1. Manuals
  2. Brands
  3. Bosch Manuals
  4. Timer
  5. PSI 6XXX.350 L1 Series
  6. Technical information

Bosch PSI 6XXX.350 L1 Series Technical Information

Timer and i/o level
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
PSI 6000
Description of Timer and I/O Level
PSI 6XXX.350 L1
Technical Information
101
Edition

Advertisement

Table of Contents
loading

Related Manuals for Bosch PSI 6XXX.350 L1 Series

Summary of Contents for Bosch PSI 6XXX.350 L1 Series

  • Page 1 PSI 6000 Description of Timer and I/O Level PSI 6XXX.350 L1 Technical Information Edition...
  • Page 2 DIN ISO 9001 Reg. no. 16149-01/2 E 2001 This manual is the exclusive property of Robert Bosch GmbH, also in the case of Intellectual Property Right applications. Without their consent it may not be reproduced or given to third parties.

  • Page 4: Table Of Contents

    Contents PSI 6XXX.350 L1 Contents Page Safety instructions and reader’s information Explanation of pictographs and symbols ....Typographic conventions ....... . . Proper use .
  • Page 5 Contents PSI 6XXX.350 L1 Page Installation ..... . Cables ......Suppression of RF noise .
  • Page 6 Contents PSI 6XXX.350 L1 Page Activating monitoring ......Other adjustments and programs ....9.10 Saving the Welding Parameters .
  • Page 7 Contents PSI 6XXX.350 L1 Your notes: 1070 080 067-101 (2001.03) GB...

  • Page 8: Safety Instructions And Reader's Information

    Safety instructions and reader’s information Automationstechnik Safety instructions and reader’s information Please read this documentation before working with the Weld Timer (WT) PSI 6XXX.350 L1 for the first time. Store this manual in a place to which all users have access at all times! The products described have been developed, manufactured, tested and documented in compliance with the fundamental safety requirements of the EU Machinery Directive.
  • Page 9 Safety instructions and reader’s information Automationstechnik 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: WARNING CAUTION NOTE...

  • Page 10: Typographic Conventions

    Safety instructions and reader’s information Automationstechnik Typographic conventions General listing Example: The message is displayed on the screen. Action Example: Insert floppy Read value Screen displays, Italics Example: Battery-Low messages, displays Tip dress request (Welding) parameters [in brackets] Example: [Weld time], [Schedule].

  • Page 11: Warning Of Magnetic Fields

    Safety instructions and reader’s information Automationstechnik Warning of magnetic fields In the environment of resistance welding systems magnetic field strengths have to be ex- pected which usually are below the limits specified in VDE 0848 Part 4; in cases of doubt, the field strength must be measured.

  • Page 12: Not Permitted For Persons With Cardiac Pacemakers

    Safety instructions and reader’s information Automationstechnik Not permitted for persons with cardiac pacemakers WARNING for persons with cardiac pacemakers! Warning signs should be posted for protecting persons with cardiac pacemakers be- cause the function of these devices may be disturbed (impulse failure, total failure) and a negative influence on the pacemaker programming or even a total program destruction may occur !!! We recommend posting a warning of the type shown below at all entrances to factory...

  • Page 13: Qualified Personnel

    Safety instructions and reader’s information Automationstechnik Qualified personnel This manual is designed for welding technicians and engineers with special training and specific knowledge of the welding technology. They require profound knowledge of the weld timers (WT) MF inverters (PSI) welding transformers and/or welding rectifier-transformers (PSG) The term qualified personnel refers to engineering personnel familiar with the safety standards of the electrical and au- tomation technology.

  • Page 14: Storage And Transport

    Safety instructions and reader’s information Automationstechnik Storage and Transport NOTE Please note the environmental conditions given in the Technical data section to avoid damages. Static discharges may destroy components of the weld timer. Therefore, the original packaging should be used for storage and transport. The equipment must be protected against humidity.

  • Page 15: Installation And Assembly

    (EMC), cf. also section 7 as well as gen- eral information contained in the Bosch EMC manual for resistance welding components. 1070 080 067-101 (2001.03) GB...

  • Page 16: Electrical Connection

    Safety instructions and reader’s information Automationstechnik Electrical connection The PSI 6XXX.350 L1 are supplied with 24 V DC. This power supply must provide safety separation in accordance with the Low-Voltage Directive (72/23/EEC, 93/68/EEC and 93/44/EEC). WARNING! Considerable dangers are associated with the mains connection of the power unit! The possible consequences of inappropriate handling include death, severe bodily injury and damage to property.

  • Page 17: Operation

    Danger of bruises through electrode movement! All users, line designers, welding machine manufacturers and welding gun produ- cers 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 18 Safety instructions and reader’s information Automationstechnik Simulate start In remote-controlled systems, program execution may begin which may result in dangerous machine movements. Therefore, before remote starting, it must be en- sured that nobody is in the dangerous area of the welding machine! CAUTION! Damage to property through excessive welding current! The maximum welding current of the welding hardware used must not be exceeded.

  • Page 19: Retrofits And Modifications By The User

    Safety instructions and reader’s information Automationstechnik Retrofits and modifications by the user The PSI 6XXX.350 L1 has been designed and manufactured by us as a safe unit. WARNING! Retrofits or modifications may have negative effects on the safety of the unit! The possible consequences include death, severe or light bodily injury (personal injury), damage to property or environmental hazards.

  • Page 20: Maintenance And Repair

    Empty batteries should always be replaced by new ones! CAUTION! The right to perform repair/maintenance work on the PSI 6XXX.350 L1 compo- nents is reserved to the Bosch service department or to repair/maintenance units authorized by Bosch! Only use spare parts/replacement parts approved by Bosch! The applicable regulations on the disposal of empty batteries or accumulators must be observed.
  • Page 21 Safety instructions and reader’s information Automationstechnik Your notes: XVIII 1070 080 067-101 (2001.03) GB...

  • Page 22: System

    System System General Welding Timers (WT) of the PSI 6XXX.350 L1 series are suitable for spot, projection and roller seam welding, as well as for other welding processes. The welding system consists of Welding hardware (welding gun, robot or multi point ...) Timer module PSI 6XXX.350 L1...
  • Page 23 System PSI 6XXX.350 L1 Up to 256 welding programs can be programmed and called up. Single spot (SING), re- peat mode (REPT) or seam operation can be selected. The welding parameters are stored in a RAM memory. The RAM memory has battery backup to prevent loss of data.
  • Page 24 Figure 2: Basic functional diagram Welding current The Bosch medium-frequency welding system uses DC current for welding. The duration of the welding current is programmed in milliseconds (ms). Because welds turn out to be more uniform than at 50 Hz, a higher output of correct welds is obtained.

  • Page 25: Programming And Operating The Timer

    System PSI 6XXX.350 L1 Programming and operating the timer The following components are required for Operation and Programming of the timer: Programming terminal with one of the following operating systems: Windows 3.1x Windows 95 Windows 98 Windows NT3.x / NT4.0 Software BOS-5000 Technical documentation: Operating and programming instructions, volume 1, part no.

  • Page 26: Technical Data

    I/O bus Proportional control valve 8 bits, equivalent to 0 through 10 bar Programming with BOS-5000 via via internal V24 / RS232 interface, laptop computer, Bosch BT oper- isolated ating terminal or INTERBUS-S Connection: 9-pin Cannon connec- interface Operational software...
  • Page 27 Technical data PSI 6XXX.350 L1 Backup battery Lithium battery Typ AA/S to buffer RAM data and internal clock during power loss. Battery life approx. 2 years. Current sensor input for toroid coils for secondary current measurement Stop function (stop circuit) via floating contact, stops schedule Fan connection +24VDC...

  • Page 28: Power Unit

    PSI 6XXX.350 L1 Technical data Power unit Overview of technical data of power unit PSI 6XXX.350 L1 System voltage 400 V -20 % to 480 V +10 % 3-phase System frequency 50 / 60 Hz Clock frequency 1000 Hz DC link voltage 550 V DC to 680 V DC (nominal voltage) Overvoltage protection...
  • Page 29 Technical data PSI 6XXX.350 L1 Your notes: 1070 080 067-101 (2001.03) GB...

  • Page 30: Hardware

    PSI 6XXX.350 L1 Hardware Hardware Structure The PSI 6XXX.350 L1 comprises the following functional units: CPU with centralized control function I/O interfaces serial I/O interface (INTERBUS-S), optical waveguide Quality module (slot prepared for subsequent retrofit) All settings required for operation can be made on the front panel or from a connected programming terminal.

  • Page 31: Module Front Panel Without Type-Specific I/O System

    Hardware PSI 6XXX.350 L1 Module front panel without type-specific I/O system U1 V1 W1 3/PE U2 V2 2/PE [10] [20] [11] [19] [12] [13] [14] [18] [15] [16] [17] Figure 4: Front panel 1070 080 067-101 (2001.03) GB...
  • Page 32 PSI 6XXX.350 L1 Hardware LED green, logics supply is ON. LED red, mains voltage and logics supply are ON. Ready LED Timer ready goes out if an internal fault occurs, e.g. ”Battery low”, or a sequence fault occurs, e.g. ”No current”. Firing LED, Control signal for thyristor unit active Battery fault LED, backup battery voltage too low Reset push button, clears pending fault messages, returns timer to ready state.
  • Page 33 GND [16] 8-pin plug-in terminal for measuring system, connection for current sensor (toroid). [17] Battery compartment; use only batteries with Bosch P/N 1070 914 446. [18] Blanking plate on slot for field bus module. [19] Elements of type-specific I/O system.

  • Page 34: Module Front Panel Type-Specific I/Os

    PSI 6XXX.350 L1 Hardware Module front panel type-specific I/Os IB-S 3/PE~ 2/PE~ Figure 5: Type-specific I/Os 1070 080 067-101 (2001.03) GB...
  • Page 35 Hardware PSI 6XXX.350 L1 Diagnostics messages of INTERBUS-S: Transmit/Receive, shows PCP communication. Cable Check, the green LED indicates that the optical waveguide is properly connected to the input. When the INTERBUS-S master module is reset, the LED goes off. Bus Active, the green LED indicates that INTERBUS-S data transmission is active.

  • Page 36: Installation

    Installation PSI 6XXX.350 L1 Installation CAUTION! Danger of life and of damage to property through insufficient protection class! The protection class of the CPU and the I/O modules of the PSI 6XXX.350 L1 is IP 20. The modules must be installed in a suitable housing. Danger of injury and of damage to property through incorrect installation! The units, and especially the operating elements, must be installed so as to be suf- ficiently protected against unintentional operation or contact.
  • Page 37 Installation PSI 6XXX.350 L1 Your notes: 1070 080 067-101 (2001.03) GB...

  • Page 38: Cables

    X3, current sensor shielded cable 0.75 mm up to 100 m 2 x 2 x 0.75 mm LiYCY corresponding to Bosch part number 1070 913 494 X4, power supply unshielded cable, 0.75 mm up to 10 m VDE 0281, 0812 1.5 mm...
  • Page 39 Cables PSI 6XXX.350 L1 Your notes: 1070 080 067-101 (2001.03) GB...

  • Page 40: Suppression Of Rf Noise

    Suppression of RF noise PSI 6XXX.350 L1 Suppression of RF noise Means of noise suppression are required to prevent radiation of radio frequency noise. Such noise is caused by transients peaks, which are transmitted by the power supply line. Noise should be neutralized at the source. If this is not practical, the noise suppression devices must be placed as close as possible to the source.
  • Page 41 Suppression of RF noise PSI 6XXX.350 L1 Your notes: 1070 080 067-101 (2001.03) GB...

  • Page 42: Electrical Connection

    PSI 6XXX.350 L1 Electrical connection Electrical connection In this section, you will find a description of the CPU ports and various connection options for power supply. WARNING! Working with system voltage may result in death, severe bodily injury or consider- able damage to property unless the appropriate precautionary measures are taken.
  • Page 43 Electrical connection PSI 6XXX.350 L1 PSI 6XXX.350 L1 <RX> Pin2 <TX> Pin3 V_24 Pin5 *1 stop circuit: +24 VDC I/O floating contact load: 24 VDC / max. 3A IBS-IN Jumper +24 VDC int. power supply Jumper 0 V internal power supply IBS-OUT Jumper +24 VDC int.

  • Page 44: Interfaces

    PSI 6XXX.350 L1 Electrical connection Interfaces 7.1.1 X1 V24 interface with programming terminal or welding current meter for current scaling. For the cable type and the maximum cable length, please refer to the cable table, Section Both ends of the shield conductor must be connected to the conductive connector shell. The connector should be screwed to the unit to improve the shielding efficiency.

  • Page 45: Current Sensor X3 (Toroid) For Current Scaling

    Electrical connection PSI 6XXX.350 L1 7.1.2 Current sensor X3 (Toroid) for current scaling For cable type and maximum cable length, please refer to the cable table, Section 5. The KSR sensor (weld current sensor) must be installed in the monitoring device. As the actual installation is concerned, remember that improper placement of the KSR sensor may lead to measuring faults.

  • Page 46: Power Supply X4

    PSI 6XXX.350 L1 Electrical connection 7.1.3 Power supply X4 see Section 7.2. 7.1.4 X5 and X9 load cell +24 V DC supply voltage for feeding the load cell /Operate (reset signal) required before measuring event, w +2 Volt analog ram force input signal, calibrated, 1 V being equivalent to 1 kN shielding 7.1.5 INTERBUS-S interfaces X12, X13, X14, X15...
  • Page 47 Electrical connection PSI 6XXX.350 L1 Your notes: 1070 080 067-101 (2001.03) GB...

  • Page 48: Power Supply

    Electrical connection PSI 6XXX.350 L1 Power supply 7.2.1 Internal power supply Configuration A The power supply to PSI 6XXX.350 L1 is completely provided by the power unit (internal supply). PSI 6XXX.350 L1 is internally supplied with 24 V DC (derived from the mains voltage). Several jumpers have to be positioned to enable the internal power supply.
  • Page 49 Electrical connection PSI 6XXX.350 L1 PSI 6XXX.350 L1 Configuration A: Power supply to weld timer logics, inputs and outputs and the load cell by internal 24 VDC power. *1 = stop circuit: floating contact, load: 24 V DC/ max. 3 A Jumper +24VDC int.

  • Page 50: External Power Supply

    Electrical connection PSI 6XXX.350 L1 7.2.2 External power supply Configuration B The power supply to PSI 6XXX.350 L1 is provided by an external unit (external supply). Several jumpers have to be positioned to enable the external power supply. The power supply to the timer is thus independent of the welding network. For configuration B, the external power supply must satisfy the following requirements: Maximum ripple <5 %, tolerance -15 % / +20 %.
  • Page 51 Electrical connection PSI 6XXX.350 L1 PSI 6XXX.350 L1 Configuration B: Power supply to weld timer logics, inputs and outputs and the load cell by an external 24 VDC power supply unit. Power supply unit *1 stop circuit: floating contact load: 24 VDC / max.

  • Page 52: I/O Functions

    PSI 6XXX.350 L1 Electrical connection I/O functions NOTE Electromagnetically activated switching and positioning devices require noise suppres- sion (see section 6). The selection of cables and the cable lengths are subject to the ”Cables” table in section The timer has an INTERBUS interface for I/O signal and programming data communica- tion via the very same bus system (IB-S and PCP).

  • Page 53: Serial Inputs

    PSI 6XXX.350 L1 Electrical connection 7.3.1 Serial inputs The inputs are driven via the serial INTERBUS-S interface. Its configuration is as follows Serial input/output field via INTERBUS-S <Start_1> <Tip dressed> <Request electrode condition > <Acknowledge Tip change> <Reset fault> <Fault reset with weld complete> <Fault reset with Reweld>...
  • Page 54 PSI 6XXX.350 L1 Electrical connection < Series designation, 0 through 15, and spot number, 0 through 1048576 > To select a welding program from the robotic control, use <Series designation and spot number>. By programming the BOS-5000, each spot number has been assigned a pro- gram number (0 through 255) and an electrode number (0 through 31).
  • Page 55 PSI 6XXX.350 L1 Electrical connection Finally, the spot table must be transmitted to the WT via Services - Spot Table -> WT. To select a weld spot from the robotic control, you must use its respective spot number assigned to it in this table. NOTE If you set the ident code to 0 and a spot number smaller than 256 on the I/Os, the respec- tive program from 0 through 255 will be selected directly.
  • Page 56 PSI 6XXX.350 L1 Electrical connection NOTE If electrode number 0 is selected with the <Spot selection> signals and an <Acknowl- edge Tip change> signal becomes high, the tip dress and wear counters of all elec- trodes are reset. If an electrode number 1 through n (n = maximum number of electrodes) is selected with the <Spot selection>...
  • Page 57 PSI 6XXX.350 L1 Electrical connection <Start_1> Activating <Start_1> will start the [Sequence] in the timer, the respective <Spot selec- tion> data are transmitted, and the pre-squeeze time [1. SQZ] beings to run. <Start_1> can still be cleared during [1. SQZ] and [SQZ] to interrupt the started [Sequence]. The [Sequence] becomes modal only upon the beginning of the [1.
  • Page 58 PSI 6XXX.350 L1 Electrical connection <Weld/No weld external> This signal allows to disable the firing of the weld timer, which may be required for set-up operations, e.g. ([Sequence] without current). Apart from the <Weld/No weld external> signal, firing may be controlled by the setting of Weld/No weld internal relating to all programs and a Weld/No weld setting relating to a specific program.
  • Page 59 PSI 6XXX.350 L1 Electrical connection <Reset fault> Faults must be reset whenever a fault prevents any further welding [sequences] in the timer. Pending faults are reset by pushing the green reset button on the front panel of the PSI 6XXX.350 L1 see front panel on page 3-2 or one of the following input signals <Reset fault>...
  • Page 60 PSI 6XXX.350 L1 Electrical connection <Tip dressed> For welding operations during which the electrodes need to be dressed once or repeat- edly, tip dressing must be included in the programming. When the Stepper function is ac- tive (Programming - Welding Parameters - Stepper) the <Tipdress request> signal indicates that the electrodes need to be dressed.
  • Page 61 PSI 6XXX.350 L1 Electrical connection Example: Current Counter, starting section Stepper Curve Counter, stepper section 10.0 Count, (wear) factor <Tipdressing request> tipdressing Curve number of tipdressing events Counts (wear) <End of Stepper> <Tipdressing request> <Tip dressed> last tipdressing before End of Stepper Example: no new <Start_1>...
  • Page 62 PSI 6XXX.350 L1 Electrical connection <Acknowledge Tip change> The timer signals the <End of Stepper>. Any further [sequences] can be disabled in the timer. NOTE A stop in the timer of any further sequence must be programmed in Basic Setup - Global Stepper Setup.
  • Page 63 PSI 6XXX.350 L1 Electrical connection Current Example: *1 Stepper Curve Counter starting section Counter stepper section 10.0 Count (wear) factor Prewarning tipdressing curve number of tipdressing events Counts (wear) <End of Stepper> 10.0 Prewarning Stop at <End of Stepper> <Acknowledge Tip change>...
  • Page 64 PSI 6XXX.350 L1 Electrical connection <Request electrode condition> With this signal the following electrode conditions can be requested: <Initial (Start) Tipdress request> <Tipdress request> <Prewarning> <End of Stepper> This signal must be active before electrode selection/<Spot selection> becomes active. The <Request electrode condition> signal inhibits the <Start_1> signal. Requesting the electrode condition: Electrode condition request Spot selection/(electrode no.) 5 least significant bits...
  • Page 65 PSI 6XXX.350 L1 Electrical connection <Current scaling> <Current scaling> is designed to compensate for variations in the values measured for current check and control. <Current scaling> must be performed whenever a system component (WT, electrode holder, etc.) has been replaced. The following components are required: welding gun monitoring unit with current sensor S reference current meter...
  • Page 66 PSI 6XXX.350 L1 Electrical connection Program 255 is used for <Current scaling>. This program cannot be used for normal operation in production because Start-Inhibit is permanently ON. The program defaults allow automatic <Current scaling> in most cases. However, they must be reviewed by the operator prior to performing <Current scaling>.
  • Page 67 PSI 6XXX.350 L1 Electrical connection 2 spots (upper and lower current value) must be selected at which current scaling is per- formed. Scaling is dependent on the value of the upper current limit (as set in the Elec- trode Parameter Menu). The lower value should be 40% of the upper current limit and the upper value should be 80% of the configured upper current limit .
  • Page 68 PSI 6XXX.350 L1 Electrical connection NOTE If you cannot use the automatic current scaling function described above, the former scal- ing function in the BOS is still available. <Current Check> <Current Check> verifies whether the measured value of the primary current I prim matches the secondary current I measured by current sensor S...
  • Page 69 PSI 6XXX.350 L1 Electrical connection Sequence: A spot must be selected in the I/O field. The gun assigned to the selected spot must be closed. The <Current Check> input signal must be set. Now, the timer is in <Current Check> mode. No starts or program selections entered in the I/O field will be accepted.
  • Page 70 PSI 6XXX.350 L1 Electrical connection <Reduced Current Scaling> With this process, the primary current is scaled (adjusted) in the timer to the secondary current. The process may be initiated e.g. following the replacement of electrodes by the RC con- trol setting the <Reduced Current Scaling> signal. Sequence of Reduced Current Scaling: Prerequisites: Automatic current scaling for the respective electrode must have been per-...
  • Page 71 PSI 6XXX.350 L1 Electrical connection <Current Scaling, Primary> This function is designed to allow a simplified current scaling process. With this function, only the primary current is scaled to an external current meter. Unlike the ”standard” current scaling function, the secondary current is not taken into account here.
  • Page 72 PSI 6XXX.350 L1 Electrical connection <Pressure calibration> Various pressure setpoints (P ) are entered in the pressure regulator with this proce- dure. The force F between the electrode caps is measured with the LC load cell. The measured force F (= value analog to the output voltage of the load cell) is used in the timer for power calibration.
  • Page 73 PSI 6XXX.350 L1 Electrical connection Procedure for <Pressure calibration> CAUTION! Make sure that all individuals stay clear of the immediate operating range of the weld gun. Only input calibration values which generate pressure values the electrode gun can support mechanicallybecause otherwise there is a risk of personal injury and/or damage to the machine.
  • Page 74 PSI 6XXX.350 L1 Electrical connection NOTE A <Pressure calibration> operation will change the value of the conversion factor entered previously. Do not change the new value by any subsequent data entry. NOTE A <Pressure calibration> operation will change the value of the zero adjust entered previously.
  • Page 75 PSI 6XXX.350 L1 Electrical connection <Pressure check> This function allows you to verify whether the programmed actual force value F in kN is reached at the electrodes. Additionally, a check is performed as to whether the electrodes reach the programmed pressure threshold value at the specified command pressure P within a specified time.
  • Page 76 After each pressure check, the pressure profile together with the date, time program number, time to pressure and final value of output pressure are written to a log file and can be saved in the BOS. An independent Bosch program is available for the visual display of these pressure profiles.
  • Page 77 PSI 6XXX.350 L1 Electrical connection Start actual pres- sure P 100% closing time in ms Figure 21: Pressure gauging Pressure gauging: You can initiate pressure gauging by setting the parameter <Export pressure value>. First, the <Operate> signal is set. Every time, the <Actual pressure> parameter is ac- cessed, the pressure is measured.

  • Page 78: Serial Outputs

    7.3.2 Serial outputs The outputs are driven via the serial INTERBUS-S interface. The setup is as follows: Outputs of the PSI 6XXX.350 L1 according to the enhanced C0 profile by Bosch <Weld complete> <Tipdress request> (tip dress inquiry) <Prewarning> <End of Stepper> reached <Control ready>...
  • Page 79 PSI 6XXX.350 L1 Electrical connection <Control ready> The <Control ready> signal indicates the ready status of the weld timer. At the same time, the green LED ⇑ lights up. This signal is cleared in the event of a fault, e.g. with: E-STOP circuit open a fault in the [Sequence] or a non-permitted deviation in a monitored value that has been defined as a fault in the Fault Allocation in the Basic Setup menu.
  • Page 80 PSI 6XXX.350 L1 Electrical connection <Weld/No weld> If the sum of all firing settings (logical AND operation) is switched on when a <Spot selec- tion> is active, the <Weld/No weld> signal is output. <Weld/No weld> signal ON: All firing settings for the selected via <Spot selection> program of the timer are active.
  • Page 81 PSI 6XXX.350 L1 Electrical connection <Without weld process monitoring> This signal indicates that welding is performed without current monitoring. If current monitoring is switched off, deviations from the tolerance band in current moni- toring are not detected. This may lead to weld quality impairment. NOTE When weld process monitoring has been deactivated, you should always check the qual- ity of your welds.
  • Page 82 PSI 6XXX.350 L1 Electrical connection <Proportional valve selection, 1 through 128> The pressure control value is output in digital form (8 bit resolution) via the serial outputs. Thus, the 0 through 100% setting range is subdivided into 256 segments. The digitized pressure value is output with <Spot selection>. If <Spot selection> = 0, the digital value that was output previously is retained.
  • Page 83 PSI 6XXX.350 L1 Electrical connection <Weld complete> (WC) If the welding operation of a single spot is properly completed by the end of the last [weld time], the signal <Weld complete> is output for as long as the <Start_1> signal is true, or, if the <Start_1>...
  • Page 84 PSI 6XXX.350 L1 Electrical connection CAUTION! In this case, the negative time value should be selected so as to ensure that the elec- trodes are already open when the robot drives are started. NOTE The earliest WC start time that may be programmed is as follows: number of milliseconds [HLD] minus 1 ms, but no earlier than 1000 ms before the end of the hold time [HLD].
  • Page 85 PSI 6XXX.350 L1 Electrical connection <Tipdress request> Whenever electrode maintenance is required, <Tipdress request> (electrode tip dress- ing) becomes high. This signal is reset when the <Tip dressed> acknowledgment signal indicates that tip dressing has been completed. If <Tipdress request> is not acknowledged in time by <Tip dressed>, the message Dressing is displayed at the programming terminal.
  • Page 86 PSI 6XXX.350 L1 Electrical connection <Initial (Start) Tipdress request> The <Acknowledge Tip change> (see page 7-21) signal is followed by the <Initial (Start) Tipdress request> signal . The ensuing tip dressing enhances the proper fit of newly installed electrodes. The tip dressing operation must be acknowledged with the <Tip dressed> signal. The <Initial (Start) Tipdress request>...
  • Page 87 PSI 6XXX.350 L1 Electrical connection <Welding fault> This signal is output in the event of a fault in the [Sequence] or a non-permitted deviation in a monitored value that has been defined as a fault. The ready state (<Control ready>) of the timer is cleared.

  • Page 88: Control Diagrams

    Control diagrams PSI 6XXX.350 L1 Control diagrams 1070 080 067-101 (2001.03) GB...
  • Page 89 <Start_1> <Spot selection> <Weld/No weld external> <Reset fault> <Fault reset with WC> <Fault reset with reweld> <Proportional valve selection> <Weld complete contact WC> É É (Start/duration programmable before end of HOLD) [Pre-squeeze time] [Squeeze time] [1st Weld time] [1st Cool time] [2nd Weld time] [3rd Cool time] [3rd Weld time]...
  • Page 90 *2: possible range for schedule interruption by cancelling start É É É É latching <Start_1> <Spot selection> <Weld/No weld external> <Reset fault> <Fault reset with WC> <Fault reset with reweld> <Proportional valve selection> É É É É <Weld complete contact WC> (Start/duration programmable before end of HOLD) [Pre-squeeze time] [Squeeze time]...
  • Page 91 *1 The time between the squeeze time and the hold time corresponds to the total time of 1st weld time, 1st cool time, 2nd weld time, 3rd cool time and 3rd weld time. The schedule is performed without welding current. <Start_1>...
  • Page 92 t>0 switch off no start = no off time É É É É É É É <Start_1> É É É É É É É <Spot selection> <Weld/No weld external> <Reset fault> <Fault reset with WC> <Fault reset with reweld> <Proportional valve selection> <Weld complete contact WC>...
  • Page 93 <Start_1> <Spot selection> <Weld/No weld external> <Reset fault> <Fault reset with WC> <Fault reset with reweld> <Proportional valve selection> <Weld complete contact WC> É É (Start/duration programmable before end of HOLD) [Pre-squeeze time] [Squeeze time] [1st Weld time] [1st Cool time] [2nd Weld time] [3rd Cool time] [3rd Weld time]...
  • Page 94 *1 possible weld schedule termination time *2 weld schedule hold time <Start_1> Termination time/hold time <Spot selection> <Weld/No weld external> <Reset fault> <Fault reset with WC> <Fault reset with reweld> <Proportional valve selection> É É É É <Weld complete contact WC> (Start/duration programmable before end of HOLD) [Pre-squeeze time] [Squeeze time]...
  • Page 95 no meaning <Start_1> <Spot selection> <Weld/No weld external> <Reset fault> <Fault reset with WC> <Fault reset with reweld> É É É É <Proportional valve selection> <Weld complete contact WC> (Start/duration programmable before end of HOLD) [Pre-squeeze time] [Squeeze time] [1st Weld time] [1st Cool time] [2nd Weld time] [3rd Cool time]...
  • Page 96 no meaning earliest new start, new program selection and parity change <Start_1> t > 0 <Spot selection> <Weld/No weld external> <Reset fault> <Fault reset with WC> <Fault reset with reweld> <Proportional valve selection> É É É É <Weld complete contact WC> (Start/duration programmable before end of HOLD) [Pre-squeeze time] [Squeeze time]...
  • Page 97 Control diagrams PSI 6XXX.350 L1 8-10 1070 080 067-101 (2001.03) GB...

  • Page 98: Commissioning

    Commissioning PSI 6XXX.350 L1 Commissioning NOTE For commissioning, please note the safety instructions, the technical data and the electri- cal wiring diagrams. The following sections contain suggestions on how to proceed during commissioning. Acceptance of these suggestions will depend on the specific circumstances and will be the responsibility of the commissioning personnel.

  • Page 99: Preparations

    Commissioning PSI 6XXX.350 L1 Preparations Connect and turn on the timer according to the wiring diagrams and safety instruc- tions. Deactivate the <Weld/No weld external> signal for as long as you do not need any welding current for commissioning. Start the BOS-5000 software and enter your user group and user password. Select Operation.

  • Page 100: Testing The Welding Program

    Commissioning PSI 6XXX.350 L1 Testing the welding program A welding program can be executed with or without firing (with or without welding cur- rent). For this purpose, weld internal or the <Weld/No weld external> function can be turned on or off. In a [Sequence] without welding current, for example, one can first examine the I/O signal exchange with the higher-level control unit and the positioning of robot electrode guns.

  • Page 101: Suggestions For A Welding Test

    Commissioning PSI 6XXX.350 L1 9.2.1 Suggestions for a welding test Check whether the power unit type used has been programmed in Basic-Setup - Thyristor (Power) Unit Setup, and change it if necessary. Perform the first test weld without firing (Weld/No weld internal ”off” or <Weld/No weld external>...

  • Page 102: Basic-Setup

    Commissioning PSI 6XXX.350 L1 Basic-Setup If the timer has already been programmed, the Quick-Programming will give you a good overview of the most important Welding Parameters. Use function key <F9> to change from Operation to Programming. Check the Basic-Setup of all programs used. Safe Delete (Delete Memory) Find out whether the protocol memories, Actual values and Welding Param- eters can be deleted.
  • Page 103 Commissioning PSI 6XXX.350 L1 NOTE If you have access to weld timers which already contain the stepper curves you want to use, you may load them to the programming terminal and then to your weld timer. Electrode Setup Check the Electrode Setup or adjust it to the hardware components of your welding equipment.

  • Page 104: Welding Parameters

    Commissioning PSI 6XXX.350 L1 Welding Parameters If the timer has already been programmed, the Quick-Programming will give you a good overview of the most important Welding Parameters. Use function key <F9> to change from Operation to Programming. Check the Welding Parameters of all programs used. Sequence Check the sequence parameters, in particular, the [Weld Times] and the [%I] values (%I or kA).

  • Page 105: Scaling Process

    Commissioning PSI 6XXX.350 L1 Scaling process For quality assurance, you should adjust your welding equipment to your real conditions by means of Scaling. The following parameters will be adjusted through Scaling: toroid sensitivity conversion factor for pressure output zero shift for pressure output Scaling by manual entry: Select Scaling on the first screen, e.g.

  • Page 106: Activating Monitoring

    Commissioning PSI 6XXX.350 L1 Activating monitoring For quality assurance, Current and/or Time Monitoring should always be switched on, and the appropriate tolerance bands should be entered. The Actual Values are displayed and can be accepted as setpoints. Activating monitoring Select Programming - Basic-Setup - Sequence Setup. Enter Current Monitoring and the tolerance band Select Programming - Welding Parameters - Current Monitoring.

  • Page 107: Saving The Welding Parameters

    Commissioning PSI 6XXX.350 L1 9.10 Saving the Welding Parameters When commissioning has been completed, you should backup your programs with the Upload (Backup) function. Create Upload (Backup): Select Operation - Services - Upload (Backup). NOTE Existing Upload (Backup) files will be replaced. You may enter a new file name for the new Upload (Backup) file using the File Reference function.

  • Page 108: Messages

    PSI 6XXX.350 L1 Messages Messages 10.1 Fault and Status Messages Messages : The ready status of the timer remains, further [sequences] are not Warnings inhibited. Faults : The timer is no longer ready, further [sequences] are inhibited. NOTE Internally the timer works with coded numbers. All messages are output on the program- ming unit in text format.

  • Page 109: Ranges Of Messages

    PSI 6XXX.350 L1 Messages 10.2 Ranges of Messages Messages concerning the connection WT Õ Programming terminal (communication messages) Messages concerning the stepper (electrode) status (Prewarning, End of Stepper reached, etc.). Messages concerning the timer status (battery low, no +24V etc.). Messages from active monitoring (Weld-time exceeded).
  • Page 110 PSI 6XXX.350 L1 Messages 10.2.2 [B] - Electrode (Stepper) Messages Code Explanation Additional code End of Stepper Electrode no. Prewarning Electrode no. Tip dress request Electrode no. Tip dress necessary Electrode no. %I (Current) Prewarning Electrode no. Maximum current Electrode no. 10.2.3 [C] - Messages Concerning the Timer Status Code...

  • Page 111: [D] - Messages For Current And Weld Time Monitoring

    PSI 6XXX.350 L1 Messages 10.2.4 [D] - Messages for Current and Weld Time Monitoring Code Explanation 1001 Current measurement loop open 1002 Current measurement loop shorted 1003 No voltage 1. HW 1004 Primary voltage measurement fault 1010 No current (standard mode) 1011 No current 1.

  • Page 112: [E] - Messages Concerning Automatic Scaling/Monitoring

    The load cell could not pick up any voltage during the pressure calibration process. Log error An error occurred when changing from the Bosch log to the 24V log of the reference current meter. Incorrect mode The monitoring mode is set to ”secondary” for current scaling.
  • Page 113 PSI 6XXX.350 L1 Messages 10-6 1070 080 067-101 (2001.03) GB...

  • Page 114: Maintenance

    CAUTION! The right to perform repair/maintenance work on the timer components is reserved to the Bosch service department or to repair/maintenance units authorized by Bosch! Only use spare parts/replacement parts approved by Bosch! Spent batteries or accumulators must be disposed of as hazardous waste.

  • Page 115: Changing Batteries

    Maintenance PSI 6XXX.350 L1 11.1 Changing batteries NOTE Data buffering is assured for about 30 hours, without internal or external 24 VDC supply voltage and after removing the battery. A 3.6 V Lithium battery is installed in the PSI 6XXX.350 L1 to provide data backup power. This battery supplies the RAM memory and the internal clock in the power down state.

  • Page 116: Ordering

    PSI 6XXX.350 L1 Ordering Ordering Spare parts Designation Part no. PCB I/O level 1070 075 808 Included in shipment (STKK plug-in terminal) Part no. please refer to section 3.2 [10] Power supply, X4: 1070 916 914 STKK 14-pin (3.5 mm) [11] Load cell, X5: 1070 914 564...
  • Page 117 Ordering PSI 6XXX.350 L1 Your notes: 12-2 1070 080 067-101 (2001.03) GB...

  • Page 118: A Annex

    PSI 6XXX.350 L1 Annex Annex Abbreviations, Terms 2.WLD 2nd Weld time: main weld time, can consist of a block comprising individual impulses, only the 2.WLD can have upslope and downslope Cool time: time between the current pulses/blocks (1., 2., 3. COOL (CT)) COOL Current Current measured in %I (scale units) or kA (same as HEAT).

  • Page 119: Regulation Terms

    Annex PSI 6XXX.350 L1 Slope Current increase (or decrease) from an initial to a final current. Solenoid Activates the cylinders to close the electrodes. valve Squeeze time that elapses before the weld time. The electrodes squeeze the parts to be welded together.

  • Page 120: Index

    PSI 6XXX.350 L1 Annex Index Delete Memory. See Safe Delete Dressing, 7-19 Acknowledge Tip Change, 7-12, 7-21 Assembly, XII Automatic monitoring, 10-5 Automatic pressure check, 7-25, 7-34 Electrical connection, XIII Automatic scaling, 10-5 Electrode condition, 7-12 Electrode-Setup, 9-5 Electrostatics, V EMERGENCY-STOP, XVII, 11-1 Backup, 9-10 EMERGENCY-STOP facilities, 11-1...
  • Page 121 PSI 6XXX.350 L1 Annex Pressure regulating valve, 3-3 Prewarning, 7-37, 7-45 Light barriers, XIV Profile specification C0, 7-11 Limit values for extremities, VIII Program 255, 7-25 Load cell, 7-5 Programming terminal, 1-1, 3-3, 7-3 Programs, 2-1 Proper use, VII Proportional control valve, 2-1 Magnetic fields, VIII Proportional control valve selection, 7-37 Maintenance, XVII, 11-1...
  • Page 122 PSI 6XXX.350 L1 Annex Stop circuit, 7-5 WT, 1-1 Storage, XI Structure, 3-1 Synchronization voltage, 7-5 System voltage, 2-3, 7-1 Zero adjust, 7-33 Temperature, 2-1 Test procedures, 11-1 Thyristor Unit Setup. See Power Unit Setup Timer module, 1-1 Tip dressed, 7-19 Tipdress Curves, 9-5 Tipdress request, 7-37, 7-44 Toroid, 7-4...
  • Page 123 PSI 6XXX.350 L1 Annex Your notes: 1070 080 067-101 (2001.03) GB...
  • Page 124 PSI 6XXX.350 L1 Annex Your notes: 1070 080 067-101 (2001.03) GB...
  • Page 125 PSI 6XXX.350 L1 Annex Your notes: 1070 080 067-101 (2001.03) GB...
  • Page 126 PSI 6XXX.350 L1 Annex Your notes: 1070 080 067-101 (2001.03) GB...
  • Page 127 PSI 6XXX.350 L1 Annex Your notes: A-10 1070 080 067-101 (2001.03) GB...
  • Page 128 1070 080 067-101 (2001.03) GB · TI · AT/VWS · Printed in Germany...

Table of Contents