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Bosch PST 6101.321 Technical Information

Timer and i/o level
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PSX 6000
Description of Timer and I/O Level
PST 6101.321 / PSI 6101.321
Technical Information
101
Edition

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Summary of Contents for Bosch PST 6101.321

  • Page 1 PSX 6000 Description of Timer and I/O Level PST 6101.321 / PSI 6101.321 Technical Information Edition...
  • Page 2 DIN ISO 9001 Reg. no. 16149-01/2 E 1999 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

    PST 6101.321 / PSI 6101.321 Contents Contents Page Safety instructions and reader’s information Explanation of pictographs and symbols ....Typographic conventions ....... . .
  • Page 5 PST 6101.321 / PSI 6101.321 Contents Page Installation ..... . Cables ......
  • Page 6 PST 6101.321 / PSI 6101.321 Contents Page Commissioning ....Preparations ........
  • Page 7 PST 6101.321 / PSI 6101.321 Contents Your notes: 1070 080 056-101 (99.09) GB...

  • Page 8: Safety Instructions And Reader's Information

    EU Machine Directive. Nevertheless, there is some residual risk! The contents of this manual refer to the functions of the timer modules PSI 6101.321 / PST 6101.321 I/O level Explanation of pictographs and symbols The following warnings and notes may be attached to the individual hardware compo- nents which are designed to inform the user of certain circumstances.
  • 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

    Proper use The present manual contains information on the proper use of the weld timer types PSI 6101.321 / PST 6101.321. In connection with the specified welding equipment, the weld timers type PSI 6101.321 / PST 6101.321...

  • 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) thyristor power units (PST) and/or 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-...

  • 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

    Danger of life and of damage to property through insufficient protection type! The protection type of the PSI 6101.321 / PST 6101.321 modules is IP 20. The modules and the power unit form a single unit which must be installed simulta- neously and incorporated in a housing or switch cabinet with a suitable degree of protection.

  • Page 16: Electrical Connection

    Safety instructions and reader’s information Automationstechnik Electrical connection The PSI 6101.321 / PST 6101.321 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 inapproriate 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 Fault reset with spot repetition If the start signal is present when a fault is reset with reweld (spot repetition), the timer will immediately start executing the program! This may result in dangerous machine movements! Therefore, before resetting a fault with reweld it must be en- sured that nobody is in the dangerous area of the welding machine! Simulate start In remote-controlled systems, program execution may begin which may result in...

  • Page 19: Retrofits And Modifications By The User

    Safety instructions and reader’s information Automationstechnik Retrofits and modifications by the user The PSI 6101.321 / PST 6101.321 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 6101.321 / PST 6101.321 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! 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 080 056-101 (99.09) GB...

  • Page 22: System

    System System General Welding Timers (WT) of the PSI 6101.321 / PST 6101.321 series are suitable for spot, projection and roller seam welding, as well as for other resistance welding processes. The welding system consists of Welding hardware (welding gun, robot or multi point ...) Timer module PSI 6101.321 / PST 6101.321...
  • Page 23 System PST 6101.321 / PSI 6101.321 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 PST 6101.321 / PSI 6101.321 System The PSI 6101.321 / PST 6101.321 is an open system timer. You can select control func- tions from a variety of selections by entering or modifying the basic setup and the welding parameters. You can configure your control by selecting various basic setups and Programming the welding parameters.
  • Page 25 The welding current can be controlled by the closed-loop constant-current regulation system (KSR) integrated in the weld timers. The Bosch medium-frequency welding system uses DC current for welding. The duration of the welding current is programmed in milliseconds (ms). The welding process is per- formed more evenly.

  • Page 26: Block Diagram Of Timer

    PST 6101.321 / PSI 6101.321 System Block diagram of timer On the front panel of the timer is a V24 interface. This can be used for connecting a laptop computer or an operating terminal (BT), for example, for programming as well as operat- ing the timer locally.

  • Page 27: Programming And Operating The Timer

    System PST 6101.321 / PSI 6101.321 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...

  • Page 28: Technical Data

    ±5% ripple optional internal supply or external supply to logic and I/O’s Note: PST 6101.321 does not offer internal supply to logic via system power, see section 7.2 Rated current (w/o I/O) at 24V approx. 250mA w/o fieldbus module approx.
  • Page 29 Technical data PST 6101.321 / PSI 6101.321 Program memory RAM memory (battery-buffered) Backup battery Lithium battery Typ AA/S to buffer RAM data and internal clock during power loss. Battery life approx. 2 years. Output for pressure regulating analog pressure output, voltage from valve (isolated) 0 V to +10 VDC, max.

  • Page 30: Power Unit

    PST 6101.321 / PSI 6101.321 Technical data Power unit Overview of technical data of power unit PST 6101.XXX PSI 6101.XXX L1 System voltage 400 V -20 % to 400 V -20 % to 600 V + 10 % 480 V +10 %...
  • Page 31 Technical data PST 6101.321 / PSI 6101.321 Your notes: 1070 080 056-101 (99.09) GB...

  • Page 32: Hardware

    PST 6101.321 / PSI 6101.321 Hardware Hardware Structure The PSI 6101.321 / PST 6101.321 comprises the following functional units: CPU with centralized control function I/O interfaces serial I/O interface (Interbus-S) parallel outputs for KSR change over Quality module (slot prepared for subsequent retrofit)

  • Page 33: Module Front Panel Without Type-Specific I/O System

    Hardware PST 6101.321 / PSI 6101.321 Module front panel without type-specific I/O system PST/PSI [19] [10] [18] [11] [12] [13] [17] [14] [15] [16] Figure 5: Front panel 1070 080 056-101 (99.09) GB...
  • Page 34 PST 6101.321 / PSI 6101.321 Hardware Line LED, mains voltage (PST) or d.c. link voltage (PSI) is present. Ready LED timer ready, turns off in case of: Internal fault, e.g. dead battery Schedule fault, 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 35 [15] 8-pin plug-in terminal for measuring system, with constant current regulation (KSR) connection for current sensor (toroid). [16] Battery compartment; use only batteries with Bosch P/N 1070 914 446. [17] Blanking plate on slot for field bus module. [18] Elements of type-specific I/O system.

  • Page 36: Module Front Panel Type-Specific I/O's

    PST 6101.321 / PSI 6101.321 Hardware Module front panel type-specific I/O’s IB-S PST / PSI 24 V 24 V Figure 6: Type-specific I/O’s 1070 080 056-101 (99.09) GB...
  • Page 37 Hardware PST 6101.321 / PSI 6101.321 9-pin D shell plug, INTERBUS-S IN interface (remote bus interface, wire). Diagnostics messages of INTERBUS-S: Transmit/Receive, not used. Remote Check, the green LED indicates that the cable is properly con- nected to the remote bus input. When the INTERBUS-S master module is reset, the LED goes off.

  • Page 38: Installation

    Danger of life and of damage to property through insufficient protection class! The protection class of the PSI 6101.321 / PST 6101.321 modules is IP 20. PSI 6101.321 / PST 6101.321 modules must be installed in a suitable housing or a sui- table switch cabinet.
  • Page 39 Installation PST 6101.321 / PSI 6101.321 IB-S PSI /PST Fastening points (4x) Figure 7: Timer module in housing 1070 080 056-101 (99.09) GB...

  • Page 40: Cables

    PST 6101.321 / PSI 6101.321 Cables Cables Cables and cable lengths. Interface Cable Cross section/max. length shielded cable min. 0.2 mm up to 20 m e.g. 3 x 2 x 0.2 mm programming terminal LifYCY (Metrofunk) (V 24) capacitance max. 2.5 nF...
  • Page 41 Cables PST 6101.321 / PSI 6101.321 Your notes: 1070 080 056-101 (99.09) GB...

  • Page 42: Suppression Of Rf Noise

    Suppression of RF noise PST 6101.321 / PSI 6101.321 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.
  • Page 43 Suppression of RF noise PST 6101.321 / PSI 6101.321 Your notes: 1070 080 056-101 (99.09) GB...

  • Page 44: Electrical Connection

    PST 6101.321 / PSI 6101.321 Electrical connection Electrical connection In this section, you will find a description of the CPU ports, various connection options for power supply, and the functions of the parallel and serial I/O interfaces of the PSI 6101.321 / PST 6101.321.
  • Page 45 Electrical connection PST 6101.321 / PSI 6101.321 PSI 6101.321 / PST 6101.321 Pin1 Pin2 *1 stop circuit: Pin2 Pin3 floating contact V_24 Pin3 load: Pin5 /DO1 24 VDC / max. 3A Pin6 IBS-IN +24 VDC I/O /DI1 Pin7 Pin1 Pin2 Pin3 Jumper +24 VDC int.

  • Page 46: Interfaces

    PST 6101.321 / PSI 6101.321 Electrical connection Interfaces 7.1.1 Programming terminal X1 V24 interface For the cable type and the maximum cable length, please refer to the cable table, see section 5. Both ends of the shield conductor must be connected to the conductive connector shell.

  • Page 47: Pressure X2

    For cable type and maximum cable length, please refer to the Table “Cables”, see sec- tion 5. The connection between PSI 6101.321 / PST 6101.321 and the pressure control valve consists of a shielded cable. The shield is connected to X2/5 and the shield ground at the pressure control valve.

  • Page 48: Ksr Sensor (Toroid) X3

    The maximum cable length between the KSR sensor and the PSI 6101.321 / PST 6101.321 is 100 meters. This limit must not be exceeded. The connection between the KSR sensor and the PSI 6101.321 / PST 6101.321 consists of a shielded cable. The shield must be connected to X3/3 of the PSI 6101.321 / PST 6101.321.

  • Page 49: Power Supply X4

    Electrical connection PST 6101.321 / PSI 6101.321 7.1.4 Power supply X4 see section 7.2 7.1.5 External device X5 +24 V DC are output at interface X5 for supplying an external unit (maximally 2A, depend- ing on the external supply). 7.1.6 Stop circuit A fault in the stop circuit is automatically acknowledged when corrected.
  • Page 50 Electrical connection PST 6101.321 / PSI 6101.321 Your notes: 1070 080 056-101 (99.09) GB...

  • Page 51: Power Supply

    Electrical connection PST 6101.321 / PSI 6101.321 Power supply 7.2.1 Internal power supply Configuration A The power supply to PSI 6101.321 is completely provided by the power unit (internal sup- ply). PSI 6101.321 is internally supplied with 24 V DC (derived from the mains voltage). Sev- eral jumpers have to be positioned to enable the internal power supply.
  • Page 52 Electrical connection PST 6101.321 / PSI 6101.321 PSI 6101.321 Configuration A: Power supply to weld timer logics, firing, inputs and outputs and the external unit by internal 24 VDC power (with PSI 6101.321 only outputs). *1 stop circuit: floating contact load: 24 VDC / max.

  • Page 53: External Power Supply

    External power supply Configuration B The power supply to PSI 6101.321 / PST 6101.321 is provided by an external unit (exter- nal 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.
  • Page 54 PSI 6101.321 / PST 6101.321 Configuration B: Power supply to weld timer logics, firing, inputs and outputs and the external unit by an external 24 VDC power supply unit (with PSI 6101.321 / PST 6101.321 only outputs). Power supply unit...
  • Page 55 Electrical connection PST 6101.321 / PSI 6101.321 Configuration C The I/O range of the PSI 6101.321 is supplied with a voltage of 24 V DC (internal supply, derived from the mains voltage). Several jumpers have to be positioned to enable this configuration.
  • Page 56 Electrical connection PST 6101.321 / PSI 6101.321 PSI 6101.321 Configuration C: Power supply for firing, parallel inputs and outputs by internal 24 VDC power (with PSI 6101.321 only out- puts). Power supply to weld timer logics, the external unit and the serial I/O interface by an external power sup- ply unit [1].
  • Page 57 PST 6101.321 / PSI 6101.321 Configuration D If the external 24 V DC supply to PSI 6101.321 / PST 6101.321 cannot be provided by one power supply unit for reasons of potential separation between the timer logic and the I/O supply, the power supply has to be designed in accordance with configuration D. Sev- eral jumpers have to be positioned to enable this configuration.
  • Page 58 X4/3 and X4/4. Opening the stop contact will interrupt: the firing the power supply to the parallel inputs and outputs (only outputs for PSI 6101.321 / PST 6101.321) the power supply to the external unit. PSI 6101.321 / PST 6101.321 Configuration D:...
  • Page 59 Electrical connection PST 6101.321 / PSI 6101.321 Your notes: 7-16 1070 080 056-101 (99.09) GB...

  • Page 60: I/O Functions

    The serial outputs are served by the Interbus-S interface. Three parallel outputs are used. Power supply The following applies to the parallel I/O’s (not with PSI 6101.321 / PST 6101.321): +24 V DC +20 % -15 % maximum ripple <5 % NOTE For determining the power supply rating, sum up the individual loads required.

  • Page 61: Serial Inputs

    Serial inputs The inputs are driven via the serial Interbus-S interface. The control word has the follow- ing structure: Inputs of the PSI 6101.321 / PST 6101.321 according to the enhanced C0 profile, Messrs. Bosch <Start_1> <Reset ”Electrodes have been dressed”> (tip dressing) <Reset power unit fault>...
  • Page 62 PST 6101.321 / PSI 6101.321 Electrical connection 7-19 1070 080 056-101 (99.09) GB...
  • Page 63 PST 6101.321 / PSI 6101.321 Electrical connection <Program selection 1 to 128> The <Program selection> has two meanings: If Start becomes active in connection with the specified program number, the se- lected program is executed. When the program number (now: stepper no.) is applied: and the <Tip dressed>...
  • Page 64 PST 6101.321 / PSI 6101.321 Electrical connection Influencing the counters via the input signals: Program selection (Program no./Electrode no.) Start Tip dressed Electrode replaced Program schedule - wear Õ reset - wear Õ 0 - tip dress counter - tip dress counter Õ...
  • Page 65 PST 6101.321 / PSI 6101.321 Electrical connection <Start_1> Activating Start will synchronously start the [Sequence] in the timer (with the first subse- quent positive half-cycle), and the solenoid valve signal is activated. Together with the start, the selected program number is taken over. The start signal also triggers off the pre-squeeze time [1.
  • Page 66 PST 6101.321 / PSI 6101.321 Electrical connection Start 1.WLD 1.SQZ SQZ Figure 19: Start in seam mode (end during 1.WELD) Start n x 2.WLD 1.SQZ SQZ 1.WLD 1. CT Figure 20: Start in seam mode (end during 2.WELD) 7-23 1070 080 056-101 (99.09) GB...
  • Page 67 PST 6101.321 / PSI 6101.321 Electrical connection <Weld/No weld external> This signal allows to disable the firing of the welding timer as for example during set-up operations ([Sequence] without current). In addition to the <Weld/No weld external> signal, the setting of weld/no weld internal for all programs and furthermore the weld/no weld setting for an individual program affect the firing.
  • Page 68 [sequences] in the timer. Pending faults are reset by software BOS-5000 using the green key on the front panel of the PSI 6101.321 / PST 6101.321 or one of the following input signals <Reset fault> This signal resets the displayed fault. The cause of the fault must be cleared first. The <Weld complete>...
  • Page 69 PST 6101.321 / PSI 6101.321 Electrical connection <Reset ”Electrodes have been dressed”> Spot welds are programmed in dressing operation, which require a dressing of the elec- trodes in one or several operating cycles. When the Stepper function is active (Program- ming - Welding Parameters - Stepper) the signal <Tipdress request>...
  • Page 70 PST 6101.321 / PSI 6101.321 Electrical connection Current Example: Counter starting section Stepper Curve Counter stepper section 10.0 Count (wear) factor Tipdressing request Tipdress Curve Max. no. of dressing operations Counts (wear) End of Stepper Tipdressing request Electrodes have been dressed last tipdressing before End of Stepper Example: no new start of a sequence without reset ”Electrodes have been dressed”...
  • Page 71 PST 6101.321 / PSI 6101.321 Electrical connection <Reset ”Electrodes have been replaced”> The timer signals the <End of Stepper>. Any further [sequences] can be disabled in the timer. This signal will be reset and turned off as soon as a <Reset ”Electrodes have been replaced”>...
  • Page 72 PST 6101.321 / PSI 6101.321 Electrical connection Current Example : Counter starting section *1 Stepper Curve Counter stepper section 10.0 Count (wear) factor Prewarning Tipdress Curve Max. no. of dressing operations Counts (wear) End of Stepper 10.0 Prewarning Stop at End of stepper Reset ”Electrodes have...
  • Page 73 PST 6101.321 / PSI 6101.321 Electrical connection <Reset power unit fault> This input signal is directly passed to the power unit and has not effect on the timer. It is intended for fault acknowledgement in the power unit. 7-30 1070 080 056-101 (99.09) GB...

  • Page 74: Serial Outputs

    Serial outputs The outputs are driven via the serial Interbus-S interface. The status word has the follow- ing structure: Outputs of the PSI 6101.321 / PST 6101.321 according to the enhanced C0 profile, Messrs. Bosch <Weld complete> <Tipdress request> (tip dress inquiry) <Prewarning>...
  • Page 75 (weld without command: the weld timer recognizes a current flow in the welding circuit for which no command was given), not with PSI 6101.321 / PST 6101.321 a battery fault that has been defined as a fault in the Fault Allocation in the Basic- Setup menu, etc.
  • Page 76 PST 6101.321 / PSI 6101.321 Electrical connection <Weld/No weld> If the sum of all firing settings (logical AND operation) is switched on when a program number is selected, the <Weld/No weld> signal ON is output. <Weld/No weld> signal ON: All firing settings for the selected program of the timer are active. The [Sequence] is performed with welding current.
  • Page 77 PST 6101.321 / PSI 6101.321 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. NOTE When weld process monitoring has been deactivated, you should always check the qual- ity of your welds.
  • Page 78 PST 6101.321 / PSI 6101.321 Electrical connection 7-35 1070 080 056-101 (99.09) GB...
  • Page 79 PST 6101.321 / PSI 6101.321 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 in the case of <Start_1>...
  • Page 80 PST 6101.321 / PSI 6101.321 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 maximally programmable value for the beginning of WC is: number of HOLD time cycles (or milliseconds) less 1 cycle (or millisecond), maximally 50 cycles (or milliseconds) before the end of HLD.
  • Page 81 PST 6101.321 / PSI 6101.321 Electrical connection <Tipdress request> For electrode maintenance, the <Tipdress request> signal (electrode tip dressing) is ac- tivated. It signals that dressing is required. The signal will be reset and turned off as soon as the signal <Reset ”Electrodes have been dressed”> reports the completed dress- ing operation.
  • Page 82 PST 6101.321 / PSI 6101.321 Electrical connection <Prewarning> The signal <Prewarning> is set when a wear is reached, which is programmed in the [sequence]. It signals that the <End of Stepper> (maximum life) for the electrode will soon be reached. The signal will be reset and turned off as soon as the <End of Stepper>...
  • Page 83 PST 6101.321 / PSI 6101.321 Electrical connection <Welding fault> This signal is output in the event of a fault in the [Sequence] or if the timer recognizes an inadmissible deviation of a monitored value which has been defined as a fault. The ready state of the timer is cleared.

  • Page 84: Parallel Outputs

    PST 6101.321 / PSI 6101.321 Electrical connection 7.3.3 Parallel outputs The timer drives the following parallel outputs (+24 V DC / max. 100 mA): A3, <KSR_selection_1> A4, <KSR_selection_2> A5, <KSR_selection_3> <KSR_selection> The outputs serve for the control of a 3-to-1 switch in order to pass one out of a maximum of three KSR signals to connector X3 (KSR) of the timer.
  • Page 85 PST 6101.321 / PSI 6101.321 Electrical connection Your notes: 7-42 1070 080 056-101 (99.09) GB...

  • Page 86: Control Diagrams

    Control diagrams PST 6101.321 / PSI 6101.321 Control diagrams 1070 080 056-101 (99.09) GB...
  • Page 87 <Start_1> <Program selection> <Weld external> <Reset fault> <Reset fault with Reweld> É É É É max. 1 cycle <Analog pressure output> <Weld complete contact WC> É É (Start/duration programmable before end of HOLD) <Welding fault> [Pre-squeeze time] [Squeeze time] [1st Weld time] [1st Cool time] [2nd Weld time] [3rd Cool time]...
  • Page 88 *2: possible range for schedule interruption by cancelling start É É É É latching <Start_1> <Program selection> <Weld external> <Reset fault> <Reset fault with Reweld> max. 1 cycle <Analog pressure output> É É É É É É É <Weld complete contact WC> (Start/duration programmable before end of HOLD) min.
  • Page 89 *1 The time between the squeeze time and the hold time corresponds to the total time of 1st weld time, 1st cool- time, 2nd weldtime, 3rd cooltime and 3rd weld time. The schedule is performed without welding current. <Start_1> <Program selection> <Weld external>...
  • Page 90 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 <Program selection> <Weld external> <Reset fault> <Reset fault with Reweld> É É É É max. 1 cycle <Analog pressure output>...
  • Page 91 <Start_1> <Program selection> <Weld external> <Reset fault> <Reset fault with Reweld> É É É É É É max. 1 cycle <Analog pressure output> <Weld complete contact WC> É É (Start/duration programmable before end of HOLD) <Welding fault> [Pre-squeeze time] [Squeeze time] [1st Weld time] [1st Cool time] [2nd Weld time]...
  • Page 92 *1 possible weld schedule termination time *2 weld schedule hold time <Start_1> Termination time/hold time <Program selection> <Weld external> <Reset fault> <Reset fault with Reweld> É É É É max. 1 cycle <Analog pressure output> É É É É <Weld complete contact WC> (Start/duration programmable before end of HOLD) min.
  • Page 93 no meaning <Start_1> <Program selection> <Weld external> <Reset fault> <Reset fault with Reweld> É É É É <Analog pressure output> <Weld complete contact WC> (Start/duration programmable before end of HOLD) <Welding fault> [Pre-squeeze time] [Squeeze time] [1st Weld time] [1st Cool time] [2nd Weld time] [3rd Cool time] [3rd Weld time]...
  • Page 94 no meaning earliest new start, new program selection and parity change <Start_1> t > 0 <Program selection> <Weld external> <Reset fault> <Reset fault with Reweld> É É É É É É <Analog pressure output> É É É É <Weld complete contact WC> (Start/duration programmable before end of HOLD) <Welding fault>...
  • Page 95 Control diagrams PST 6101.321 / PSI 6101.321 8-10 1070 080 056-101 (99.09) GB...

  • Page 96: Commissioning

    Commissioning PST 6101.321 / PSI 6101.321 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 97: Preparations

    Commissioning PST 6101.321 / PSI 6101.321 Preparations Connect and turn on the timer according to the wiring diagrams and safety instruc- tions. Deactivate the <Weld external> signal for as long as you do not need any welding current for commissioning.

  • Page 98: Testing The Welding Program

    Commissioning PST 6101.321 / PSI 6101.321 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 external> function can be turned on or off.

  • Page 99: Suggestions For A Welding Test

    Commissioning PST 6101.321 / PSI 6101.321 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 100: Basic-Setup

    Commissioning PST 6101.321 / PSI 6101.321 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. Safe Delete (Delete Memory) Find out whether the protocol memories, Actual values and Welding Param- eters can be deleted.
  • Page 101 Commissioning PST 6101.321 / PSI 6101.321 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 102: Welding Parameters

    Commissioning PST 6101.321 / PSI 6101.321 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.

  • Page 103: Scaling Process

    Commissioning PST 6101.321 / PSI 6101.321 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 Select, e.g., Starting Window - Scaling.

  • Page 104: Activating Monitoring

    Commissioning PST 6101.321 / PSI 6101.321 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.

  • Page 105: Saving The Welding Parameters

    Commissioning PST 6101.321 / PSI 6101.321 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 106: Messages

    PST 6101.321 / PSI 6101.321 Messages Messages 10.1 Fault and Status Messages Messages Warnings : The ready status of the timer remains, further [sequences] are not inhibited. Faults : The timer is no longer ready, further [sequences] are inhibited. NOTE Internally the timer works with coded numbers.

  • Page 107: Ranges Of Messages

    PST 6101.321 / PSI 6101.321 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.).
  • Page 108 PST 6101.321 / PSI 6101.321 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.

  • Page 109: [D] - Messages For Current And Weld Time Monitoring

    PST 6101.321 / PSI 6101.321 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 110: Maintenance

    CAUTION! 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! Spent batteries or accumulators must be disposed of as hazardous waste.

  • Page 111: Changing Batteries

    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 6101.321 / PST 6101.321 to provide data backup power. This battery supplies the RAM memory and the internal clock in the power down state.

  • Page 112: Ordering

    PST 6101.321 / PSI 6101.321 Ordering Ordering Spare parts Designation Part no. PCB I/O level with Interbus-S interface 1070 077 832 Graduated plate (front cover) for PCB of I/O level 1070 079 710 Included in shipment (STKK plug-in terminal) Part no.
  • Page 113 Ordering PST 6101.321 / PSI 6101.321 Your notes: 12-2 1070 080 056-101 (99.09) GB...

  • Page 114: A Annex

    PST 6101.321 / PSI 6101.321 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))

  • Page 115: Regulation Terms

    Annex PST 6101.321 / PSI 6101.321 Squeeze time: time that elapses before the weld time. The electrodes squeeze the parts to be welded together. Stepper Current (heat) stepping for compensating for electrode wear Temp Temperature Upslope Time; time during which the Current (HEAT) stops after beginning of 2.WLD...

  • Page 116: Index

    PST 6101.321 / PSI 6101.321 Annex Index Counts. See Wear Current sensor, 3-4 Numbers Data buffering, 11-2 1000 Hz, 1-3 Degree of protection, 2-1 50 / 60 Hz, 1-3 Delete Memory. See Safe Delete Dressing, 7-26 Assembly, XII Electrical connection, XIII...
  • Page 117 PST 6101.321 / PSI 6101.321 Annex Monitoring stopped, 7-34 I/O Parameters, 9-5 Inductive devices, 6-1 Noise suppression devices, 6-1 Inputs, 7-17, 7-18 NOTE, VI Installation, XII, 4-1 Interbus-S, 7-17 Interfaces, 7-3 Operating mode, 3-3 Operating system, 1-5 Operating voltage, 2-1...
  • Page 118 PST 6101.321 / PSI 6101.321 Annex Programs, 2-1 Serial outputs, 7-31 Proper use, VII Shield conductor, V, 7-3 Signal lines, XII Simulate start, XV Spare parts, 11-1 Qualified personnel, X Spot repetition. See Reweld Quality module, 3-1 Start_1, 7-18, 7-22...
  • Page 119 PST 6101.321 / PSI 6101.321 Annex Weld current sensor, 7-5 Weld process monitoring, 7-31 V24 interface, 1-5, 3-3, 7-3 Weld Transformer Selection, 9-5 Weld/No weld, 7-24, 7-33 Welding current, 1-4, 7-18 Welding fault, 7-31, 7-40 WARNING, V, VI Welding hardware, 1-1...
  • Page 120 1070 080 056-101 (99.09) GB · TB · AT/VWS · Printed in Germany...

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