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Bosch BT220 Technical And Operations Manual

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PS 5000
Operating Terminal BT 220
Technical Information and Operation
101
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  • Page 1 PS 5000 Operating Terminal BT 220 Technical Information and Operation Version...
  • Page 2 1070 080 037-101 (99.01) GB Reg. No. 16149-03 E 1999 by Robert Bosch GmbH, Erbach / Germany All rights reserved, including applications for protective rights. Reproduction or handing over to third parties are subject to our written permission. Discretionary charge 20.00 DM...

  • Page 4: Table Of Contents

    Display and Acknowledge Events, if necessary ....Display / Change Internal Time Setting of the BT220 ... .
  • Page 5 ....... . 5-30 5.13 Overview: BT220 Specific Functions and Parameters ...

  • Page 6: Safety Instructions

    BT220 Technical Information and Operation Safety Instructions Safety Instructions The product described hereunde was developed, manufactured and tested in accordance with the basic safety stipulations of the EC Machine Directive. You should nevertheless be aware of residual risks! You should therefore read this manual before mounting, setting up, commis- sioning or programming the system or working with this control system for the first time.
  • Page 7 BT220 Technical Information and Operation Safety Instructions There is a certain hierarchy of warnings in this manual. The warnings are printed in bold letters and marked by a warning sign at the margin. The hierarchy of the warnings is as follows: 1.

  • Page 8: Warning Of Magnetic Fields

    BT220 Technical Information and Operation Safety Instructions Warning of magnetic fields In the environment of resistance welding systems magnetic field strengths have to be expected which usually are below the limits specified in VDE 0848 Part 4; in cases of doubt, the field strength must be measured.

  • Page 9: Normal Use

    BT220 Technical Information and Operation Safety Instructions Normal use In conjunction with the connected PS 5000 weld timer the Operating terminal serves for the ‘ Display and change of parameters ‘ Display of faults, warnings and signals It is only suitable for ‘...

  • Page 10: Retrofits And Modifications By The User

    ATTENTION! The right to perform repair/maintenance work on the timer compenents is reserved to the BOSCH service department or to repair/maintenance units authorized by BOSCH! Only use spare parts/replacement parts approved by BOSCH! −...

  • Page 11: Installation And Assembly

    BT220 Technical Information and Operation Safety Instructions Installation and assembly ATTENTION! Please observe all applicable safety and accident prevention regula- tions! Danger of damage to property through short-circuits! When drilling or sawing out openings, metal burr may get inside modules or plant sections that have already been installed.

  • Page 12: Units Without Monitoring Contact Ük

    Danger of bruises through electrode movement! All users, line designers, welding machine manufacturers and welding gun producers are obliged to connect the output signal of the Bosch weld timer which initiates the electrode movement so that the applicable safety regulations are complied with.

  • Page 13: Working Safely

    BT220 Technical Information and Operation Safety Instructions Working safely WARNING! During operation of the welding equipment welding splashes are to be expected! The consequence may be injuries to the eyes or burns. Therefore: ‘ wear protective goggles ‘ wear protective gloves ‘...

  • Page 14: Overview

    Because of this the BT220 is available to you as a stationary control ter- minal of your PS 5000 (supported control types: PSS 5100.510 and PSS 5200.510;...

  • Page 15: Fig. 2-2: Connection Of A Ps 5000

    STK is already prepared for the connection of 3 PS 5000. It can be easily retrofitted with additional plug-in RS232 interface modules. For communication with a BT220-x, the multi-contact interface board is optionally available with a separate RS485 or RS232 interface.

  • Page 16: Fig. 2-3: Connection Of 2 Ps 5000

    7th PS 5000 Channel 4 Channel 8 RS232 RS232 RS485 Cable lengths for BT220-x - RS232 connections max.15m - RS485 connections max.1000m Fig. 2-4: Connection of max. 7 PS 5000 to BT220 via STK multi-contact interface board 1070 080 037-101 (99.01) GB...
  • Page 17 BT220 Technical Information and Operation Overview 1070 080 037-101 (99.01) GB...

  • Page 18: Installation And Assembly

    BT220 Technical Information and Operation Installation and Assembly Installation and Assembly The BT220 is intended for installation in a control panel, a control cabinet or a front plate. Weight: approx. 1.5 kg Installation position: 0_ to max. 90_ slant Installation type: in a desk or hinged frame, sealed as per IP 65 Degree of protection: IP 65 (front face);...
  • Page 19 BT220 Technical Information and Operation Installation and Assembly ’ Fix the BT220 with the 4 screw terminals. For this purpose, first insert the BT220 into the assembly cutout and then engage the screw terminals in the recesses on the top and bottom sides of the BT220 housing.

  • Page 20: Electrical Connection

    X5: RS232 interface for the connection of PS 5000, or STK multi-contact interface board Fig. 4-2: Connections on the BT220-2 Remarks BT220-2: If an STK multi-contact interface board is connected to X5, only a report printer may be connected to X4. 1070 080 037-101 (99.01) GB...

  • Page 21: Power Supply (X1)

    BT220 Technical Information and Operation Electrical Connection PE/Screening X1: 24 VDC power input X2: Outputs (indicator lamps, ready state) X4: RS232 interface for connection of report printer X5: RS485 interface for connection of STK multi-contact interface board Fig. 4-3: Connections on the BT220-3/7...

  • Page 22: Lamp And Ready Outputs (X2)

    The outputs for the display of warnings and fault messages are functionally identical with the warning (red LED) and fault message (yellow LED) on the front panel of the BT220. The output signals are static (not flashing). NOTE Overloading the output drivers possible! ’...

  • Page 23: Rs232 Interfaces

    PS 5000 (X1; Sub-D, 9-pin) BT220 max. 15 m Plug Socket Shield continuity via the metal housing of the plug connection, or via a spade connector on the housing Fig. 4-6: Connection of PS 5000 to BT220 1070 080 037-101 (99.01) GB...

  • Page 24: Fig. 4-7: Connection Of A Serial Printer

    Connection of a Serial Printer Remarks Many printers output the READY signal to Pin 20. In such cases the CTS input on the BT220 must be connected with Pin 20 on the printer. RS232 Connection: STK (Channel 4; Sub-HD, 15-pin)

  • Page 25: Rs485 Interface

    BT220 Technical Information and Operation Electrical Connection RS485 Interface BT220-3/7: X5 Connection: Sub-D socket, 25-pin. Type: RS485 Lead length: max. 1000m Lead type: 2-wire, twisted and shielded, core cross-section min. 0.14mm Transmission rate: adjustable: 38400, 57600, 76800, 115200 bits/s Parameters:...

  • Page 26: Operation

    Help texts, depending on the current status. shows the day, date, time and calendar week (see page 5-3). MEN depending on the current status of the BT220: calls up the Main Menu of the BT220 (for menu tree see page 5-33) cancels parameter changes cancels a function awaiting acknowledgment.

  • Page 27: Display And Acknowledge Events, If Necessary

    Cursor keys Fig. 5-2: Front View BT220 After it is switched on the BT220 is in Message Display Mode. All events which are transmitted by the connected weld timers can be displayed and acknowledged, if necessary. If no event has occurred, the text “No message” is shown in the display (see Figure).

  • Page 28: Display / Change Internal Time Setting Of The Bt220

    The language for message and menu texts can be set. The BT220 offers German and English as standard. Other languages can be added as re- quired (max. 10 in total). In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). Procedure 1 Press the MEN key.

  • Page 29: Displaying / Changing Welding And Process Data

    Display and change heat correction parameters of all electrodes. To display or change the welding or process data of all programs of the con- nected PS 5000, switch the BT220 to the ”Function Key Mode”. 1070 080 037-101 (99.01) GB...
  • Page 30 The BT220 in this case automati- cally returns to the last active display level of the function key mode. In the following description of the procedure we assume that the BT220 is in the message display mode (see chapter 5.1, page 5-2).
  • Page 31 BT220 Technical Information and Operation Operation = press corresponding key Function Key Mode (Main Menu) from F9 to F9 Message display mode F1 Help To the individual (see A) sub-menus: see page F2 Sequence (see A) see page F3 Monitoring...

  • Page 32: Selection Of Program And Weld Timer

    Numbers of timers not connected (TIMx) are not recognized on selection and not accepted. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6). = press corresponding key Change pro-...

  • Page 33: F2: Sequence

    2. heat, pulsation, 2. cool time, 3. weld time, 3. cool time, 3. heat, hold time, off time. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F2: Sequence”. Back to the Main...

  • Page 34: F3: Monitoring

    Monitoring is deactivated for weld time. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F3: Monitoring”. 1070 080 037-101 (99.01) GB...
  • Page 35 BT220 Technical Information and Operation Operation Back to the Main Menu = press corresponding key " Scroll display forward or backward Call up Sub- Monitoring Menu proceed to B Monitoring Scroll display for- ward or backward Is STANDARD mode selected?

  • Page 36: F4: Data Of The Last Weld

    In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F4: Last Weld”. Back to the Main...

  • Page 37: F5: Slope

    In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F5: Slope”.

  • Page 38: F6: Pressure Profile

    Only when the pressure control function is active can the individual pressure parameters be displayed/changed. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F6: Pressure Profile”. = press corresponding key...

  • Page 39: F7: Stepper Diagnostics

    ”Electrode Change” (individual or all electrodes) In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F7: Stepper Diagnostics”. = press corresponding key...

  • Page 40: F8: Fpo_1 (Freely Programmable Analog Output)

    Only when the analog output is activated can the individual parameters be displayed/changed. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F8: FPO_1”. = press corresponding key...

  • Page 41: F9: Heat Correction

    BT220 and the weld timer has been re-established. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F9: Heat Correction”. = press corresponding key...

  • Page 42: Deleting The Message Memory

    Normally each entry is removed again from the message memory in this way. As an exception it can happen that the BT220 may not receive a ”Depart message” for an event present. This effect may for example happen when during an event the communica- tion between BT220 and PS 5000 is interrupted for some reason and during the interruption the event again changes to logically FALSE;...

  • Page 43: Display Diagnostic Memory

    Operation Display Diagnostic Memory To log all events the BT220 has a diagnostic memory with a battery back-up. It is structured as a ring memory and comprises a maximum of 400 entries. Should the memory be completely full the oldest entry is overwritten by the new entry.
  • Page 44 BT220 Technical Information and Operation Operation Should you reach the beginning or end of the diagnostic memory, the BT220 displays the message ”Selected time period exceeded!” (see Figure below). to change between both information blocks of an entry: press Y or B to return to the message display mode: press MEN key twice.

  • Page 45: Printing The Diagnostic Memory

    ’ When switched on, the PS 5000 should not be disconnected from the BT220-1! ’ For this reason use the BT220-2 or BT220-3/7 if you want to use the ”Print” function. For printing you need a printer with a serial interface. On page 4-5 you will find instructions for connecting a printer.
  • Page 46 BT220 Technical Information and Operation Operation corresponding message. Acknowledge the message with and then press the MEN key. The BT220 returns to the message display mode. ’ If you do not want to limit the evaluation time: Press key . Proceed to step 8.
  • Page 47 BT220 Technical Information and Operation Operation Unsorted (= only in chronological order) __________________________________________ No.: arrive:_________ depart:___ quit:___ TIM 1: Weld without command 81 21.04.98 20:19:44 20:19:50 20:19:49 __________________________________________ No.: arrive:_________ depart:___ quit:___ TIM 1: Sequence inhibited program 94 21.04.98 20:20:06 20:20:11 20:20:10 _________________________________________ No.: arrive:_________ depart:___ quit:___...

  • Page 48: Deleting The Diagnostic Memory

    ’ Therefore, you should print the diagnostic memory contents before the deleting if the memory contains important data (for printing see page 5-20). In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). Procedure 1.

  • Page 49: Adapting The Bt220 Display

    First value without priority: the oldest event is displayed first. In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). Procedure 1. Press the MEN key.

  • Page 50: Setting The Flash Rate

    Events which have to be acknowledged are shown in the display as flashing text. The times for the on and off phases are adjustable. In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). Procedure 1.

  • Page 51: Setting "Automatic Message Scrolling

    Operation 5.9.3 Setting ”Automatic Message Scrolling” In case of events with a text of more than 2 lines, the BT220 only shows the first 2 lines initially. The remaining text can then be made visible in the follow- ing way:...

  • Page 52: Display Parameters

    Please note that a reduced brightness protects the VFD tube of the display monitor. In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press the MEN key.

  • Page 53: Testing The Bt220 Keyboard

    5.10 Testing the BT220 Keyboard If need be you can test the keyboard for proper functioning. In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). Procedure 1. Press the MEN key.

  • Page 54: Configuring The Printer Interface (X4)

    (inc. any necessary Handshake leads), the interface parameter settings of both units are identical. In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press the MEN key.

  • Page 55: Inhibiting The Control Function

    Operation 5.12 Inhibiting the Control Function To protect the BT220 from unauthorized access a 4-digit freely definable key code can be assigned both to the menu items within the BT220 (see page 5-33) and to the menu items in the function key mode (see page 5-6).
  • Page 56 BT220 Technical Information and Operation Operation In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press the MEN key. Procedure The menu item ”Diagnostic memory” appears in the second display line.
  • Page 57 BT220 Technical Information and Operation Operation 16.- To select an entry: Press Y or B. To change the data of the selected entry: Press the VAR key. To cancel the function: Press the MEN key twice. 17.The cursor flashes in the first line.

  • Page 58: Overview: Bt220 Specific Functions And Parameters

    A see B Change key code (p. 5-30) Test functions Key test (p. 5-28) see B Change language (p. 5-3) see B Fig. 5-15: Menu Tree of the BT220 Specific Functions and Parameters 1070 080 037-101 (99.01) GB 5-33...
  • Page 59 BT220 Technical Information and Operation Operation 1070 080 037-101 (99.01) GB 5-34...

  • Page 60: Maintenance

    1. Switch the unit off. 2. Remove all connection cables from the BT220. 3. Make sure that the BT220 cannot fall out of the assembly cutout and loosen the screw terminals on the top and bottom of the BT220 housing.

  • Page 61: Reset

    BT220 Technical Information and Operation Maintenance Reset Should a software reset of the BT220 be necessary (e.g. after faults of the BT220), proceed as follows: 1. Switch off the BT220 power supply. 2. Press and hold down keys ”1” and Y at the same time.

  • Page 62: Appendix

    6 PS 5000: ON ON 7 PS 5000: ON ON Fig. 7-3: Setting the Baud Rate and Number of Connected PS 5000 ’ Make sure that the selected Baud rate is identical with that on the BT220. 1070 080 037-101 (99.01) GB...
  • Page 63 ’ Make sure that pin 15 is not wired. No external consumer should be con- nected without consulting us. Connection: Communication between STK and BT220 is established via a separate in- terface module (RS232 or RS485) on the multi-contact interface board STK - BT220 (channel 4).

  • Page 64: List Of Figures

    ........Fig. 2-4: Connection of max. 7 PS 5000 to BT220 via STK multi-contact interface board .
  • Page 65 BT220 Technical Information and Operation Appendix 1070 080 037-101 (99.01) GB...

  • Page 66: Subject Index

    Close all messages, 5-17 Heat correction, 5-16 Command keys, 5-1 Connection, 4-1 Lamps, 4-3 of PS 5000 to BT220, 4-4 Inhibiting the control function, 5-30 of STK to BT220, 4-5, 4-6 Printer, 4-5 Installation, 1-6, 3-1 PS 5000 to STK, 7-2...
  • Page 67 Qualified personnel, 1-4 Magnetic fields, 1-3 Ready output, 4-3 Maintenance, 6-1 Reset of the BT220, 6-2 Menu Tree of the BT220 Main Menu, 5-33 Message Display Mode, 5-2 Adjust, 5-24 Message memory, delete, 5-17 S1, 7-1 Minimum all-round clearance, 3-1...
  • Page 68 BT220 Technical Information and Operation Appendix Hold time, 5-8 Monitoring Conditional welds, 5-9 Temperature ranges, 3-1 Reference current, 5-9 Test procedures, 1-5 Tolerance, 5-9 Off time, 5-8 TIM, 5-7 Phase angle, 5-11 Tip wear, 5-14 Pre-squeeze time, 5-8 Pressure control...
  • Page 69 BT220 Technical Information and Operation Appendix 1070 080 037-101 (99.01) GB...
  • Page 70 1070 080 037-101 (99.01) GB · HB BT220 · AT/VWS · Printed in Germany...

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