of the command buttons offered here:
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Reset with WC: - The timer is restored to “Ready” state. - The Weld Complete contact is output if the start signal is still high.
Reset with Reweld: - The timer is restored to “Ready” state. - The program sequence is repeated if the start signal is still high. Cancel : Closes the "Detail info” window. Help : Opens the BOS 6000 Help function containing more information concerning the error displayed.
Possibili ty of imm ediate machine movements after “Fault reset with WC”! DANGER
If the start signal is present upon Fault reset with WC, the timer will immediately output the “WC” signal. This may result in machine movements. Therefore, please make sure that there is noone in the hazard zone when fault reset with WC is selected.
Possibili ty of imm ediate welding sc hedule start afte r “ Fault reset with rewe ld” ! DANGER
If the start signal is present when a fault is reset with reweld, the timer will immediately start repeating its program run! Welding will be repeated! Therefore, please make sure that there is noone in the hazard zone when fault reset with reweld is started.
4. Depending on the desired behavior, click on the Reset wit h WC or Reset with Reweld command button in order to reset the fault.
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Add fault information You may integrate your own information concerning fault messages into the BOS 6000 Help system. For this purpose, the “My notes” link is provided for each fault message within the Help window. This link leads to a fault-specific HTML file that may be designed by the user to provide his own, detailed instructions andhimself methodsinfororder troubleshooting. In very simple cases, you may proceed as follows to add your own information: 1. Cancel the write protection of all files in the ..\Help\User subdirectory. 2. Click on the “My notes” link for the relevant fault message in the BOS 6000 Help window. The file provided for user information will now be displayed in the screen area in which the various contents are shown within the BOS 6000 Help window. 3. Right click in this screen area and select Show source in the pop-up menu displayed. This will start the Windows text editor. 4. Enter the user-specific texts between the and delimiters. : Example : This is my own text. : Own formatting instructions, colors, fonts or graphics may be included in the user-specific information if programmed in HTML format. 5. Save the modified file under its srcinal name in the \ Help \User subdirectory and close the editor. When the function is called up the next time, the information entered will be displayed.
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Perform current calibration When? •
Whenever an active component (relevant for the current) has been changed, each electrode (gun) must be calibrated.
How? •
With the electrodes shorted. Two test welds are performed at different programmed %I values while measuring the actual currents flowing in each case (in kA) and entering the current values measured in the timer. Based on this data, the timer will automatically adjust parameter "Toroid sensitivity" to the necessary setting.
Conditions: 1. Separate programs whose sequence is not inhibited for calibrating the electrodes (guns). The respective calibration program must have been allocated to the electrode to be calibrated.
2. 3.
4.
5.
The programmed WLD and electrode force should be in the same range as for the real welding program (weld time may be selected a little longer than in reality, but not too short). %I data are not relevant for current calibration. Use the same reference ammeter for all systems to be calibrated. For calibration and checking the calibration, the setting at the reference ammeter must be identical and match the relevant system. The following settings are of special importance: Type of current: PST: AC current; PSI: DC current. Fade-out time/trail current: the welding current exhibits a transient behavior upon making/breaking which is being accounted for by the timer in parameters "Fade-out time" and "Trail current". The welding current meter used must be set to identical values for these parameters. The working range of the welding system must be known (which %I value is normally used to drive the power unit). The value last used can be viewed in the “Middle PHA” display field in windows "Programming: Schedule" or "Programming: Stepper". The electrode gun and the robot, if any, are in the position intended for calibration.
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Procedure: 1. In the BOS 6000 main window, select the Current calibration command button in the “Programming” menu, “Electrode” tab. The “Calibration” window will be displayed.
2. Enter suitable %I values for the 2 test welds into the two %I fields.The upper %I value should not exceed the working range of the welding equipment (refer to conditions listed above). The lower %I value should be in the lower working range of the welding equipment and should be at least 20 %I lower than the
3. 4.
5. 6.
upper value. check box “Store values”, you can cause the By activating timer to present the values input without the need to re-enter them when calibration is repeated for the relevant electrode. Select a suitable calibration program. Check whether the appropriate electrode number is displayed! Click on OK command button. The next window of the current calibration function will be shown. Move the sensors of the reference ammeter to the proper position and check the setting of the reference ammeter. Close the electrode gun.
Possibility of welding schedule sta rt immedia tely afte r hitti ng “ Schedule” button! Therefore, please make sure that there is noDANGER
one in the hazard zone when the button is activated.
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7. Hit the Start Wld command button. A spot is welded with the (upper) %I value specified before. Read the actual current flown at the reference ammeter and enter the value into the upper field “Measured current (kA)”. Accept the value by hitting the Enter button. Repeat this step 2-3 times. The system will calculate the mean value of all values entered. The number of inputs already performed will be displayed to the right of the input field.
8. Hit the Continue command button. 9. Hit the Start Wld command button. A spot is welded with the (lower) %I value specified before. Read the actual current flown at the reference ammeter and enter the value into the lower field “Measured current (kA)”. Accept the value by hitting the Enter button. Repeat this step 2-3 times. The system will calculate the mean value of all will values entered. The number inputs already performed be displayed to the right ofofthe input field. 10. Hit the Continue command button. Now, the timer will calculate the necessary calibration values, calibration has been completed. Afterwards, check the calibration with the help of a KSR test weld.
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Perform force calibration When? •
Whenever an active component (relevant for the generation of force, e.g., gun, proportionate control valve) has been changed, each electrode (gun) must be calibrated.
How? •
Two measurements are performed at different programmed force values (in kN) while measuring the actual forces present at the electrode and entering the measured values in the timer. The timer will use this data to automatically adjust the "Conversion-Factor" and "Zero adjust" parameters to the necessary settings.
Conditions: 1. Separate programs whose sequence is not inhibited for calibrating the electrodes (guns). The respective calibration program must have been allocated to the electrode to be scaled. 2. Use the same reference force measuring device (e.g., pressure pickup) for all systems to be calibrated. 3. The force working range of the welding system must be known (which kN value is normally used for welding). 4. The electrode gun and the robot, if any, are in the position intended for calibration.
Procedure: 1. In the BOS 6000 main window, select the Force calibration command button in the “Programming” menu, “Electrode” tab. The “Calibration” window will be displayed.
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Possibility of damaging guns! CAUTION
In the course of the calibration process, you should only use programmed values by which the gun is not mechanically overloaded! If you do not know the behavior of the electrode gun, you should initially use low values when starting the calibration process, and increase these values in further calibration cycles until you have reached the working force.
2. Enter the amount of the desired force-influencing variable (in % of the hardware-related, maximum possible value of the influencing variable) into the two % fields for the 2 test measurements. The upper input value corresponds to the force-influencing variable that causes the lowest force used for welding. The lower input value corresponds to the force-influencing variable that causes the highest force used for welding. The two values should differ by at least 20%. By activating check box “Store values”, you can cause the timer to present the values input without the need to re-enter them when force calibration is repeated for the relevant electrode. 3. Select a suitable calibration program. Check whether the appropriate electrode number is displayed! 4. Move the reference force measuring device to the proper position.
Electrode gun closes! Therefore, please make sure that there is no unauthorized person in the hazard zone. DANGER
5. Click on OK command button. The next window of the force calibration function will be shown. Now, the timer will output the previously entered value of the (lower) influencing variable.
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6. Read the force present at the reference force measuring device and enter the value into the upper “Force” field. 7. Click on OK command button. Now, the timer will output the previously entered value of the (higher) influencing variable. 8. Read the force present at the reference force measuring device and enter the value into the lower field “Force”. 9. Click on OK command button. The timer will use this data to automatically adjust the "Conversion-Factor" and "Zero adjust" parameters to the necessary settings, and calibration has been completed.
Note:
If the timer proposes to automatically raise parameter "Maximum pressure", you should answer "No". Otherwise, a force parameterized there will be replaced with the force that can be theoretically achieved using the maximum force-influencing variable and the new, calculated force characteristic.
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Fault messages
Faul t mess ages Please note: •
Due to the large number of different applications, the Help function can only provide some general clues to possible causes. Detailed instructions for troubleshooting cannot be given in all cases for this reason.
•
Some types! messages are type-specific and not available for all timer •
•
In some cases, the messages can be configured as a fault or a warning "Setup”, tab “Fault Setup". Any active faults will be included in the "Error Table".
•
For fault reset, refer to sect. “How to …”, paragraph "Reset faults".
•
For a description of how to add your own fault information, refer to sect. “How to …”, paragraph "Add fault information".
Stop / No 24V Possi ble cause No +24V at the stop circuit input
Remedy Close stop contact Check +24VDC supply at the stop circuit terminals
Stop circ uit clo sed Possi ble cause OpenStop circuit was closed again
Remedy None. This message only appears in the log
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Fault messages
Weld with out Command (Transformer Primary Current without SCR Firing Signal)
Possi ble cause
Remedy
Voltage is supplied to the primary side of the welding transformer outside the weld time: Thyristors defective
Replace PST or thyristor unit
Welding transformer improperly
Check connection
connected Effects of other welding currents
Note:
Check: is another timer welding on the same part at the same time?
This message is not output by the PSI models.
Control stop Possi ble cause Function that is influenced by the “Ready” input
Remedy Customer-specific application
Power-U nit not ready (SCR or PSU Power Supply Fault)
Possi ble cause Message of the power unit temperature contact
Remedy Check cooling Check duty cycle/load Check cables/connectors For PSU: correct this unit’s fault message
Note:
After a re-installation, you should verify whether the Thyristor temperature sensor parameter matches the temperature contact of the power unit.
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Fault messages
External Over-Temperatur e (External Device Over Temperature Fault)
Possi ble cause
Remedy
Message of an external temperature input: Cable between timer and temperature sensor broken
Check cable/connector
Insufficient cooling Excessive welding %I/duty cycle
Check cooling circuit Reduce welding %I, shorter duty cycle
Cooli ng tempera ture too hi gh (Over Temperature Fault - Power Unit Heatsink)
Possi ble cause Heat sink is too hot (more than 70°C) or Ambient temperature is too high (more than 70°C):
Remedy Check cooling
Check duty cycle/load Air cooler: If the heat sink temperature reaches 55°C or more, the external fan is switched on via X4/13 (+24V) and X4/14 (GND). Check the output and the fan by directly applying 24V to the fan Check temperature inside switch cabinet and/or cabinet cooling
Transformer te mp to o hig h (Transformer Over Temperature Fault)
Possi ble cause
Remedy
The temperature of the welding transformer is controlled by thermostatic switches:
Check cooling
Cable between temperature sensor and timer broken
Check cable/connector
Insufficient transformer cooling
Check cooling circuit of the welding transformer
Excessive welding %I/duty cycle
Reduce welding %I
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Fault messages
Battery-Low Possi ble cause The voltage of the timer’s buffer battery has dropped
Note:
Remedy Replace battery
All data of a weld timer may be deleted if the battery voltage is low and there is no supply voltage!
Memory d eleted Possi ble cause
Remedy
All data has been deleted from this timer: New firmware was copied to timer:
Copy data
Battery is low or defective
Replace battery and copy data
Note:
If the error occurs repeatedly, replace timer!
Data down load st arted (Data Restore to Timer In Process)
Possi ble cause Backup data is transmitted from programming terminal to timer
Remedy If the Restore/Download function invoked from the GUI is still active, wait until data transmission is finished If the Restore/Download function invoked from the GUI has been aborted, cycle power to the timer.
No sch edule progr ammed Possi ble cause
Remedy
Wrong program selected
Check program selection
Invalid spot selection
Check spot selection
Invalid parameters in selected program
Check value range of the following parameters: power unit number, electrode number, program number
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Fault messages
Hardware Fa ul t (Hardware Fault - Replace Timer / Inverter)
Possi ble cause
Remedy
Defective module
Replace module or timer
A module is detected during powerup which does not match the firmware:
Replace module
A firmware was copied to the timer which is not permitted for the existing hardware
Copy proper firmware to the timer
Additional code for hardware fault:
Bit code:
Decimal:
Module:
0x0001
1
Damaged flash
0x0002
2
Damaged RAM
0x0004
4
Analog module
0x0008
8
Additional analog module
0x0010
16
Power supply module
0x0020
32
I/O module
0x0040
64
Additional I/O module
0x0080
128
Field bus module missing (missing module is not a fault!)
0x0100
256
Additional_module_I
0x0200
512
Additional_module_II
If several hardware errors are detected, a group message will be output. The following code has the following meaning, e.g.
Fault message
132
Field bus module
128
Analog adapter fault
4
=
132
Note:
In the event of a hardware fault, the timer can not be reset to Ready state by a "Fault reset".
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Fault messages
I/O-Bus Faul t (Serial I/O Bus Fault)
Possi ble cause The serial I/O module has signaled a bus error to the timer
Remedy Replace I/O module or timer
Half-C ycl e Monito rin g (Transformer Half cycling Fault)
Possi ble cause
Remedy
During the welding process, two subsequent half-cycles with the same polarity were detected: Synchronization voltage too low
Check synchronization voltage
Thyristor unit defective
Check thyristor unit and fuses
Current sensor or connection cable defective
Check current sensor and connection cable
Circui t Br eaker Off (Main Breaker Tripped by Timer)
Possi ble cause
Remedy
The timer has energized the main switch relay: The connected main circuit breaker tripped
Sync / Power Fa ul t (Loss of Synchronization Voltage to Timer)
Possi ble cause
Remedy
Welding power was switched off, or is not in the range of 50 or 60 Hz +5%
Switch welding power on, and check response
Disturbances in welding power system
Reset fault, check all mains phases
Fuse in welding system tripped
Check synchronization voltage
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Fault messages Fuse in power unit defective
Check all fuses of the power unit, or replace power unit
Synchronization OK Possi ble cause Welding power has been reconnected. Also refer to Sync / Power Fault
Remedy None: This message only appears in the log
Start I nhi bi ted (Weld scheduled stopped)
Possi ble cause The schedule of the selected program was inhibited:
Remedy Enable program at the programming terminal (“Start-Inhibit” parameter) Check program selection, select proper program
Sequence externally cancelled Possi ble cause The signal at the “Prop. valve active” input was reset to 0 during the weld schedule
Remedy Check input, connectors, cable, and proportionate valve
Prog ram Pa rit y Fault (Parity error)
Possi ble cause The parity bit does not match the selected program:
Remedy Check parity setting at the programming terminal (“Parity” parameter) Check program selection, select proper program
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Fault messages
24V off/to low Possi ble cause
Remedy
The 24V supply for the internal logic is too low (approx. 19V): 24V supply is too low
Check the 24V supply
Connection fault in the area of the 24V supply
Check connections
24V supply switched off by operating process
Note:
This message is only output by PSI / PST variants!
Supp ly Volt age Fault Possi ble cause The 24VDC supply for the internal logic was missing or switched off:
Remedy Check the 24V supply Check connections
Timer switc hed on Possi ble cause
Remedy
24V supply was reconnected Control reset was triggered from the GUI
Power voltage to high (DC Bus voltage too high - AC input voltage too high)
Possi ble cause
Remedy
An excessively high mains voltage was measured at the DC link level. The mains voltage was above approx. 680V for units PSI 6xxx.xxxL1 or above approx. 870V for the high-voltage version PSI 6xxx.xxxL2: Mains overvoltage or mains transient
Check mains power supply
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Fault messages
Note:
This message is only output by PSI variants!
Power vol tage off/to l ow (DC Bus voltage too low - AC input voltage low or off)
Possi ble cause The mains voltage is too low or no longer available. The mains voltage is monitored at the DC link level. For a mains voltage of 380V or more, the next 10 mains cycles are measured. If the voltage values decrease steadily (indicating a steady discharge of the DC link electrolyte capacitor), this message is generated in order to avoid welding without mains power. A phase loss will not be detected. The DC link capacitors store sufficient energy to bridge the missing phase.
Note:
Remedy Check mains power supply
This message is only output by PSI variants!
Power vol tage off /to low receipt Possi ble cause Acknowledgement of the previous message Power voltage off/to low
Note:
No Weld external
Remedy None: This message only appears in the log
This message is only output by PSI variants!
Possi ble cause External weld signal was deactivated
Remedy Check signal at the Weld external input
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Fault messages
Weld external Possi ble cause External weld signal was activated
No Weld internal
Possi ble cause Weld signal switched off at programming terminal
Remedy None: This message only appears in the log
Remedy Check setting at the programming terminal (“Weld/No weld (Global)” parameter)
Weld i nternal Possi ble cause Internal weld signal activated
Remedy None: This message only appears in the log
With stroke, with w eld Possi ble cause Schedule with ignition and with solenoid valve (gun closes)
Remedy Input “Schedule with stroke, with weld” is high
No stro ke, no w eld Possi ble cause Schedule without ignition and without solenoid valve (gun does not close)
Remedy Input signal “Schedule with stroke, with weld” is low
%I too large/ Force/ Pressure too hig h/PHA is to o h igh Possi ble cause The programmed %I or pressure value is too high
Remedy
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Fault messages %I/pressure increase in stepping is too high
Check inputs in %I/pressure stepper (Stepper)
%I limitation /Pressure limit too low
Check parameters of the corresponding limits
Base %I or Base pressure value) too high
Check base %I(programmed current, %I) or base pressure
%I/pressure correction too high
Check Correction values
Extend stepping request Possi ble cause
Remedy
The specified electrode has reached the Extend Electrode Life Near End of Stepper/Waiting condition: The counts have exceeded the programmed end of stepper
Replace electrode
Extended electr od e li fe Near End of Stepp er Possi ble cause
Remedy
The specified electrode was set to Extend Electrode Life Near End of Stepper/Waiting condition: The counts may exceed the programmed end of stepper by a specified number of spots
Replace electrode soon, because the programmed end of stepper may be exceeded by a specified number of spots only
End o f st epper Possi ble cause
Remedy
The specified electrode has reached the End of stepper condition The count value has reached the
Replace electrode
programmed wear until end of stepper
Note:
Continued welding may or may not be possible, depending on the programming of parameter “Stop at end of stepper”.
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Fault messages
End o f st epper Possi ble cause The weld timer was stopped by End of stepper
Electro de changed Possi ble cause The electrode change was acknowledged externally
Remedy Replace electrode
Remedy None: This message only appears in the log
Stepper exceed Possi ble cause An external request was made to exceed the end of stepper
Remedy Replace electrode
Prewarning reached Possi ble cause
Remedy
The specified electrode has reached the Prewarning condition: The count value has reached the programmed wear until Prewarning
The electrode will soon reach the End of stepper condition
Dress-R equest reached Possi ble cause
Remedy
The specified electrode has reached the Dress-Request condition The count value has reached the programmed wear until DressRequest
Dress electrode
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Fault messages
Dressi ng necessary Possi ble cause
Remedy
The specified electrode has exceeded the Dress-Request condition The count value has exceeded the programmed wear until dress request
Note:
Dress or replace electrode
Continued welding may or may not be possible, depending on the programming of parameter “Stop at end of stepper”.
Max. num ber of spo ts welded before dressing Possi ble cause The weld timer was stopped by Dressing requirement
Remedy Dress electrode
Electro de dressed (Stepper tip dressed)
Possi ble cause The electrode tip dress was acknowledged externally
Remedy None: This message only appears in the log
Tipdr ess prewa rning Possi ble cause The specified electrode has reached the Tipdress Prewarning condition
Remedy The cutter blade should be replaced soon
Electrode lif e tipdr ess Possi ble cause The specified electrode has reached the Electrode Life Tipdress
Remedy Replace cutter blade
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Fault messages condition:
Cutter bl ade cha nged Possi ble cause The cutter blade counter was reset
Remedy None: This message only appears in the log
Cutter1 : Cutter not ru nnin g Possi ble cause
Remedy
Cyclic signal at “rpm counter 1” input missing
Check connectors and cables
rpm sensor failure
Check cutter, cutter motor
Cutter jammed
Cutter1 : Dressi ng p roc ess abort ed Possi ble cause Inputs “Start cutter 1” or “Close gun 1” became low during dressing operation
Remedy Check input signals
Cutter1 : Max. mil l dur ation exceeded Possi ble cause The programmed rpm was not reached during max. duty cycle
Remedy Check connectors and cables Check cutter, cutter motor Check programmed duty cycle
Cutter1: Temperature fault Possi ble cause The temperature contact was opened during dressing
Remedy Check “Cutter temp. contact” input, connectors and cables Check cutter motor temperature.
1070087074 / 01
Electric Drives | Bosch Rexro th GmbH and Controls
| BOS 6000
Fault messages
Cutter1 : Motor pro tection tri p Possi ble cause The motor protection contact was opened during dressing
Remedy Check “Motor protection trip” input, connectors and cables Check cutter motor
Cutter1: Emergency-Stop Possi ble cause The stop circuit of the weld timer was opened during dressing
Remedy Check weld timer stop circuit Check connectors and cables
Cutter2 : Cutter not ru nnin g Possi ble cause
Remedy
Cyclic signal at “rpm counter 2” input missing
Check connectors and cables
rpm sensor failure
Check cutter, cutter motor
Cutter jammed
Cutter2 : Dressi ng p roc ess abort ed Possi ble cause Inputs “Start cutter 2” or “Close gun 2” became low during dressing operation
Remedy Check input signals
Cutter2 : Max. mil l dur ation exceeded Possi ble cause The programmed rpm was not reached during max. duty cycle
Remedy Check connectors and cables Check cutter, cutter motor Check programmed duty cycle
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Fault messages
Cutter2: Temperature fault Possi ble cause The temperature contact was opened during dressing
Remedy Check “Cutter temp. contact” input, connectors and cables Check cutter motor temperature.
Cutter2 : Motor pro tection tri p Possi ble cause The motor protection contact was opened during dressing
Remedy Check “Motor protection trip” input, connectors and cables Check cutter motor
Cutter2: Emergency-Stop Possi ble cause The stop circuit of the weld timer was opened during dressing
Remedy Check weld timer stop circuit Check connectors and cables
Phase Angl e prewarning reached Possi ble cause The limit set for %I prewarning was reached/exceeded
Remedy Check the phase value setting in “%I Prewarning” parameter.
Also refer to Maximum Phase Angle Reached
Maxi mum Phase Ang le Reached Possi ble cause The maximum was reached phase angle setting
Remedy Check secondary circuit/cables for wear Check the phase value setting in “%I Limitation” parameter.
Mains voltage dip
Repeat spot weld
Welding transformer/power unit rating too low
Use higher next transformer tap
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Fault messages
Note:
The current phase value can be viewed under “Middle PHA”.
Note:
The message will be active until the electrode has been replaced!
Note:
Excessively by % correction and % stepping canhigh alsovalues triggerachieved this message.
Secondary monito ring cir cuit is open (Current measurement circuit open)
Possi ble cause
Remedy
Broken sensor cable
Replace cable
Detached plug-in connections
Check plug-in connections
Incorrect connector assignment
Check connector assignment
Defective sensor
Replace sensor
Secondary monito ring ci rcuit is sho rted Possi ble cause
Remedy
Squeezed-in sensor cable
Replace cable
Incorrect connector assignment
Check connector assignment
Defective sensor
Replace sensor
Termi nation of Weld / no cu rrent Possi ble cause No current was measured at the beginning of the weld for 40 ms (the schedule is aborted)
Remedy Check closing mechanisms (robot, machine) Check position and pressure of electrodes Clean sheets Check conductivity Check connector assignment Replace sensor
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Fault messages
No vo lt age 1.HW Possi ble cause No primary voltage was measured in KUR mode
Remedy Check KUR connectors and cables
Prim ary Volt age Measuri ng Faul t - KUR Mode Possi ble cause A primary voltage of more than 200% or less than 50% of the programmed voltage was measured during KUR mode.
Remedy Check turns ratio of primary voltage transformer.
Check the programmed mains voltage
Reweld By Timer Act ive Possi ble cause The spot weld was repeated
Remedy Refer to %I fault signaled
Inhib it Monitori ng Mode Activ e Possi ble cause Schedule for which monitoring stopped has been activated
Remedy Check programming of Inhibit Monitoring Mode/Monitoring stopped (P) and Inhibit Monitoring Mode/Monitoring stopped (T).
No Weld Possi ble cause Weld signal was switched off during the schedule
Remedy
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Fault messages
Without regula tion, without monitoring Possi ble cause Schedule for which monitoring stopped and control stopped have been activated
Remedy Check programming of Inhibit Monitoring Mode/Monitoring stopped (P) and Inhibit Monitoring Mode/Monitoring stopped (T), control stopped (P) and control stopped (T).
No cur rent … Possi ble cause
Remedy
Electrodes not closed
Check closing mechanisms (robot, machine)
No electrical contact at the point to be welded
Check position and pressure of electrodes
Contamination of sheets
Clean sheets
Sealant used
Check conductivity
Low Current … Possi ble cause
Remedy
Current measured is below tolerance band: Tolerance band too small
Check tolerance band
Programmed value too high, e.g., because of stepping
Check programmed value, stepper values
Contamination of electrodes
Repeat weld, clean electrodes
Contamination of sheets
Repeat weld, clean sheets
Bad electrode positioning
Improve positioning
Welding transformer underrating
Change over or replace welding transformer
Over Curr ent … Possi ble cause
Remedy
Current measured exceeds tolerance band: Programmed value step-change to lower %I values
Select broader tolerance band, reduce programmed value stepchanges
Handling of different sheet thicknesses or sheet layers
Use several programs with different parameters
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Fault messages Change in electrode pressure conditions
Check electrode force system
Change in resistance conditions (impedance) in secondary circuit, e.g., shunt circuit
Check secondary circuit
Mains voltage fluctuations
Select broader tolerance band, ensure constant conditions, use NBS
Low Curr ent- series of welds-… Possi ble cause
Remedy
Current measured is below the limited tolerance band after n repetitions: Programmed value step-change to higher %I values
Select broader tolerance band, reduce programmed value stepchanges
Handling of different sheet thicknesses or sheet layers
Use several programs with different parameters
Change in electrode pressure conditions
Check electrode force system
Change in resistance conditions in secondary circuit
Ensure constant conditions
Mains voltage fluctuations
Select broader tolerance band, ensure constant conditions, use NBS
Current measurement r ange exc eeded … Possi ble cause The current measured is above the programmed measuring range
Remedy Select more appropriate measuring range Check current for excessive fluctuations
Weld ti me too shor t … Possi ble cause
Remedy
The permitted time tolerance is not reached
Check setting in Time Monitoring
External termination of weld/No current Fault signal
Check signal
Also refer to Weld time too long
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Fault messages
Weld t ime too lo ng … Possi ble cause The permitted time tolerance is exceeded
Note:
Remedy Check the "Reference time" and "Tolerance" parameters
Changing a weld time presupposes a modification of the related reference time if time monitoring is active.
Diode Over Current (Transformer Diode Over Current Fault)
Possi ble cause
Remedy
The computational emulation of the welding diode temperature has determined a junction temperature of more than 150°C. This value corresponds to the power limit (mainly caused by alternating loads) of the welding diode, taking into account a safety margin with respect to the stationary limit: Excessive welding %I
Reduce welding %I or use longer welding breaks in order to reduce the duty cycle
Duty cycle too long
Switch off diode monitoring (Loss of guaranty/warranty! )
Note:
This message is only output by PSI variants!
Diode defect (Transformer Diode Defective)
Possi ble cause A defective welding diode is detected in “Measurement: Secondary” mode due to the saturation current peaks caused by the welding transformer that has been shorted by the defective diode:
Remedy
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Fault messages Welding diode defective
Note:
Replace transformer (PSG)
This message is only output by PSI variants!
Overcurr ent or Ea rth -fault (Transformer Diode Defective)
Possi ble cause
Remedy
The inverter output current is in excess of 110% of the maximum current, or there is a major earth leakage current (no personal protection): The transformer supply line or the welding transformer has a shortcircuit or an earth fault
Replace transformer supply line or welding transformer
Output current too high
In PHA mode, the current may become too high. Reduce %I or work in KSR mode
For weld times above 1s, currents at the power limit and ”Measurement: Secondary” mode, the integrator for
Change over to “Measurement: Primary” mode for currents with a duration of more than 1s
current measurement maycurrent drift off,to pretending a lower actual the inverter, which results in an overcurrent response due to the regulation mode
Note:
This message is only output by PSI variants!
Max. pri mary cu rrent reached Possi ble cause Primary current is cut off by internal primary current limit at a value higher than 25% of the half-cycle
Remedy Check transformer settings
Check: Has the maximum capability of the system been reached? Check: Does the system produce current overshoots ?
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Electric Drives | Bosch Rexro th GmbH and Controls
| BOS 6000
Fault messages
Driver-Fault (Transistor Fault or External Short Circuit Fault)
Possi ble cause
Remedy
A fault was detected in the IGBT power transistor control which indicates a short-circuit or overload. Defective power transistor inside inverter, or external short-circuit, if the fault can only be reset by cycling power to the unit.
Replace timer
if the fault can simply be reset, please call technical service
No weld co ntacto r enable Possi ble cause Weld contactor enable input signal missing
Remedy Check input and wiring
Isolation contactor feedback fault Possi ble cause The feedback signal from the welding circuit contactor is missing
Remedy Check input, wiring, and contactor
No Weld Enable or We ld Press ur e Input Gun 1 Possi ble cause After the Start signal, the feedback at input “Weld enable, Pressure contact 1” is missing
Remedy Check input, cables and electrode gun
No Weld Enable or We ld Press ur e Input Gun 2 Possi ble cause After the Start signal, the feedback at input “Weld enable, Pressure contact 2” is missing
Remedy Check input, cables and electrode gun
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Fault messages
No Water Flo w Gun 1 Possi ble cause After the Start signal, the signal at input “Water flow gun 1” is missing
No Water Flo w GunPossi 2 ble cause After the Start signal, the signal at input “Water flow gun 2” is missing
Remedy Check connector, cables and cooling water
Remedy Check connector, cables and cooling water
Weld Cont acto r Gun 1 O pen Possi ble cause After the Start signal, the main switch signal at input “Weld contactor 1 closed” is missing
Remedy Check connector, cables and main switch
Weld Cont acto r Gun 2 O pen Possi ble cause After the Start signal, the main switch signal at input “Weld contactor 2 closed” is missing
Remedy Check connector, cables and main switch
Weld Cont acto r Gun 1 D id Not Open Possi ble cause The timer has switched main switch 1 off via output “Main switch 1”, but the signal at input “Weld contactor 1
Remedy Check output, connectors, cables and main switch
closed” is still high after 100 ms
Weld Cont acto r Gun 2 D id Not Open Possi ble cause The timer has switched main switch
Remedy Check output, connectors, cables
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Fault messages 2 off via output “Main switch 2”, but the signal at input “Weld contactor 2 closed” is still high after 100 ms
and main switch
Monit or con tact ope n Possi ble cause At the 24V pressure input, the feedback signal is missing after a waiting time of 5 seconds, which signals a closed gun or attainment of the programmed force to the timer
Remedy Check connectors, cables and pressure/gun switch
Mains Power Balance Monito rin g Act ivated Possi ble cause The “ELCB” input signals a fault
Remedy Check connectors, cables and elcb
Mains Power Balance M oni tor ing Ok Possi ble cause The “ELCB” input signal is OK
Remedy None: This message only appears in the log
Auxiliary contactor monitor Possi ble cause
Remedy
The “Auxiliary contactor monitoring” input drops from 24V to 0V and the stop circuit does not follow within 5 seconds Check auxiliary contactor and timedelay element Check inputs
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Fault messages
Fault-Reset Possi ble cause ALL faults have been reset
Weld in g-Fault Reset Possi ble cause Welding faults have been reset
Remedy None: This message only appears in the log
Remedy None: This message only appears in the log
Slave e rr or Possi ble cause Display in master-slave operation that the slave inverter is not ready
Remedy Check slave Read error from slave Reset error in slave
Current Measurement Rang e Exc eeded Possi ble cause For PSI with third-party control: The current measured is outside the measuring range
Remedy Set proper measuring range
Check: Has the maximum capability of the system been reached?
Scaling: Communi cation error Possi ble cause
Error in data telegram received from the external weld current meter
Remedy
Switch weld current meter on, select proper operating mode Use proper weld current meter Check display on weld current meter: are values plausible?
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Fault messages
Scaling : no v alid mea sur ing value re ceived Possi ble cause
Remedy
The weld current meter signals an incorrect measurement in the data telegram transmitted
Repeat scaling
Scaling : no m easur ing value re ceived Possi ble cause No signal was received during communication with the external weld current meter.
Remedy Connect cable to RS232/V24 port of the timer and the weld current meter Use suitable cable. Also refer to V24 in the terminal diagram of the timer Switch weld current meter on Install current measuring belt Check trigger setting on weld current meter
During pressure calibration, no voltage was measured by the force measuring outlet:
Check connection and cable for force sensor: 24V supply and reset signal available? Use force sensor with 1 kN / Volt Check programmed force values Check pressure control valve Check pressure build-up at the gun
Scaling: prot ocol fault Possi ble cause A fault was detected when changing from the Bosch protocol to the V24 protocol of the reference current meter.
Scaling: wrong mo Possi de ble cause “Secondary” measuring mode was set for current calibration. Calibration is aborted.
Remedy First connect weld current meter, then reset fault message and repeat scaling.
Remedy Set to “primary” measurement
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Fault messages
Scaling : Sequence abor ted Possi ble cause A fault has occurred during a program run by which the schedule was aborted (e.g. Emergency-Stop).
Remedy Read the fault from the Error table and correct it. Fault Reset and repeat calibration
Furthermore, a welding process fault was signaled with the additional code “Calibration aborted”.
Scaling: cur rent out of range Possi ble cause The primary or secondary current measured deviates from the programmed value by more than 30%.
Remedy Check the sensor on the secondary side and its connection
Check transformer selection Check toroid sensitivity
Scaling: Diff. pri mary / se condary cu rrent too large Possi ble cause
Remedy
During current monitoring, the difference between the primary current and the secondary current is outside the programmed tolerance band: Secondary circuit shunted
Check secondary circuit
Secondary sensor and connection have been changed since scaling was performed for the last time
Repeat scaling
Changes in secondary circuit, e.g., gun replaced without scaling
Repeat scaling
Toroid sensitivity or transformer selection have been changed since last scaling
Check welding transformer selection and current sensor responsiveness, repeat scaling if necessary
The values for fade-out time, trail current or current measuring range have been changed
Check fade-out time, trail current and current measuring range, repeat scaling
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Fault messages
Scaling: result i nvalid Possi ble cause Force scaling and subsequent processing of the force values measured yielded inconsistent results:
Remedy Check programmed force values
No rising force characteristic can be calculated between the first and the second force measuring point Check connection and cable for force sensor: 24V supply and reset signal available? Check pressure control valve
Force monitoring: t ime too long Possi ble cause The time for building up force is longer than the pre-squeeze time plus squeeze time less “force monitoring before end of squeeze time”. That means, the electrode gun is too slow in building up the force.
Remedy Check the values for 1.SQZ/PreSqz , SQZ and ”Force monitoring before end of squeeze time”
Check programmed pressure value Worn electrode gun
Check electrode gun
Force monitoring: t ime too short Possi ble cause The time required for building up force is shorter than the presqueeze time. That means, the electrode gun is too quick in building up the force.
Remedy Check the values for 1.SQZ/PreSqz, SQZ and ”Force monitoring before end of squeeze time”
Check programmed pressure value Check electrode gun
Force moni tori ng: Force/ Pressure too h igh Possi ble cause The calculated final force value is above the tolerance band for the
Remedy Check programmed force value and tolerance band
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Fault messages programmed force value. Repeat scaling Check force sensor Check pressure control valve
Force moni torin g: Force/ Pressure too l ow Possi ble cause The calculated final force value is below the tolerance band for the programmed force value.
Remedy Check programmed force value and tolerance band Repeat scaling Check force sensor Check pressure control valve Replace electrode gun
Error US measurement Possi ble cause Fault in ultrasonic measurement
Note:
Remedy Refer to additional fault message
This fault message signals a fault in the ultrasonic measurement and occurs together with an additional fault message. For remedial action, refer to additional fault message.
Error US contr ol l oop Possi ble cause Fault in ultrasonic control: the timer changed the regulation mode from USR to KSR during the weld
Note:
Remedy Refer to additional fault message
This fault message signals a fault in the ultrasonic measurement and occurs together with an additional fault message. For remedial action, refer to additional fault message.
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Fault messages
PSQ Sequ ence Cancel led Possi ble cause Ultrasonic measurement/control not possible
Note:
Remedy Refer to additional fault message
This fault message signals a fault in the ultrasonic measurement and occurs together with an additional fault message. For remedial action, refer to additional fault message.
USP no t calc ul ated Possi ble cause An ultrasonic signal was measured, but the ultrasonic point of the transmission curve cannot be calculated
USP too h igh
Possi ble cause The transmission curve indicates too low temperature for weld
Remedy Check for welding splashes: check pressure, electrodes, and fit
Remedy Checked programmed limit value “Max. USP” Check weld
USP too lo w Possi ble cause The transmission curve indicates too high temperature for weld
Remedy Checked programmed limit value “Min. USP” Check weld
spot repe titi on wit h US Possi ble cause The spot weld was automatically repeated
Remedy Check programmable parameter “spot repetition”
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Fault messages The spot weld was automatically repeated after Fault Reset with Reweld
Note:
Use “Fault Reset with WC”.
In this case, it is not possible to record a meaningful ultrasonic transmission curve. Even if the welding process fault “Spot repetition” was defined as a warning, no other faults specific for ultrasonic mode will be output.
Check spot welds!
PSQ hardw are fault Possi ble cause
Remedy
Initialization fault when switching the timer on
Check firmware version of the US controller board of the timer
Hardware fault of US controller board
Cycle power or Reset timer
PSQ int ernal com mun icatio n erro r Possi ble cause
Communication fault between the timer and the US controller board
Remedy Check firmware version of the US controller board of the timer Cycle power or Reset timer
PSQ tempe rature to o h igh Possi ble cause Temperature on US regulator board is higher than 60°C
Remedy Let unit cool down
USP temperature to o hig h Possi ble cause Temperature inside front-end above 70°C
Remedy Let unit cool down
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Electric Drives | Bosch Rexro th GmbH and Controls
| BOS 6000
Fault messages
USP hardw are fault Possi ble cause Hardware fault in front-end
Remedy Replace front-end.
PSQ watch dog fault Possi ble cause Timer detected that US controller board no longer responds
Remedy Reset Fault Cycle power or Reset timer
PSQ not avail able Possi ble cause US controller board has not yet completed the previous schedule when next schedule is started
Remedy Extend spot interval to approx. 1 second
PSQ sequenc e err or Possi ble cause In the beginning of schedule: Frontend did not perform measuring loop test.
Remedy Check front-end and CAN connection
During schedule: no values from front-end
USP com mun icatio n erro r Possi ble cause Communication between the ultrasonic controller board and the front-end is disturbed during the schedule
Remedy Check voltage supply to front-end and links with front-end
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Fault messages
US measur ing l oop f aul t Possi ble cause The front-end does not receive an ultrasonic signal, or a very low signal, during the measuring loop test
Remedy Close electrode gun
Electrode caps are not upright Bad fit of sheet Check receiversensors: Transmitter and Defective front-end Check US parameters: gain factor, sensor spacing, direction of polarization
Note:
Use the “Test measuring channel” function for this purpose.
PSQ memor y deleted Possi ble cause New US controller board installed in the timer.
Remedy Re-program parameters or restore parameters with Download function
Different memory structure after firmware update
PSQ ok Possi ble cause No faults in the ultrasonic system (PSQ)
Remedy None: This message only appears in the log
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Glossary
Glossary
AC A lternating Current.
Base %I Programmed current in kA or the phase value in %I for a weld time. It is defined as 100% and serves as a basis for calculating the %I correction and %I stepping.
CAN
Controller A rea Network. Data link between the ultrasonic controller board and the front-end
Check box Square object used to activate/deactivate a function. A group of check boxes is used for an “m from n” selection.
Configuration tool Separate program for the administrator that may be used to adjust many features of BOS 6000 to your specific requirements.
Count
Refer to Counts.
Count factor Program-specific value that can be configured in “Programming: Stepper” window. When a welding program is executed, the counts are incremented by the value of the count factor.
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Glossary
Counts Electrode-specific counter. Indicates the current Counts value of an electrode. In contrast to the spot counter, the counts are not incremented by the fixed value of 1 for each spot welded, but rather by an adjustable, program-specific count factor.In this way, the electrode count can be exactly recorded even when welding different sheet thicknesses or materials.
CT Cool time.
DC Direct Current.
dimmed The relevant object or a part of it is shown in gray color. In this condition, the relevant function is blocked or cannot be activated for reasons immanent to the system.
double click Move mouse pointer to the desired element, shortly press the left mouse button twice and release it immediately afterwards.
drag Move mouse pointer to the desired element, press and hold down the left mouse button and move the mouse. The mouse pointer drags the element along as it moves. Drag the element to the desired location and release the left mouse button.
Dressing counter Electrode-specific counter. Indicates how often the electrode has already been dressed (first tip dress not included).
DST Down-slope time.
ED Duty cycle.
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Glossary
First tip dress Is used to obtain a defined contact area when new electrodes have been installed.
Front-end Electronic equipment used in connection with ultrasonic welding.
HLD Hold time.
HTML HyperText Markup L anguage.
%I Phase value (%I). Programmed %I for PHA mode.
Icon Small symbols shown by the system instead of windows or entire applications. In connection with the safety instructions, the icons draw the reader’s attention to specially important safety issues.
I/O Input/Output.
IP Internet Protocol.
IP addr ess Address of a timer that communicates with BOS 6000 through an Ethernet network. The address consists of four numbers between 0 and 255 each separated by dots. Also refer to our documentation on “Programming field buses”, no. 1070 087005.
kA k ilo-A mps.
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Glossary
Keyboa rd control Operating the BOS 6000 via the keyboard. Refer to shortcuts.
kN k ilo-Newton.
KSR K onstantStromRegelung (constant-current regulation). Drives the power unit so as to ensure that the programmed current is reached in the secondary circuit.
KUR Constant-voltage regulation.
Link Blue, underlined text. A left-click on this text will open a new window or invoke a function.
List box List containing options for selection.
Menu List containing a number of commands/functions for selection.
Menu l ine Line containing a number of commands/functions for selection.
Mixed mode In contrast to Standard mode, the PreWld, WLD, PostWeld are treated
separately for the purpose of monitoring and regulation.
mouse click Move mouse pointer to the desired element, shortly press the left (unless specified otherwise) mouse button once and release it immediately afterwards.
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Electric Drives | Bosch Rexro th GmbH and Controls
| BOS 6000
Glossary
ms Millisecond.
mV Millivolts.
NBS Mains load limitation control. Function designed to prevent an overload of the welding network caused by simultaneous welding of several timers.
OFF Off time.
PHA Non-regulated timer mode as compared to KSR and KUR. The welding %I (programmable as %I) is determined by the phase value (of thyristor power units) or the pulse width (of medium-frequency inverters).
Popup menu Menu that appears after a right click at the mouse pointer position.
PSI Weld timer with integrated medium-frequency inverter.
PSQ Ultrasonic quality assurance system.
PST Weld timer with integrated thyristor unit.
PSU Separate medium-frequency inverter unit (without integrated control logic).
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Glossary
Radio but ton Round object used to activate/deactivate a function. A group of radio buttons is used for a “1 from n” selection.
Scrollbar A bar at the right and/or bottom margin of an object (e.g., a window or a list box). By moving it, you can shift the contents of the object (e.g., in order to display more information).
Shortcuts Many commands/functions can be invoked by pressing a key or by pressing several keys simultaneously. In order to trigger a key combination, you first have to press and hold down one of the keys Ctrl , Alt or Shift , then press the key indicated after “+”, and finally release both keys.
Important shortcuts:
Alt+
Alt+Esc Alt+F4
To select menu items via the keyboard. : Wildcard character for the character underlined in the relevant menu text. Brings the next currently active application into the foreground. Closes the active window
Alt+Space bar Alt+Cursor down Alt+Cursor up
Opens the system menu Opens/closes a list box selected.
Alt+Tab
Selects a currently active application and brings it into the foreground.
Print
Copies the current screen display to the clipboard Executes a command.
Enter key End
F1 F10
In text/number field: Places the cursor behind the last character. In list box: Selects the last entry in the list. Calls up the Help function Selects the first item in the menu bar.
Space bar
Selects or deselects an element from within the
Cursor down Cursor up Home
checkbox Selects an element from a list box, or increments/decrements the numerical value displayed. In text/number field: Places the cursor in front of the first character. In list box: Selects the first entry in the list.
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Glossary
Ctrl+C Ctrl+V Ctrl+X
Copies selected characters. Pastes the last string copied to the clipboard with Ctrl+X or Ctrl+C to the left of the cursor. Deletes selected characters.
Tab Shift+End
Selects the next object/input field. Selects all characters to the right of the cursor in a text/numerical field. Shift+Cursor down Selects several consecutive elements from Shift+Cursor down within a list of choices Shift+Home Selects all characters to the left of the cursor in a text/numerical field. Shift+Tab Selects the previous object/input field.
Slope Linear %I change in the form of a current slope.
Spot counter Electrode-specific counter. Indicates the number of spots already welded by the respective electrode. In contrast to the counts, the spot counter is incremented by the fixed value of 1 for each spot welded. The spot counter is only displayed below “spots” in the “Detail-Info” window.
SQZ Squeeze time.
Standard mode In contrast to Mixed mode, the PreWld, WLD, PostWeld are treated jo in tly for the purpose of monitoring and regulation.
Status line Is located at the lower margin of the BOS main window and contains the following information: Name of the parameter that can be modified in the current input field (containing the cursor) and its applicable input limits (important for dynamic limit values, e.g., due to %I stepping). Timer communication status: green: online, blue: offline, red: fault Date, time and key conditions.
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Glossary
UST Up-slope time.
WLD Weld time. Time in which the power unit is activated. Three different weld times can be set in the timer: PreWld Warming-up time. For heating up the parts to be welded. WLD: Main welding time. PostWeld: Post-heating weld time. Prevents parts from cooling down too quickly The duration and %I of all 3 weld times can be configured separately. The PreWld and PostWeld are optional.
WT Weld t imer. Other names include, e.g., timer, module, controller module, etc.
Title bar The horizontal bar on the upper edge of a window or dialog that shows the title of the window or dialog and the command buttons for maximizing, minimizing or closing the window, if available. Is dimmed, for example, for those windows which are not active.
Tool tip When the mouse pointer remains motionless on an input field/object for a moment, a relevant explanation appears in a small window.
ÜK Monitoring contact
US Ultras onic.
USR Ultrasonic control
Waiti ng/Extended e lectro de life Counts range between the end of stepper and the point where no schedule can be performed any more with this timer.
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Glossary
WC Weld complete contact. Signal that is output by the weld timer after a welding schedule. It normally causes the robot to move on to the next spot weld. Whether weld complete is output for faultless welds only or independent of the welding result can be selected in parameter “WC with error".
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Glossary
BOS 6000 | 1070087074 / 01
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235
Index
Index % %I after last dressing 69 %I at the end of 1st stepper phase 66 %I Correction (Elec.) 119 %I (Prg.) 119 %I Correction for new electrode 64 %I Limitation 82 %I Prewarning 82 %I too large/Force/Pressure too high/PHA is too high 200
< Para.-Data Import/Export (Parameter-Restore) 145
> >%I Step.-Value 64 >Monitor Step.-Value 64 >Press. Step.-Value 64
1 1. Halfcycle after Pause-Time 45 1. Halfcycle limit 82 1.CT 48
2 2. Toroid sensitivity 83 2.CT 50 24V off/to low 198
3 3.CT 50
A Activating Help 10 Active reference current (Programming, schedule) 55 Active reference current (Programming, Stepper) 72 Actual value (Dressing counter) 70 Add fault information 183
Addition (Diagnosis, Timer-Information, Last Weld) 107 Addition (Diagnosis, Timer-Information, Timer) 106 Address mode 115 After each dressing 65 Autobackup 138 Auxiliary contactor monitor 216 Average/Middle PHA (Programming, Stepper) 72
B Backup 137 Base pressure value (Correction, Correction) 120 Base pressure value (Programming, Schedule) 47 Base pressure value (Programming, Seq. Pg.2) 56 Basics 23 Battery-Low 194 Baudrate 115 Book symbols 12 BOSServ.exe 31
C Change parameters and transfer to timer 169 Change the communication data of logged-in timers 155 Choose parity 77 Circuit Breaker Off 196 Code (Diagnosis, Timer-Information) 106 Compare 133 Compare spot reference 172 Compare Timer Data 160 Conditional tolerance band 54 Confirm electrode change 174 Connection set-up 39 Contents (structure) 12 Control stop 192 Control stopped 75 Conversion-Factor 92 Cooling temperature too high 193 Copy 141 Copy the contents of a numerical input field 165 Copy Timer Data 157 Correction 117 Correction 118 Corresponding Programs 149 Count 65 Count-Factor 71
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Index
Counts 67 Current at 0% I 85 Current at 50% I 85 Current calibration 147 Current Measurement Range Exceeded 216 Current measurement range exceeded… 210 Current measuring/Current supervision 80 Current monitoring 53 Cutter blade changed 204 Cutter1 Cutter not running 204 Dressing process aborted 204 Emergency-Stop 205 Max. mill duration exceeded 204 Motor protection trip 205 Temperature fault 204 Cutter2 Cutter not running 205 Dressing process aborted 205 Emergency-Stop 206 Max. mill duration exceeded 205 Motor protection trip 206 Temperature fault 206
D Data download started 194 Define access levels for individual objects 163 Delete spot references 173 Delete timers from BOS 6000 154 Deleting topics from the Favorites list 15 Description of the symbols in the menu lines 11 Detail Info 151 Diagnosis 97 Diagnostics I/O 98 Last Weld 107 Start Simulation 102 Timer-Information 105 User Diagnostics I/O 101 Diode defect 212 Diode Over Current 211 Diode temperature 90 DIP switch 116 Display spot comments 173 Displaying topics 71 in the Favorites list 14 Dress new the electrode Dressing necessary 203 Dressing-Curve (Programming, Seq. Pg.2) 59 Dressing-Curve (Programming, Stepper) 69 Dressings 70 Dress-Request 70 Dress-Request reached 202 Driver-Fault 213
DST 49
E Edit | Autobackup 29 Edit | Copy 29 Edit | Correction 29 Edit | Export record set 29 Edit | Firmware changing 29 Edit | Login 29 Edit | Oscilloscope function 29 Edit | Programming 28 Edit | Setup 29 Edit | Timer change 29 Electrode changed 202 Electrode dressed 203 Electrode life tipdress 203 Electrode range 84 Electrode/Stepper 46 End of stepper 201, 202 End of Stepper (refer to maximum counts) 68 End-Slope 52 Enter/change spot references 172 Error table 124 Error US control loop 221 Error US measurement 220 Exit BOS 6000 153 Export parameter data to ASCII file 175 Export spot reference 171 Export spot reference to an Excel file 171 Export timer data (backup) 158 Export Timer Reference 156 ext. data change 169 Extend stepping request 201 Extended electrode life Near End of Stepper 201 Extended electrode life/Waiting 71 external data change 169 External Over-Temperature 193
F Fade-out time 78 Fault messages 191 Fault-Reset 216 File | Exit 28 File | Para. data import/export | Export … 28 File | Para. data import/export | Import … 28 Filter tables 166 Find Text 13 Find keyword 12 Firmware change 142
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Index
Force calibration 148 Force monitoring Force/Pressure too high 220 Force/Pressure too low 220 time too long 219 time too short 220 Force x.PV 60 FPO (freely programmable output) 60 FTP-Upload 135 Functions (Setup, Communication) 116 Functions | Compare 30 Functions | Error table 30 Functions | Network overview 30 Functions | Parameter overview 30 Functions | Prewarning 30 Functions | Protocol 30 Functions | Rights administration 30 Functions | Spot reference 30 Functions | Timer reference 30 Functions in the menu line 28
G Getting to know the BOS 6000 user interface 23
H Half-CycleFault Monitoring Hardware 195 196 Help | About 31 Help | Help 31 History 9 HLD 51 How to … 153
I I% and pressure correction displays 48 I/O Signals 97 I/O-Bus Fault 196 Ignition Type 96 Import parameter data from ASCII file 176 Import spot reference 171 Import Timer Reference 156 Impulse 50 Including topics in the Favorites list 14 Influence data comparison at program start 162 Information concerning the last welding schedule performed 97 Information concerning the timer 97 Inhibit Monitoring Mode Active 208 Inputs / Outputs 100 Interval (Diagnosis, Start Simulation 104 Interval (Diagnosis, Timer-Information) 106
IP Address (Setup, Communication) 114 Isolation contactor feedback fault 213
K Keyword search 12
L Language 30 Last weld program31chosen 104 Laufzeitbibliothek Log in timers to BOS 6000 153 Login 32 Low Current… 209 Low Current-series of welds… 210 Lower tolerance band 54
M MAC-Adresse 116 Main weld current 51 Mains Power Balance Monitoring Activated 215 Mains Power Balance Monitoring Ok 215 Mains voltage 90 Max repeat welds (max. repetition in series) 76 Max. %I correction 73 Max. number of spots welded before dressing 203 Max. Pressure-Correction 74 Max. primary current reached 213 Max. welding time 75 Maximum count 68 Maximum Phase Angle Reached 206 Maximum pressure 90 Meaning of important icons 26 Measuring loop check 80 Memory deleted 194 Menu line of the Help window 11 Middle/Average PHA (Programming, schedule) 55 Min. %I correction 74 Min. Pressure-Correction 74 Mode 115 Mode pressure output 78 Monitor contact open 215 Monitor st epper 64 Monitoring 46 Monitoring stopped 76
N Network overview 126 Next 11
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Index
No current… 209 No schedule programmed 194 No stroke, no weld 200 No voltage 1.HW 208 No Water Flow Gun 1 214 No Water Flow Gun 2 214 No Weld 209 No weld contactor enable 213 No Weld Enable or Weld Pressure Input Gun 1 214 No Weld Enable or Weld Pressure Input Gun 2 214 No Weld external 199 No Weld internal 200 No. parallel (diodes) 89 Nominal current (transformer) 87 Nominal voltage (Thyristor-Unit-Parameter) 94 Number of transformers 86
O OFF 51 Off-time 61 On-time 61 Over Current… 210 Overcurrent or Earth-fault 212 Overview of the interface structure 24
P Para.-Data Import/Export (Parameter-Backup) 144 Parameter Overview 134 Perform current calibration 184 Perform force calibration 187 Phase Angle prewarning reached 206 ping 36 Port Number 114 PostWeld 50 Power voltage off/to low 199 Power voltage off/to low receipt 199 Power voltage to high 198 Power-Unit not ready 192 Pre Sqz 48 Pre Weld kA 51 Pressure after last Dressing 59 Pressure at end of 1.Stepper-Phase 58 Pressure for new electrode 57 Pressure profile 60 Pressure stepping 57 Pressure-Correction (Elec.) 119 Pressure-Correction (Prg.) 119 Previous (Back) 11
Prewarning 122 Prewarning Count 68 Prewarning reached 202 PreWld 48 Primary transformer ratio (transformer) 87 Primary Voltage Measuring Fault - KUR Mode 208 Print 11 Print spot reference 172 Print Timer Reference 156 Program (Diagnosis, Timer-Information) 106 Program (display field in 100 Program Parity Fault 197 Programming 42 General 73 Schedule 43 Seq. Pg.2 56 Stepper 62 Stepper/Electrode 81 Thyristor-Unit-Parameter 94 Proper use 19 Protocol 128 Protocol memories 129 PSQ hardware fault 222 PSQ internal communication error 223 PSQ memory deleted 225 PSQ not available 223 PSQ ok 225 PSQ Sequence Cancelled 221 PSQ sequence error 224 PSQ temperature too high 223 PSQ watchdog fault 223 Pst Wld kA 52
Q Qualified personnel 20
R Range of training courses. 20 Readme 9 Ref.-Current at end of 1.Stepper-Phase 67 Reference current 52 Reference current for new electrode 65 Reference current last dressing 70 Reference time 61 Regulation 46 Regulation mode 52 Renaming the topics in the Favorites list 15 Repeat factor 55 Replace a defective timer 177 Reset faults 181
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Index
Response to data mismatch 40 Restore 137 Restore Timer data (download) 159 Reweld By Timer Active 208 Rights Administration 135
S Safe working practices 21 Safety Instructions 17 Scaling Communication error 217 current out of range 218 Difference primary / secondary current too large 218 no measuring value received 217 no valid measuring value received 217 protocol fault 218 result invalid 219 Sequence aborted 218 wrong mode 218 Schedule 45 Schedule (Diagnosis, Timer-Information) 107 search keyword 12 Secondary monitoring circuit is open 207 Secondary monitoring circuit is shorted 207 Sequence externally cancelled 197 Set Access Level 135 Set Counter 146 Set electrode counter 175 Setup 108 Communication 113 Fault-Setup 112 Stepper curves 109 Tipdress curves 111 Show (Unhide)/Hide 11 Show / Print / Export logs 167 Show Contents (structure) 12 Show electrode status 173 Show structure 12 Signals 97 Slave error 216 Slope 49 SMTP Address 114 Software version 9(Diagnosis, TimerSoftware-Version Information) 106 Software-Version (Thyristor-Unit-Parameter) 96 Sort tables 166 Spot Comment 150 Spot Reference 120 spot repetition with US 222 Spot-Repetition 47
SQZ 48 Standard gateway 114 Start Inhibited 197 Start page (Home) 11 Start with ignition (Diagnosis, Start Simulation 104 Start without ignition (Diagnosis, Start Simulation) 104 Start-Inhibit (P) 44 Start-Inhibit (T) 74 Start-Slope-Current 51 Status (Diagnosis, Start Simulation 104 Status (Diagnosis, Timer-Information, Actual Cycle) 106 Status (Diagnosis, Timer-Information, Timer) 106 Stepper 71 Stepper exceed 202 Stepper-Curve (Programming, Seq. Pg.2) 59 Stepper-Curve (Programming, Stepper) 66 Stepping and dressing 63 Stop / No 24V 191 Stop at end of stepper 73 Stop circuit closed 191 Subnet mask 114 Supervision (diodes) 88 Supply Voltage Fault 198 Switch-off temperature (diodes) 89 Symbols used 18 Sync / Power Fault 196 Synchronization OK 197
T Termination of Weld / no current 207 Text search 13 The available windows 32 The BOS 6000 Help System 9 Thyristor-Unit temperature 95 Thyristor-Unit-Type 95 Time Monitoring (Programming, Seq. Pg.2) 61 Time x.PT 60 Time-Monitoring (Programming, Schedule) 47 Timer 36 Timer 14033 Timer change Reference Timer switched on 198 Timer type (Diagnosis, Timer-Information) 106 Timer type (Thyristor-Unit-Parameter) 96 Tipdress prewarning 203 Tolerance standard 61 Toroid sensitivity 83 Trademarks, copyright 22
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Index
Trail current 79 Transformer temp too high 193 Turns ratio (Thyristor-Unit-Parameter) 95 Type (diodes) 88 Type (transformer) 85 Type of connection (transformer) 86
U Upgrade the timer firmware 179 Upper current limit 82 Upper tolerance band 54 US measuring loop fault 224 Use favorites 14 USP communication error 224 USP hardware fault 223 USP not calculated 221 USP temperature too high 223 USP too high 222 USP too low 222 UST 49
W WC (Diagnosis, Start Simulation) 105 WC Period 77 WC Start time 77 WC with 77 Wear pererror component 71 Weld Contactor Gun 1 Did Not Open 215 Weld Contactor Gun 1 Open 214 Weld Contactor Gun 2 Did Not Open 215 Weld Contactor Gun 2 Open 214 Weld external 200 Weld internal 200 Weld program chosen 104 Weld time too long… 211 Weld time too short… 211 Weld without Command 192 Weld/No weld (Global) 74 Weld/No Weld (P) 44 Welding-Fault Reset 216 Why 17 Width of a table column 166 With stroke, with weld 200 Without regulation, without monitoring 209 WLD 49
Z Zero adjust 93
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Bosch Rexroth AG ectr c r ves and ontro s . . o x1 7803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 7816 Lohr, Germany hone +49 (0)93 52-40-50 60 ax +49 (0)93 52-40-49 41 ervce.s vc boschrexroth.de www.boschrexroth.com
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