2011 Bos6000_V1_36_0 _PSI201_EN_11_02_18

7/26/2019 2011 Bos6000_V1_36_0 _PSI201_EN_11_02_18

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.

!lectric "rives and #ontrols

B$%&''' ( )%*&''' Weld #ontrol

)%*&''' *nverter

+ardware and

B$%&''' %oftware

raining )ac-age '

/laus /lic-/laus /lic-

"##0%1#2"##0%1#2

1ersion .3&.'1ersion .3&.'

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%ystem overview )g 4

Welding %e5uence )g '

+ardware configuration )g 3

imer standard configuration )g 2

imer 6ame ( *0$ configuration )g 4

%oftware communication )g

!thernet configuration )g 3B$% &''' %oftware )g 2

)rogramming page )g 7

*cons )g 3'

Welding %e5uence )g 3

)rogramming exercise )g 32#opy )arameter )g 3&

#opy )rograms 0 imer )g 34

#urrent 8onitoring )g 9&

!xtended Welding %e5uence 0 )ressure )rofile )g 2

#ontents ))age

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3!lectric "rives and #ontrols

+eat %tepper )g 23

+eat %tepper ( ip dressing )g 22

General set:up )g 2&

!lectrode set:up )g 2;

)ower <nit set:up )g &

*0$ "iagnosis )g &3

%imulate %tart )g &&imer *nformation )g &4

=ast Weld )g &;

)lant =ayout )g &7

=og *n 0 #ompare )g 4

)rotocols )g 4&$verview )g ;'

!rror able )g ;

)re:Warning > )g ;3

#orrection )g ;4

#ontents )age

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>orce #alibration )g ;7

#urrent #alibration )g 7&%et <p +eat %tepper #urves )g '&

%et <p ip "resser #urves )g '4

Bac-up )g ';

Restore )g

+elp )age > )g &+ow to extract spatter data )g ;

#ontents )age 3

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B$%&''' ( )%*&''' Weld #ontrol

%ystem $verview

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&!lectric "rives and #ontrols

Welding !5uipment

8achine *nterface,

*0$ Bussystem

)ressure 0 >orce ?' :'1"#@

9 1"# %upply 0

%top #ircuit

Welding Gun

Optional Voltage-Feedback

Current-Feedback

*nverter

-+

"#:=in-

#urrent:>eedbac-

Rectification

1oltage:>eedbac-

Mains Input

Welding

Gun

7/26/2019 2011 Bos6000_V1_36_0 _PSI201_EN_11_02_18

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$verview )%*&''' *nverter and ransformer

)rimary sensorsfor /%R

*nverter output

2''1 '''+ to the

Gun

%econdary coil ?/%R@

<*R #onnections

ypical ouput 2:v "#

9 '-A, '''+depending on

ransformer

#onfiguration.

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;!lectric "rives and #ontrols

Welding %e5uence

> C >orce D-6E

* C #urrent D-AEt C time DmsE

Weld #urrent

%F W=" +="

+old timeWeld time%5ueee time

close openGun

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Contact-resistance Electrode-Sheet1

Contact-resistance Electrode-Sheet2

Current I

k!"

Sheet 1

Sheet 2

Electrode 1

Electrode 2

Material-resistance 1

Material-resistance 2

Electrode-Force F k#"

$ % & ' I( ' t

Contact-resistance Sheet-Sheet

Resistance Welding )rocess Basics

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'!lectric "rives and #ontrols

B$%&''' ( )%*&''' Weld #ontrol

+ardware >amiliarisation

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Bosch Rexroth Welding #ontrol )anel "evice

>amiliarisation typical setup

)*+ %ignal lamps

,*+ 8ain %witch

*+ x )%&2'.333=

.*+ x 8ain %witch

/*+ >uses

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Bosch Rexroth Welding #ontrol )anel "evice

>amiliarisation typical setup

Roboter bus system ?hereH optical *nterbus@

Bosch Rexroth Welding #ontrol ?timer@

Main switch including FI

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%ide 1iew

imer %tandard #onfiguration

*0$ #ard slot

Adaptive control

slot

>ield bus module

slot

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<nderstanding Weld imer ype #odes

Welding controls

)%*&3''.''=

)%*&3''.333=

)%*&3''.32'=

)%*&3''.443=

)%*&3#'.324=

)%*&3%.27=

ransformers

)%G&3'

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)rofibus *0$

9 1olts internal 0

external supply, see

next page.

!xternal pressure

control to prop valve

%econdary current

feedbac-,

ransformer temp

feedbac-.

$utput to the

transformer

imer #onfiguration )%* &''.'=

)arallel *0$

%erial #om

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9volts "istribution

*nternal lin-s

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!xternal >an $peration

he fans are normally located at the rear of the panel, forcing airto be driven across the fins of the heat sin-.

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)roportional 1alve #ontrol and feedbac-

I9volt feedbac-, from the prop valve, tells the welding controlthat the demanded pressure has been reached, this then allows

robot control to give the command to close the gun and allow the

weld schedule to commence.

*f no prop valve is used, then 02)olts and olts 3ust be

supplied to pin ) 4 2 55

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ransformer >eedbac-ransformer >eedbac-

A normally closed contact in the

transformer, feeds bac- temperature

$/. *f no feedbac- is available, thenthese pins must be shorted.

*ndustry %tandard is 2'm1 0 -A. his

is adJusted automatically during a

calibration procedure to suit the

individual application

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'!lectric "rives and #ontrols

%oftware #ommunication

%oftware #ommunication is

normally via a specific

communications card, via*nterbus 0 !thernetKetc.

Lou can also connect directly

to individual timers via the

serial port, M

Wiring schedule for the %erial port

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!thernet #ommunication configuration

When connecting via an !thernet lin-, please ensure

you have set the *.) address correctly on the

computer, otherwise no communication will be

possible.

his indicates that your computer has detected a local

area connection.

o access the *) setting, double clic- the icon, with

your mouse.

*f you do not have this icon present, select the

option below

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!thernet #ommunication #onfiguration

%etting the *) Address !nter an *) Address and subnet mas- then $/

he General tab will

now become visible

!nsure that the *) address you select does not

exactly match the *) address of the imer, the

last digit should be different

A further

configuration screen

will appear

%elect )roperties

%elect *nternet )rotocol ?#)0*)@ then $/

%elect, <se the following *) Address then $/

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B$%&'''

B$%&''' %oftware >amiliarisation

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B$%&''' <sername ( )assword

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2* Add the timer name

1*o add a new or additional

timer, select the Add button

first, the Add0change imer

box will then appear above

6* Add any reference

comment

)* %elect your

communication method.

19, !thernetK.etc

,* *f you are connectingvia !thernet, then insert

the *) address here

7* %elect $nline or $ffline

mode

.* %elect the direction of

data flow, on initial

communication

/* When the information

has been installed, press

$/

1* %elect continue buttonto access the program

imer Reference

* %elect protocol to

enable the <*R monitoring

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8onitor the %tatus and"escription window, if a red bar

appears and stays then there is

a problem with your

communication path, cable, or

the timer may be switched off.

8onitor the %tatus and "escription

window, a yellow bar should

proceed a green bar.

his indicates that communication

path is operational, and the

database is being populated withthe timer information.

)lease be patient, on the initial

start:up it can ta-e several minutes

to gather all the data for the

database.

All subse5uent connections will only

ta-e seconds to get on:line

imer %tatus

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)rogram )age

he spot number, programand communication status is

found at the top of program

page, as well as the drop

down menuNs

he raised tab indicates the

page that is currently being

viewed

A single clic- will select the

re5uired page, and another

single clic- will return you to

your previous screen.

6early all functions0pages

can be 5uic-ly accessed via

the OiconsP that are situated

at the top of the pages.

)rogramming

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%pot reference

able

)re:warning able

Rights

Administration

#ompare)rotocols

)lant layout!rror able

)arameter $verview,

incorrect parameters

$verview

#orrection )rogram )age

?)arameter data@ "iagnosis

?i0o interface@

%et:up

=ogin

%pot reference#omments

imer

reference

B$%&''' *cons

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%e5uence

he B$%&''' software

onl8 sho9s tabs, which

are available.e.gH )%F:ab is

only shown, if MFR )#B

is mounted in the timer.

he B$%&''' software

only sho9s para3eter:

which are accessible.e.gH #$$= time is

only shown, if the

number of impulses is

bigger than .

8onitoring parametersare only shown, if

-A:monitoring is O$6P

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3'!lectric "rives and #ontrols

)rogram tabs

By selecting individual tabs within thepages you can navigate around the

software at the clic- of a button

Lou can also see at a glance if the weld

has a pre:heat, a post heat, or even if

upslope or down slope.

"ependent on the timer status, you can

see if the timer is online, or offline.

Blue is wor-ing offlineGreen is wor-ing online

)rogramming

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%e5uence

he se5uence screen allowsthe user to see the

programmed weld

parameters at a glance

Squeeze

Weld time

Weldcurrent

Pressure

Hold

Program

>or )%*&''' inverters the

times are all programmed in

milliseconds.

)%&''' timers are

programmed in cycles

cycle C 'ms

Timer

)rogramming

%

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Se;uence<- here are 3 se5uence options,

Single< weld se5uence per start signal

&epeat< weld se5uence repeated until the start signal is dropped

Sea3< weld permanently on till the start signal is dropped

=o select a 9eld progra3<- to

access the re5uired program,

simply select the program fromthe up0down buttons, or type in

the actual program number. he

electrode number will update

when a program is selected.

=o select a spot nu3ber H:

utilising the down arrow select

the re5uired spot number, and

the program that is associated

with it will automatically appear

Inhibit Se; >?+ ?*nhibit this

program se5uence@

his needs to be set to @OAAB, if

not then the weld se5uence willbe inhibited for this program only

Weld OnOAA Int >?+

?*nternal weld on0off@

his needs to be set to @OnB, if

not then the weld will be turned

$ff for this program only

%e5uence

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)rogramming exercise

)lease enter the

following Weld programs

%tepH )rog

%tepH )rog3 2

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)rogramming exercise #opy

*f you select one

)arameter,

1+ Lou see the input range of this parameter

2+ Lou may copy

this parameter

<sing the right

mouse button

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)rogramming exercise #opy

<sing the #opy feature from the main menue, you have all $ptions

to copy any data from the weld timers.

%

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3&!lectric "rives and #ontrols

&egulation<- Mi' or

Standard

*f Mi' is selected, weld (

weld 3 can be programmed

in )+A ?phase angle@ or

/%R ?constant current@

mode

*f Standard is selected then

weld and weld 3 can only

be programmed in the same

mode as weld

%e5uence

%

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Monitoring<

Mi' or Standard

Standard 3ode< the actual

current is determined by the

complete weld cycle includingany cool times

Mi' 3ode< the actual current

is determined by the individual

weld times

Qsee illustration on the next sheet

%e5uence

%e5 ence

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3;!lectric "rives and #ontrols

%e5uence

%e5uence

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)rogrammed in scale units ,the greater the +t, thenthe greater age of current flowing

Half-cycle of

mainsvoltage

Phase angle, xedvalue determined by

program

!" !# " - $lectrical

degrees

#" !%# "

!&# '' # -!( - )cale units *+

High current Programmable range ow current

)+AH )hase Angle Regulation

%e5uence

)rinciple of <nregulated )hase angle welding

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)rinciple of <nregulated )hase angle welding

)rinciple of #onstant current regulation

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)rinciple of #onstant current regulation

%e5uence

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Electrode<

' 3 different electrodes

can be selected, dependent

on your firmware version

&e9eld<

*f this function is activated

and a low weld current

occurs with the start signal

still high, the control will

automatically attempt toreweld the program, if the

weld is low again a weld fault

is output.

6oteH: if there is no current,

then a reweld will not be

activated

%e5uence

%e5uence

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*f the impulse function has a

figure greater than , then

the portion of the program

that is inside the green

shape is repeated however

many times is programmed

I3pulse<

his function indicates how

many times the weld , cool

function is repeated during one

weld se5uence.

%e5uence

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Current 3onitoring<

When the monitoring is

activated ?$6@, the

reference current and all the

tolerance band parametersbecome visible

%e5uence #urrent monitoring

%e5uence

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Repeat factor, is the number

of consecutive welds allowed

in the conditional permissible

tolerance bandS

if this occurs, the actual

figure is displayed here

1

3

2

4

1234

%e5uence

%e5uence

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Ref, -A is the

programmed reference

current

Average )+A is theactual )hase angle

re5uired to achieve the

re5uired current

Act. Ref. -A is the

actual current

achieved

%e5uence

%pot table

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*n the spot reference table a particular spot name is lin-ed to a program number and a

timer.

his allows selection of spots by their individual name.

I3portant< he %pot reference table must be transferred into the timer to get activeTT

%pot table

.@

.@

3.@

%pot table

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%pot table

9.@

%e5uence

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*f this *con is coloured, then

when pressed, the

comments sheet for the

actual spot number that is

assigned to this program will

be displayed

he number of comment

fields can be altered in the

#onfig tool

%e5uence

!xtended %e5uence

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from this page the pressure

profile function can be activated.

When the profile is activated theforce can be programmed to a

specific value at any time during

the weld se5uence.

he force can be altered up to '

times during the weld process

!xtended %e5uence

+eat %tepper

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+eat %tepper

8ax WearH:

he number of welds over which the

heat is stepped ?incremented@

+eat increase

in the lifetime of

electrode caps

+eat stepperH:

activation on0off

Wear0compH: he

number of welds ta-en

to complete one cycle

Wear factorH:individual welds can be

given a greater or

lesser OweightingP,

dependent on the

actual wear to the tips

Warn WearH:

6umber of weldsbefore the end

of the max:life,

that pre:warning

becomes active

?2'@

+eat %tepper

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+eat %tepper

8ax WearH:


heat is stepped ?incremented@

+eat increase

between tip

dresses

+eat %tepper and tip dressing

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?lease note<-

he 8ax life is

calculated by the

multiplying

?8ax Wear x tip dress

steps@ I 8ax Wear

i*e* >, ' 1+ 0 , %

,, 9elds

8ax WearH:


heat is stepped ?incremented@ ?2''@

+eat increase

between tip

dresses

ip "ress %tepsH:

he number of dress

steps ?'@

"ress new !lectrodeH:

he weld is

inhibited, until the gun

is dressed,

immediately after theelectrode has been

"ress:Re5uestH: he

number of welds before

the max wear that the tip

dress re5uest output is

activated

i.e. (/(# welds

+eat %tepper and tip dressing

General set:up

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General set up

*f activated the weld will be

inhibited when max life is

reached

8ax ReweldsH: this the

number of consecutive

rewelds at one position

he ?%@ indicates that the

function will be activated for

!DD programs

8ax Weld ime, this is the

control of the max weldtime, for all programs

8ode )ressure $utputH

here are several

options for pressureoutput, 9:'mA, ':

'mA, ':'1 output to

the prop valve

his parameter *nhibits the

current 8onitoring on All

programs

A measuring loop chec- is a verification of the current sensor in the secondary circuit.

On < 8easuring loop test active, sensor faults are detected. .

OAA < 8easuring loop test not active, sensor faults are not detected.

#urrent measurement

selects the type of

monitoring, either

secondary or primary

General set:up

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he Fade out ti3e parameter is used to suppress the natural

current rise at the beginning of the weld time for current

measurement

he =rail current parameter is used to activate or deactivate

measurement of the trail current after the last weld time.

On < he trail current is included in the measured result.

OAA < he trail current is not included in the measured result.

oth settings in OS7 3ust 3atch the settings oA the

e'ternal current 3eter Aor co3paratie 3easure3ents*

General set up

!lectrode %et:<p

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!lectrode %et <p

he I ?re9arning parameter indicates the heat

value ?in scale divisions %/@

for which an imminent *

limitation is to be detected for

the electrode displayed.

Bosch sensors have been

adJusted to 2' m1 0 -A.

When using third:party

sensors, the appropriate

transmission ratio can beprogrammed using the

=oroid sensitiit8 parameter

>or details on the

measuring range,

see the next sheet

<pper currrent limit is the

maximum programmable setlimit of the current in the

individual electrode

!lectrode %et:<p

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p

!lectrode %et:<p

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ransformer type. When a pre:

defined transformer is selected,

this automatically selects the

transformer ratio, and the diodetype, *f the transformer type is

un-nown, then you must

program the diode type and

nominal current.

he iode

superision3onitoring

parameter may be used to

deactivate diode monitoring?secondary diodes of the

welding transformer@.

he computational emulation

of the welding diode

temperature determines

whether the Junction

temperature is rising to morethan 2'U#, the switch off

temp can be programmed

from this parameter

Actual welding diode temp

Actual 8ains supply 1oltage

p

!lectrode %et:<p

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>or the calibration

procedures see next

few slides.

p

)ower <nit %et:up

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&'!lectric "rives and #ontrols

imer typeH:

%oftware 0 >irmware

1ersionH:

p

)ower unit type,

8edium fre5uency

*nverter &''' series

"iagnosis <ser:"iagnostics *0$

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g g

Start signalS

this is a signal sent fromthe robot, to initiate the

start of a weld se5uence

depending on the

program: 0spotselection.


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!ckno9ledge tip dressS

after a ip "ress re5uest

is output from the timer, it

is ac-nowledged by a

response from the )=#

only when the robot is in

the tip dresser.

ypically there are

specific weld programs

associated with tip

dressing.

g g


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&3!lectric "rives and #ontrols

&ead8 Weld ti3er< the

status of the weld timer

is healthy and the timeris ready to weld, this

signal stays +i unless a

fault has occurredWeld process error<

this signal only goes hi

when a weld fault has

occurred, it can be

reset via input '9, '2 or

'&

Weld O#< this shows

the status of the

external and internal

weld on, if both are hi

then current can be

passed

g g

"iagnosis %imulate start

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"iagnosis %imulate start

%tarting the weld from the

timer.

)ress the "iagnosticButton

%elect %imulate %tart

%elect the )rogram you

wish to fire.

At the position

%tart with *gnition

clic- once in the O$nP tab

he timer will now execute

a weld

"iagnosis imer information

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"iagnosis =ast Weld

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&&!lectric "rives and #ontrols

g

his page givesyou all information

about the last

weld se5uence.

)lant =ayout

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)lant =ayout

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&;!lectric "rives and #ontrols

y

)lant =ayout

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According to the status

chart on the previous

page, what is the

condition of the timers

on the right KV

. !rror state pending,

i.e. control fault

. !nd of stepper

3. $ffline

#lic- on the imer icon willredirect you to the

timer information page

y

=ogin

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g

*f you want to log in, or change user,

select the change user icon, or press

F12* %elect your username from thedrop down menu and enter your

password

#ompare

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*t is possible to compare data

from one timer to another, or

even to a bac-up stored on

the hard drive.

he data compared will be

displayed under the titles

here.

hen clic- #ompare

#ompare

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)lease wait while the

data is compiled

he number and

type of differences

are then listed.

o view them select

"etail view

#ompare "etails

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. 43!lectric "rives and #ontrols

)rotocols

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Lou can view the

protocols from the

following sub titles.

Error ?rotocols

Weld Aault ?rotocolsata Change

?rotocols

Weld current

?rotocols

!ach one will give you

information about anevent, that has

occurred.

)rotocols

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Lou can also select

specific dates to view.

"ependent on the sie

of the database, you

can have between

2',''' and 2','''entries in the protocol

database

"ata #hange )rotocols

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. 4&!lectric "rives and #ontrols

!ach entry will giveyou information

ate =i3e

=i3er na3e

#a3e oA para3eter

?rogra3 #u3ber Old data

#e9 data

#a3e oA user who

has changed the data

Any co33ents

entered by the user atthe time of the change

"ata #hange )rotocols

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Weld current

protocols are

activated from the

imer reference

page on start up.

*f this option is

6$ selected thispage and the <*R

8onitoring page

will not show any

data.

$verview

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. 4;!lectric "rives and #ontrols

he overview page is very useful for

5uic-ly finding out the status of all the

programs at a glance%elect the button on the right and side

and the active programs for your

selection will appear in pin-

!rror table

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Access to the fault table can also be via the F6

function -ey.

*f more information is re5uired for the actual fault,

double clic- the error description, and more detailed

information will appear.

*f still more information is re5uired, clic- the help

page

!rror table

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he help page will

appear with a complete

description on the fault,

and a possible remedy.

he !rror page is also

used to display statusmessages.

)re:Warning >

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. ;!lectric "rives and #ontrols

he information held on this page,

can be critical for

identifying

. Wear on the caps

. 6umber of remaining parts

3. !lectrode status,

. Green H : healthy

o Access the )re:

Warning page, clic- on the

pre:warning *con or press

the short cut -ey >

F&

)re:Warning >

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can be critical for identifying

. Wear on the caps



. Green H : healthy

. $rangeH : ip dress

re5uired

o Access the )re:



the short cut -ey >

F&

)re:Warning >

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. ;3!lectric "rives and #ontrols



. Wear on the caps



. Green H : healthy


re5uired

3. LellowH : )rewarning

active

o Access the )re:



the short cut -ey >

F&

)re:Warning >

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. Wear on the caps



. Green H : healthy


re5uired

3. LellowH : )rewarning

active

9. RedH : !nd of stepper

life

o Access the )re:Warning

page, clic- on the pre:

warning *con or press the

short cut -ey >

F&

#orrection

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hese are the default

correction figures that are

displayed on the actual

correction page.

*f these parameters are not

programmed , then the

correction parameters can

not be utilised.

%o limits need to be set.

#orrection

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. ;&!lectric "rives and #ontrols

he limits set on the

previous page can

be seen here, ?)@ is

for this specific

program.

?!@ *s for the

complete electrode

B$%&''' ( )%*&''' Weld #ontrol

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>orce #alibration >or Welding Guns>orce #alibration >or Welding Guns

>orce #alibration

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. ;;!lectric "rives and #ontrols

)lease select the correct timer,

from the drop down menu

%elect the calibration routines. hese

can found on the !lectrode )age

!nsure that the ransformer ype,

and <pper current limit are set

correctly

o access >orce #alibration

)ress the >orce #alibration /ey

>orce #alibration

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1+ ype here the upper

and lower pressurelimits for the calibration

routine ? ensure that

you are not in the force

limitation@

he lower limit should

be set to around 'to allow for accurate

pressure for tip "ress

Routines.

6+ %elect here the)rogram you wish to use

for the calibration

routine. Lou should

select a program that is

associated with the

relevant electrode you

wish to calibrate

he /6 display is only

used with %ervo Guns.)+ )ress the $/

button to enter the

next screen

2+ *f you want to

change the values,place a tic- in the box

before you type in the

new values. he

changes will then be

stored for the next time

the routine is entered.

>orce #alibration

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. 7'!lectric "rives and #ontrols

,+ As this screen appearsyou should hear the

proportional valve either

pressurise or exhaust to

the upper limit value set in

the previous screen.

7+ Lou should now

manually close the Gunonto the force meter.

+ !nter the read value

into the upper box.

.+ o proceed press !nter

on your )# this enters the

upper limit actual value

into the timer.

/+ open the gun

>orce #alibration

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As !nter is pressed you shouldhear the )ar-er )roportional valve

exhaust to the lower limit set on the

previous screen.

1+ Again close the Gun onto the

force meter.

11+ !nter the read value into the

lower box and press the !nter -eyon your )#

his enters the lower limit actual

value into the timer.

12+ As the $/ button is pressed an

information point appears showing

the value of the now calibrated8ax. )ressure.

*f this is o-. for your gun C

)ress $/ to Accept this.

16+ As the $/ button is pressed an

information point is displayed.

)ress $/ to accept this.

0As a rule: the upper and lower alue must !e inthe operating range o" the gun #

>orce #alibration

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1)+ Lou should now return to the

%e5uence page and close theGun on the force meter to test the

)rogrammed )ressure set in the

Base )ressure 1alue.

?lease note<- check the IO

page to see 9hich progra3

is being actiated*

=he pressure in this progra3

Will be output to the prop ale*

>orce #alibration

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1,+ he calibration routine has set the

figures shown .

*f after adJustment the measured

values are found to be out of range

another >orce #alibration routine

should be carried out.

B$%&''' ( )%*&''' Weld #ontrol

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#urrent #alibration >or Welding Guns#urrent #alibration >or Welding Guns

#urrent #alibration

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?reparation

!nsure that the following

settings are made

*n the General ab the

#urrent 8easurement

8ode should be set

correctly.

1+ *f you have a

secondary toriod

attached to the gun armor in the transformer,

then secondary should

be selected.

*f not, then primary

should be selected.

#urrent #alibration

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2+ %elect the calibration routines

which are located on the !lectrode)age

6+ !nsure that the ransformer

ype, and <pper current limit are

set correctly

)+ !nsure that the "iodes

settings are as follows

,+ o access #urrent %caling)ress the #urrent %caling /ey

#urrent #alibration

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7+ ype here the upper

and lower heat limits forthe calibration routine

? As a rule the upper

limit should be ' more

than the value of the

lower limit@

.+ %elect here the)rogram you wish to use

for the calibration

routine. Lou should

select a program that is

associated with the

relevant electrode you

wish to calibrate.

/+ )ress the $/

button to enter the

next screen

+ *f you want to

change the values,

place a tic- in the box

before you type in the

new values. he

changes will then be

stored for the next time

the routine is entered.

#urrent #alibration

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. 7;!lectric "rives and #ontrols

1+ Lou should nowplace a calibrated "#

#urrent meter over

the secondary of the

Gun.

11+ !nsure the gun

head is closed beforeyou start the weld.

12+ )ress the %tart

Wld button to perform

a short circuit weld

#urrent #alibration

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16+ Read the recorded

value from the #urrent8eter and enter it into

the <pper +eat

8easured #urrent box

as shown

1)+ )ress the !nter /ey

and a OP appears at the

side of the box indicatingthat the first reading

attempt has been carried

out and the data has

been sent to the timer.

1,+ Again press the %tart


another %hort #ircuitWeld and repeat the

steps above. his time

when the !nter /ey is

pressed a OP appears

indicating the second

attempt.

#urrent#urrent #alibration

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. ''!lectric "rives and #ontrols

&0 6ow press the continue

-ey to proceed to the lower

heat limit calibration routine

40 Again press the %tart


another %hort #ircuit Weld.

#urrent #alibration

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. '!lectric "rives and #ontrols

1.+ Read the recorded

value from the #urrent

8eter and enter it intothe =ower +eat

8easured #urrent box

as shown.

1/+ )ress the !nter /ey

and a OP appears at the

side of the box indicating

that the first readingattempt has been carried

out and the data has

been sent to the timer.

2+ Again press the %tart


another %hort #ircuit

Weld and repeat thesteps above. his time

when the !nter /ey is

pressed a OP appears

indicating the second

attempt.

#urrent #alibration

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21+ 6ow press the continue

-ey to exit the #urrent

#alibration Routine

22+ When the #ontinue /ey

is )ressed an *nformationpoint appears that shows the

new calibrated oroid %ens.

26+ At this point the

%econdary of the Gun can

be opened and you can

proceed with $/

#urrent #alibration

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. '3!lectric "rives and #ontrols

2)+ Lou should now return to the

%e5uence page and manually close theGun. he #urrent meter should

%till be in place to test the

)rogrammed #urrent set in the

Weld +eat 1alue.

Lou can either fire the %hort circuit

Weld from the control panel or fire

the se5uence with the bos&'''

%oftware by using the procedure on

the next page.

Bos&''' %et:<p, +eat %tepper #urves

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Lou can also create

your own curve, by

dragging the line into

the re5uired position or

by typing the re5uired

figure directly into the

specific box

+eat stepper curves

can be accessed via

the setup icon.

%everal curves are

standard, they can be

selected by the curve

number.

Bos&''' %et:<p #ontinued

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ip dress curves, as with

heat stepper curves areselectable, or can be

created.

#ommunications page

shows confirmation of

the !thernet address,

with the subnet mas-.

With error reference page, you have

the ability to program the severity of

the fault into a warning if re5uired. A

fault will inhibit the weld from starting,

A warning will not inhibit the weld

Bac-ing up ..T

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. '&!lectric "rives and #ontrols

>rom any page the drop

down menu should be

visible,

%elect !dit, and thenbac-up

$r #trl I B

$nce selected , thenext option is to pic-

which imer or imer s

are to bac-ed up.

By clic-ing on the top

box, all timers will be

selected, or individual

timers can be selected

by clic-ing on the box

adJacent to the timer

name

he bac-up path and folder is located here.

An alternative can be selected by selecting the K button,

and choosing a new location

When ready press

$/

Bac-ing up ..T

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1he status of each timercan be seen as thebac2up is proceeding

Bac-ing up ..T

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. ';!lectric "rives and #ontrols

Restoring "ataK.

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1* >rom the next page,

you have to select

which bac-up needs tobe restored, select the

browse -ey

. >rom the imer

reference page, select

the Restore Button

Restoring "ataK.

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2* >ind the bac-up file

that will be restored.

6oteH this will be a ip

file.

hen select open

Restoring "ataK.

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. !lectric "rives and #ontrols

6* %elect $/ to start the

restore process.

Restoring "ataK.

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)* With the next screen

you have a chance to

review the file data you

are restoring, you can

also see what is already

in the timer, %elect $/

to start restoring the

data bac- into the

database

Restoring "ataK.

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,* he data is now

being sent to the

database,

after a short while, you

will get notification of

completion

3. 4lic2 4ontinue

to complete the

restore function

+elp page >

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1he Help page can beaccessed by pressingthe F! function 2ey onyour 2eyboard, or byclic2ing on the Helpmenu.

If you have a specic5uery, !st highlight thespecic parameter, thenpress the F! 2ey.

F!

+elp page >

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1he Help page can beaccessed by pressingthe F! function 2ey onyour 2eyboard, or byclic2ing on the Helpmenu.

If you have a specic5uery, !st highlight thespecic parameter, thenpress the F! 2ey.

1he help page that now

appears will be relevantto the parameter thatyou have high lighted

F!

+ow to extract spatter data from the B$%&'''

software

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. &

Within the B$%&''' software is a %pot 0 !xpulsion overview page.

his can show the user an over view of the spatter that exists on a complete

line )#, or on an individual timer, thereby assisting in spatter detection and

subse5uent removal.

his page can be exported as a text file and then imported into excel.

"ata can be shown program specific or spot number specific.

*f you wish to view the data with the spot table an additional re5uirement is

to ensure the spot table has been extracted from the timer first. %ee the

next few slides for details on how to extract the spot table.

+ow to extract the spot table from the B$%&'''

software

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. 4

!nsure thatbefore

you extract the

spatter data, the spot

table has been

extracted.

#lic- on add


software

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© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. ;

%elect %pot able XC

imer.


software

7/26/2019 2011 Bos6000_V1_36_0 _PSI201_EN_11_02_18


© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. 7

he spot table then

be displayed.


software

7/26/2019 2011 Bos6000_V1_36_0 _PSI201_EN_11_02_18


© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. '

Within the B$%&'''.

"rop down menu,>unction.

%pot 0 !xpulsion

$verview ?#trlI>3@


software his screen will be shown

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his screen will be shown.

%elect the configuration of the data, %pot name

or program 6o

%elect a date and time from the drop downmenu, this will be the start of the data to be

extrapolated.

%elect a date and time from the drop down

menu, this will be the end of the data to be

extrapolated

*f you wish all programs or spots to shown

regardless of the expulsion status tic- the box

%elect update to display the data


software

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"ata is displayed and can be

sorted according to your

re5uirements via the headings

at the top of the page.

his information can beexported, and displayed in excel

for further diagnosis.

he expulsion data is

calculated and displayed

graphically as well as

numerically

2011 Bos6000_V1_36_0 _PSI201_EN_11_02_18

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Transcript of 2011 Bos6000_V1_36_0 _PSI201_EN_11_02_18