Bosch Rexroth PS5000 Comissioning, Operating Instructions
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Bosch Rexroth PS5000 Comissioning, Operating Instructions

Operating and diagnostic terminal bt 6.00
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Electric Drives
and Controls
Hydraulics
Rexroth PS5000 / PS6000
Operating and Diagnostic Terminal
BT 6.00
Comissioning, Operating Instructions
Linear Motion and
Assembly Technologies
Pneumatics
Service
1070080078
Edition 03

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Summary of Contents for Bosch Rexroth PS5000

  • Page 1 Electric Drives Linear Motion and and Controls Hydraulics Assembly Technologies Pneumatics Service Rexroth PS5000 / PS6000 1070080078 Edition 03 Operating and Diagnostic Terminal BT 6.00 Comissioning, Operating Instructions...
  • Page 2 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Title Rexroth PS5000 / PS6000 Operating and Diagnostic Terminal BT 6.00 Type of Documentation Commissioning, Operating Instructions DOK-PS6000-BT6.00*****-IB03-EN-P Document Typecode The present manual provides information on Purpose of Documentation D Structure, installation, connection and D Operation of the control and diagnostic terminal BT 6.

  • Page 3: Table Of Contents

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG and Controls Contents Contents Page Safety Instructions ..... . .
  • Page 4 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Contents BT 6 Firmware version .......

  • Page 5: Safety Instructions

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 1−1 and Controls Safety Instructions Safety Instructions The products described were developed, manufactured, documented and tested in compliance with the fundamental safety requirements of the EU machinery directive. These products normally pose no danger to...

  • Page 6: Safety Instructions In This Manual

    1−2 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Safety Instructions Safety Instructions in this Manual DANGEROUS ELECTRICAL VOLTAGE This symbol is used to warn of dangerous electrical voltage. The fail- ure to observe the instructions in this manual in whole or in part may re- sult in personal injury.

  • Page 7: Intended Use

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 1−3 and Controls Safety Instructions Intended Use The product described D serves in connection with a suitable weld timer (PS 5000, PS 6000) to − display and change parameters − display and reset faults...

  • Page 8: Environmental Protection, Recovery Of Materials And Re-Use 1−4

    1−4 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Safety Instructions Environmental protection, recovery of materials and re-use Environmental protection Our products do not contain any hazardous materials which may be re- leased by their intended use. Therefore, no negative effects on the envi- ronment are to be expected under normal circumstances.

  • Page 9: Qualified Personnel

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 1−5 and Controls Safety Instructions Qualified Personnel The requirements as to qualified personnel are based on the require- ment profiles defined by the ZVEI (Zentralverband Elektrotechnik und Elektronikindustrie − German Electrical and Electronic Manufacturers’...
  • Page 10 1−6 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Safety Instructions No entry for persons with cardiac pacemakers! Danger! Please note our comprehensive range of training courses. More infor- mation is available from our training center (Phone: +49 (6062) 78-600).

  • Page 11: Installation And Assembly

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 1−7 and Controls Safety Instructions Installation and assembly DANGEROUS ELECTRICAL VOLTAGE Danger of life when performing assembly works on live systems! Please ensure that all plant sections worked on in the course of the...

  • Page 12: Electrical Connection

    1−8 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Safety Instructions Electrical Connection DANGER Danger of life through inappropriate EMERGENCY-STOP devices! EMERGENCY-STOP devices must be active and within reach in all system modes. Releasing an EMERGENCY-STOP device must not...

  • Page 13: Operating The Product

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 1−9 and Controls Safety Instructions Operating the product DANGER One has to expect that magnetic fields are present in the vicinity of resistance welding systems, which are above the limits speci- fied in VDE 0848 Part 4.

  • Page 14: Retrofits And Modifications By The Operator

    1−10 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Safety Instructions DANGER Danger of bruises and of being caught by electrode and/or work- piece movements! All users, line designers, welding machine manufacturers and welding gun producers are obliged to connect output signals which initiate the electrode movement so that the applicable safety regulations are complied with.

  • Page 15: Maintenance, Repair

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 1−11 and Controls Safety Instructions 1.10 Maintenance, repair DANGEROUS ELECTRICAL VOLTAGE Unless described otherwise, maintenance works must be performed on inactive systems that have been sufficiently protected against reclosing! Measuring or test activities that might be necessary on the live...

  • Page 16: Safe Working Practices

    1−12 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Safety Instructions 1.11 Safe working practices DANGER Program start is immediately possible after fault reset! If the start signal is present when an error is reset (acknowledged),...

  • Page 17: Ce Marking

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 1−13 and Controls Safety Instructions 1.12 CE Marking CAUTION The CE mark for the described combination of devices is applica ble for use in industrial environments. For other combinations/applications, the certificate must be de- rived from the above requirements, or a new certificate must be is- sued, if necessary.

  • Page 18: Documentation, Software Release And Trademarks

    1−14 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Safety Instructions 1.13 Documentation, software release and trademarks Trademarks All trademarks of software installed on Rexroth products upon delivery are the property of the respective manufacturer. Upon delivery, all installed software is copyright-protected. The software may only be reproduced with the approval of Rexroth or in accordance with the license agreement of the respective manufacturer.

  • Page 19: Overview

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 2−1 and Controls Overview Overview This manual contains information on D the mechanics D the electrical connection and D the functions of the control and diagnostic terminal − BT 6.00 (built-in terminal) and −...
  • Page 20 2−2 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Overview Notes:...

  • Page 21: Assembly And Connection

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 3−1 and Controls Assembly and Connection Assembly and Connection BT 6.00 − Built-in unit 3.1.1 Dimensions and assembly Weight : ca. 0.6 kg Location: desk or hinged frame or control cabi- net;...
  • Page 22 3−2 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Assembly and Connection Required Front panel dimensions assembly cutout +1, −0 +1, −0 All dimensions in mm. Front panel thickness: 4 mm Required installation depth: approx. 40 mm.
  • Page 23 1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 3−3 and Controls Assembly and Connection Run all connection cables in loops, and use strain reliefs for all cables. Fasten the BT 6.00 with the 2 fastening clamps included in the delivery: 1.

  • Page 24: Connection

    3−4 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Assembly and Connection 3.1.2 Connection For operation, the BT 6.00 needs the power supply to X1 as well as the communication port X2 (RS 232 C, connected to X1 of the weld timer).
  • Page 25 1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 3−5 and Controls Assembly and Connection Power supply (X1) Connection: Screw-type terminal connector, Phoenix Combicon, 3-pole, max. 2.5 , MSTBV 2.5 / 3 − GF. Mating connector (female) is comprised in the delivery.
  • Page 26 3−6 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Assembly and Connection Communication (X2) Connection: Subminiature D, female, 9-pin Type: RS232C, electrically isolated Cable length: max. 15m Cable type: LiYCY; shielded, concentrically stranded; min. core area of 0.25 mm...

  • Page 27: Bt 6.00 − Hand-Held Programming Terminal (Bt 6.00 Hpg) 3−7

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 3−7 and Controls Assembly and Connection BT 6.00 − Hand-held programming terminal (BT 6.00 HPG) Dimensions (WxHxD; in mm): 130 x 201 x 52 Weight : approx. 1.2 kg Enclosure:...

  • Page 28: Connection

    3−8 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Assembly and Connection When using the manual programming terminal, please also note the information relevant for operation in Section “Safety Instructions”. Within the functioning range of the manual programming terminal, the operator’s view of any moving machine elements must never be ob-...
  • Page 29 1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 3−9 and Controls Assembly and Connection Power supply: via pin 15 (+24V) and pin 11 (0V). Safety extra-low voltage (SELV) in accor- dance with DIN EN 61131. 19.2 ... 30.2 V typ.
  • Page 30 3−10 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Assembly and Connection Notes:...

  • Page 31: Operation

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 4−1 and Controls Operation Operation The BT 6 gives you access to important user- and control-specific data of the production process (e.g. display/modification of welding parame- ters, reset counters after electrode change, display of I/O signals pres- ent, etc.).

  • Page 32: Control Elements Of Bt 6 − Overview

    4−2 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Operation Control elements of BT 6 − Overview 1 Display. 4 lines with 20 characters each can be displayed. For contrast setting, refer to page 4−12. 2 Function keys for direct selection of a main menu entry.
  • Page 33 1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 4−3 and Controls Operation 4 Insertable stripes for labeling the function keys (cf. 2). The delivery contains a labeled (”F1” to ”F6”) and an unlabeled insert- able stripe. 5 Fault display key.

  • Page 34: Main Menu Items And Their Functionality − Overview

    4−4 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Operation Main menu items and their functionality − Overview The scope of functions depends on the timer type connected! For example, the number and representation of parameters or menu items offered may be different, depending on the timer type used.
  • Page 35 1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 4−5 and Controls Operation D FPO (freely programmable output). Options: − Activate / deactivate the output − Display and change on/off times D Control mode. Options: − Display and change of control mode D Sequence setup.

  • Page 36: Selection Of Main Menu Items And Navigation In Sublevels 4−6

    4−6 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Operation Selection of main menu items and navigation in sublevels Proceed as follows: 1. Press key. 2. Move the cursor to the desired line with the keys 3.

  • Page 37: Quick Mode

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 4−7 and Controls Operation Quick mode You may use the Quick mode in order to call up a certain screen of any sublevel without any detours. Proceed as follows: At any time, you may...
  • Page 38 4−8 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Operation 4.4.1 List of parameter numbers for quick mode The availability of individual parameter numbers depends on the timer type connected! Active range Description Parameter number (alternative description) Weld program se- 1.Squeeze time...
  • Page 39 1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 4−9 and Controls Operation Active range Description Parameter number (alternative description) Current monit. 1.Wld Reference curr. 1.Wld Cond. Tol.Band 1.Wld Repeat factor 1.Wld Upper Tolerance 1.Wld Lower Tolerance 1.Wld Current monit. 2.Wld Reference curr.
  • Page 40 4−10 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Operation Active range Description Parameter number (alternative description) Reference curr. 1.Wld Commanded current 1.Wld Actual current 1.Wld %heat 1.Wld 2.Weld time (weld current time): − Reference curr. 2.Wld Commanded current 2.Wld...

  • Page 41: Special Control Functions

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 4−11 and Controls Operation Special control functions 4.5.1 Display error messages The BT 6 informs you through the flashing LED in key that one or sev- eral errors have occurred.

  • Page 42: Set Lcd Contrast

    4−12 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Operation 4.5.3 Set LCD contrast The contrast of the display can be set as needed. In a well-lighted work environment you should increase the contrast, in a less bright environ- ment you should reduce it.
  • Page 43 1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 4−13 and Controls Operation 3. Press key 4 times. 4. If a master key number has already been assigned, the BT 6 now ex- pects input of this master key number.

  • Page 44: Display Electrode Wear / Reset Counter

    4−14 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Operation 12. Press the key in order to display the next screen for code number input. In order to change code numbers, proceed to 10. Otherwise, procee- d to 12.

  • Page 45: Display Data Of The Last Weld

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 4−15 and Controls Operation 4.5.6 Display data of the last weld You may have the BT 6 show D the schedule that performed the last weld. D the commanded current, actual current and heat value most recently used by a certain schedule.

  • Page 46: Display I/O Signals

    4−16 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Operation 4.5.7 Display I/O signals All input and output signals of the timer can be visualized on the BT 6. Proceed as follows to display the signals: 1.

  • Page 47: Maintenance

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 5−1 and Controls Maintenance Maintenance Battery A battery is integrated to back up the internal data. Battery type: Lithium Size: Voltage: 3.6 V When the remaining battery capacity becomes critical, the BT 6 gener- ates the fault message ”BT6 battery low”.
  • Page 48 5−2 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Maintenance 7. Loosen the housing screws (1) and the threaded bolts of the inter- faces (2). Remove housing: Side view − − Reinstall housing: 2 2 2 2 −...

  • Page 49: Fusing

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 5−3 and Controls Maintenance Fusing The BT 6 is equipped with a self-regenerating semiconductor fuse. Therefore, the fuse need not be replaced after a trip. If the fuse was tripped, proceed as follows: 1.

  • Page 50: Load Firmware Version

    5−4 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Maintenance 5.3.2 Load firmware version In rare cases, it may be necessary to update the BT 6 firmware. Firmware updates may only be carried out at the instruction of the Rexroth service! All code numbers (cf.
  • Page 51 1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG 5−5 and Controls Maintenance 10. Connect the BT 6 to the weld timer. Communication with the weld timer is automatically reestablished. 11. Display the firmware version (cf. section 5.3.1, page 5−3).
  • Page 52 5−6 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Maintenance Notes:...

  • Page 53: A Annex

    1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG A−1 and Controls Annex Annex Abbreviations General abbreviation for current, can be Protective Earth measured in kA or in SKT (scale values) Programming device / welding computer Alternating Current Phase angle (shift)

  • Page 54: Index

    A−2 Bosch Rexroth AG Electric Drives BT 6.00 1070080078 / 03 and Controls Annex Index Adapter, 3−7, 3−9 I/O signals, 4−16 Assembly, 1−7, 3−1 Installation, 1−7 Assembly cutout, 3−2 Installation depth , 3−2 Assembly cutout for built−in unit, 3−2 Intended use, 1−3 Interfaces, RS232, 3−6...
  • Page 55 1070080078 / 03 BT 6.00 Electric Drives Bosch Rexroth AG A−3 and Controls Annex Signals, 4−16 Spare parts, 1−11 System language, 4−11 Temperature ranges, 3−1, 3−7 Test activities, 1−11 Trademarks, 1−14 Training center, Phone, 1−6 Ventilation, 3−2 Weight , 3−1, 3−7 Welding splashes, 1−12...
  • Page 56 Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Phone +49 (0)93 52-40-50 60 +49 (0)93 52-40-49 41 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany 1070080078 DOK-PS6000-BT6.00*****-IB03-EN-P...

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