Bosch Weld Timer Manual

Bosch Weld Timer Manual

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Bosch Weld Timer ManualBulgaria Croatia Czech Republic Denmark Finland France Germany Greece Hungary Ireland Italy Netherlands Norway Poland Portugal Romania Russia Serbia Slovenia Spain Sweden Switzerland Turkey Ukraine United Kingdom North America Canada Mexico USA South America Argentina Brazil Chile Colombia Peru Venezuela Africa South Africa Contact myRexroth Basket Select your location Location International Argentina Australia Austria Belarus Belgium Bosnia and Herze. The extensive control functions guarantee high process reliability. The PSI family offers a variety of additional functions for welding high-strength metals, aluminum and three-member joints. Welding controllers and transformers from Rexroth offer the user fast commissioning, optimized programming, control and monitoring functions, simple operation and high flexibility. 80 of the world's automobile manufacturers trust in the performance of Rexroth's spot welding controllers. Discover everything Scribd has to offer, including books and audiobooks from major publishers. Start Free Trial Cancel anytime. Report this Document Download Now save Save Bosch Manual REXROTH BOS6000 Users Manual For Later 2K views 1 1 upvote 0 0 downvotes Bosch Manual REXROTH BOS6000 Users Manual Uploaded by Boby Description: Bosch Manual REXROTH BOS6000 Users Manual Full description save Save Bosch Manual REXROTH BOS6000 Users Manual For Later 1 1 upvote, Mark this document as useful 0 0 downvotes, Mark this document as not useful Embed Share Print Download Now Jump to Page You are on page 1 of 242 Search inside document Browse Books Site Directory Site Language: English Change Language English Change Language. Bosch Manual REXROTH BOS6000 Users Manual.All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). Validity Published by The data specified above only serve to describe the product.http://viaggi.abruzzo.it/img/3m-mp8610-manual.xml

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No statements concerning a certain condition or suitability for a certain application can be derived from our information. The given information does not release the user from the obligation of own judgement and verification. It must be remembered that our products are subject to a natural process of wear and aging. All information is provided for reference only and is subject to change at any time. No liability is accepted. Note: In many areas, the Help is “context-sensitive“. That means that the current system status (active window, input field below mouse pointer) is detected and a suitable help topic is called up when Help is invoked by pressing F1. You can choose whether you only want to print the current Help topic or its sub-topics as well (if existent). The available Help topics are shown in a tree structure. By clicking on a Help topic, the system displays the description relating to the contents. Note: Book symbols represent a topic with sub-topics. Note: To fully extend the structure tree or to close the branches except the main topics, move the mouse pointer to the left window area, press the right mouse button and then select “Open all” or “Close all” in the pop-up menu appearing. Keyword search 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Index” tab in the left window area. All keywords are listed in alpha-numerical order in the keywords list. The description relating to the topic can be displayed by double-clicking on an index entry. 3. For searching, enter the desired term in the “Find keyword“ field. After each character input, the system will select a corresponding keyword from the index list. For this purpose, it compares the string entered to the available index entries.The search itself is not casesensitive, however, the operators have to be written in capital letters.http://www.belleantonio.it/foto_fck/3m-mp8030-projector-manual.xml Example: The query “help AND (version NOT 2003)” will find all topics containing both the terms “help” and “version”, but not “2003”. 4. Use the check boxes in the lower left part of the window to define the desired search scope. 5. Click on the List topics command button to list all topics that match the query. In the lower left display area, the system will enter the name of the topic in the “Current topic” field. 4. If desired, you can change the topic name according to your requirements. The topics displayed can be included in the Favorites list under the name displayed by clicking on the Add command button. Displa ying t he topics i n the Fa vorites list 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Favorites” tab in the left window area. 3. If there are any entries in the list, you can display the relevant topics by double-clicking on a list entry or by clicking on the Show (View) command button after having selected a topic. Renaming th e topi cs in t he Favorites lis t 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Favorites” tab in the left window area. 3. Right-click to select the relevant topic and select the “Rename” menu item 4. Enter the new name for the topic. 5. Acknowledge the new topic name with the Enter key. Why” and “ What for”. The products described were developed, manufactured and tested in compliance with the fundamental requirements of the EU machinery directive. These productssafety pose no danger to persons or property if they are used in accordance with the handling stipulations and safety notes prescribed for their configuration, mounting, and proper operation. Nevertheless, there still is som e residual ris k! ? Please note the information provided in the previous section in this context. There, you will also find safety information that is important for product handling.http://www.drupalitalia.org/node/69546 Store this documentation in a place to which all users have access at any time. DANGER This symbol is used wherever insufficient or lacking compliance with instructions may result in damage to pro perty. CAUTION Note: ? This symbol is used to draw the user’s attention to special circumstances. This symbol indicates that you have to do something or have certain conditions. Any other application is deemed improper use. Therefore, our products should only be used for their intended purpose. For operating the hardware in residential environments, in trade and commercial applications and small enterprises, an individual permit of the national authority or test institution is required; in Germany, please contact the Regulierungsbehorde fur Telekommunikation und Post (RegTP) or its local branch offices. They must have sound knowledge of the software and hardware components of the weld timers, the power units used, and the welding transformers. Project engineering, programming, start and operation as well as the modification of program parameters is reserved to properly trained personnel. This personnel must be able to judge potential hazards arising from programming, program changes and in general from the mechanical, electrical, or electronic equipment. Risks for person s with c ardiac pa cemake rs.This may cause the death or considerable health damages. Therefore, these persons should avoid the welding system. Please note our comprehensive range of training courses. DANGER ble after If the start signal is present when a fault is reset (acknowledged), the timer will start its program run immediately. This may result in dangerous machine movements. Therefore, prior to fault reset, make sure that there is no-one in the hazard area of the welding equipment. Strong magnetic fields. CAUTION Due to the strong magnetic fields arising from resistance welding, the function of wristwatches, pocket watches or magnetic stripe cards (e.g., EC cards) may be disturbed for ever.http://asyasunger.com/images/bosch-wet-2820-instruction-manual.pdf Therefore, you should not carry such items on you while working in the immediate vicinity of the welding system. CAUTION Note: Never expose floppy disks to the effects of magnetic fields. Therefore, you should not carry any floppy disks on you while working in the immediate vicinity of the welding system. Provide suitable packaging to protect data media against hazardous external influences (such as dust, moisture, heat) or store them in a proper place. Also note safety information that is important for product handling. Basics The BOS 6000 software (i.e. the welding user interface) can be used for weld timers of the PSS 5000 and PSx 6000 series. While this ensures an identical operating philosophy of all timers, there may be timer-specific differences in terms of scope of functions. Using the Set counter command button, the Count and the Dressing-counter of the relevant electrode can be manipulated. This strategy is normally referred to as “Stepping” or “Stepper”. The “dressing” function outputs various signals to ensure that electrodes are mechanically worked on by external devices in configurable time intervals. The parameter defines the I (in of the program-specific base I) to be used for welding at the beginning of the start phase (normally when the relevant electrode has been replaced). During the further development of the start phase, the I value is linearly changed up to 100 of the program-specific base I of a weld, depending on the actual count value. If the value 0 has been entered there, no start phase will be used. The parameter defines the reference current (in of the programspecific reference current) to be compared to an actual current at the beginning of the start phase (normally when the relevant electrode has been replaced), taking into account the tolerances. During the further development of the start phase, the reference current is linearly changed up to 100 of the program-specific reference current of a weld.https://www.andeanskyline.com/wp-content/plugins/formcraft/file-upload/server/content/files/16270484910846---boss-me-20b-manuale-italiano.pdf In this case, you should enter the value 100 as “Reference current for new electrode. Count Defines the maximum count at the end of the start phase for the stepper, monitor stepper and pressure stepper function. Within the span indicated here, the individual stepper values will be linearly increased to 100. After each dr essing Note: This parameter is not available for all timer types. If activated, the count status of the relevant electrode is reset to “0” after the “Tips have been dressed” input signal has become high. That means that the start phase is carried out after each dressing cycle. The parameter defines the reference current (in of the programspecific reference current) to be compared to an actual current at the end of the stepping phase (immediately before a dressing cycle or before replacing the relevant electrode), taking into account the tolerances. In the course of the stepping phase, the reference current is increased up to the value entered for this parameter (in of the program-specific reference current), starting from 100 of the program-specific reference current. Note: If parameter “Reference current at the end of 1st stepper phase“ is set to 100 (), no Stepper-Curve influences the monitoring during the stepping phase. Counts Indicates the current Counts of the relevant electrode. Within the span indicated here, the individual stepper, monitor stepper and pressure stepper values will be increased from 100 to the relevant target values. When the maximum count has been reached, the “Prewarning” signal will be reset, and “End of Stepper” will become high. Increasing the Count further will not change the stepping values. Within this span, a programmed Stepper Curve will be processed. When the maximum count has been reached, the timer will output the “Dressing” signal (increasing the count further will not change the stepping values).www.clinicaponce.com/galeria/files/brinsea-octagon-20-advance-manual.pdf During the last cycle, the timer resets the “Prewarning” signal when the maximum count has been reached and outputs the “End of stepper” signal. The “Electrodes have been replaced” input signal resets the count and the Dressing counter of the electrode in question (to “0”). The change will be performed after each dressing cycle and will remain constant until the next dressing cycle (stepper function). The parameter serves for automatically calculating any I changes to be activated after a dressing cycle. It initially determines the complete I change desired in the course of all dressing cycles until the last dressing (in of the program-specific base I). A I change will be performed after each dressing cycle and will remain constant until the next dressing cycle (stepper function). It will act in addition to a I change generated within the stepping phase by the Stepper-Curve. Note: If parameter “I after last dressing“ is set to 100 (), no Dressing-Curve is active for I stepping. The parameter serves for automatically calculating any reference current changes to be activated after a dressing cycle. It initially defines the reference current (in of the program-specific reference current) to be compared to an actual current after the last dressing, taking into account the tolerances. A reference current change will be performed after each dressing cycle and will remain constant until the next dressing cycle (stepper function). It will act in addition to a reference current change generated within the stepping phase by the StepperCurve. Note: If parameter “Reference current last dressing“ is set to 100 (), no Dressing-Curve is active for monitor stepper. Actual value (Dressing counter) Indicates how often the relevant electrode has already been dressed. Dressings Indicates how often the relevant electrode should be dressed in the course of its life cycle (including first tip dress.https://enville.com/wp-content/plugins/formcraft/file-upload/server/content/files/162704854e312a---boss-me-33-manual-espa-ol.pdf Only when activated will electrode-specific signals (“End of Stepper”, “Prewarning”, etc.) be generated or checked by the timer. Count-Factor Program-specific definition of the amount by which the count of an electrode is incremented after each spot welded. The count factor is an experimental value that may be adjusted to the individual welding task. When set properly, the electrode can be automatically used under optimum conditions even when welding different sheet thicknesses or materials. If only count factors of 1.0 are used, the counts correspond to the spot count. Wear per com ponent Defines the wear experienced by an electrode when manufacturing a part with the electrode in question. Dress n ew electrod e Note: This function is not available for all timer types. Turns the “first tip dress” function on or off. “First tip dress” is used to ensure a defined condition (diameter, shape, etc.) of a new electrode. Extended e lectrod e life Note: This function is not available for all timer types. Indicates the number of wear counts that will be accepted before the timer is inhibited when the relevant electrode has reached its End of Stepper. The “Standard” field shows the mean actual rms current during all 3 heat blocks. The “Standard” field indicates the mean command value of all 3 heat blocks for driving the power unit (in I). Stop at end of st epper If assigned the value “ON”, another welding schedule is no longer possible using the relevant electrode if this electrode has reached its end of stepper condition. Also refer to parameter “Start-Inhibit (P)”.This condition will be symbolized by a red frame surrounding the timer symbol in question in the Network overview. If the current sensor or the connection cable is defective, Control stopped may be activated, e.g., for emergency operation. Possibility of incor rect welds CAUTION When control has been stopped, the current in the secondary circuit is no longer regulated with respect to the programmed value.https://www.mercedesbenzofaustinservice.com/wp-content/plugins/formcraft/file-upload/server/content/files/16270486152ebe---boss-me-50-bass-manual.pdf Therefore, changes in resistance in the secondary circuit (since the last weld of a program with operative regulation) will directly affect the quality of the spot weld. You should never activate Control stopped without good reason. This condition will be symbolized by a red frame surrounding the timer symbol in question in the Network overview. If the current sensor or the connection cable is defective, Monitoring stopped may be activated, e.g., for emergency operation. Possibility of incor rect welds CAUTION If current monitoring is inhibited, the current in the secondary circuit will not longer be compared to the programmed Reference current. Actual currents outside the programmed tolerance bands will no longer be signaled in this condition. Possible consequences include direct effects on the quality of the spot weld. You should never activate Monitoring stopped without good reason. Make sure that all spot welds are checked if Monitoring stopped has been activated. Max r epeat welds (max. To select the type of parity check. If the parity check has been activated, the timer can verify, through the additional “Parity” input signal, whether or transmitted. The number of active input signals “Program selection xx” must be odd if the “Parity” input signal is high. WC with error Defines whether the “WC” signal is to be output after the end of a welding schedule for “good” welds only, or after any welds. WC Period If the start signal is no longer present in “Single spot“ Mode at the end of a welding schedule, the WC will be automatically reset after the period of time defined in this parameter. Note: I Prewarni ng The value input must not be lower than the value of parameter “I Prewarning ”. Defines the current in I for the relevant electrode which is to trigger a I Prewarning. This parameter is relevant and displayed for equipment with thyristor power units only. Upper cu rrent limit Limits the maximum configurable I values for the electrode in question.www.ckt-works.com/userfiles/files/brinsea-mini-eco-manual.pdf In order to determine the maximum configurable I values, the system may strip out any I compensation from the value input. Example: Input value: 16.8 kA Maximum I stepping: 120 In input fields for I values, inputs greater than 14.00 kA are not possible. When using third-party sensors, the appropriate sensitivity can be programmed using this parameter. Possibility of incor rect welds. The value is automatically adjusted by the timer in the course of current calibration. CAUTION Making arbitrary changes to the toroid sensitivity will render current calibration useless. The accuracy of current measurement is no longer guaranteed. Therefore, you should never make any arbitrary changes to the value displayed! 2. Toroid sensitivity Note: This parameter is not available for all timer types. When using third-party sensors, manually enter the appropriate sensitivity in this parameter. Possibility of error messages. Arbitrary changes of the 2nd toroid sensitivity may result in recurring error messages. CAUTION Therefore, you should never make any arbitrary changes to the value displayed. Timers offering automatic measuring range changeover display the currently active measuring range in this parameter. For timers with a programmable measuring range, the electrode range must be manually entered here, depending on the toroid sensitivity. Curr ent at 0 I Note: This parameter is not available for all timer types. Input of the appropriate current value that is generated by the inverter (PSU) at 50 I with a linear current control characteristic. Type (transfo rmer) Note: This parameter is not available for all timer types. Serves to select the welding transformer for the electrode (gun) in question. The necessary information is shown on the nameplate of the welding transformer (e.g. “PSG 3100.00”). If the proper transformer type cannot be selected from a list box, you have to select the “Other transformers” option. In this case, the following information must be additionally entered: Transformer ratio Nominal current Type of diode and No.CAUTION The timer derives additional important information from the transformer type specified here that is necessary for safe operation. Therefore, you should never make any arbitrary changes to the input value. CAUTION The timer derives additional important information from this parameter that is necessary for safe operation. Number (of transformers) Note: This parameter is only relevant for weld timers of the PSI 6000 series. Number of welding transformers connected. ? If several welding transformers are connected, the electrical characteristics of these transformers must be identical. ? Use connection leads of the same conductor area and length for all transformers in question. Possibility of damaging the transformers. CAUTION The timer from derives information this additional parameter important that is necessary for safe operation. Transformer ratio of the primary transformer used. This information is normally shown on the nameplate of the welding transformer. Nomina l current (tra nsformer) Note: This parameter will not be displayed unless “Other transformers“ has been selected in Transformer-Type. Nominal current of the welding transformer in kA. The timer limits the maximum welding current to the value specified in this parameter in order to protect the transformer. The CAUTION timer derives additional important information this parameter that is necessary forfrom safe operation. If yes, the welding sequence is immediately aborted. CAUTION If diode supervision is deactivated, the diodes may be destroyed in the event of overload. Therefore, we strongly recommend to leave diode supervision active at all times. Diode type used for the welding transformer. Number of diodes used for each secondary branch. Switch-off temperature (diodes) Note: This parameter will not be displayed unless “Other transformers“ has been selected in Transformer-Type. Diode tempera tur e Displays the calculated junction temperature of the high-current diodes during the last weld performed with the relevant electrode (gun). Mains v oltage Displays the mains voltage during the last weld performed with the relevant electrode (gun). Maximum pressure Limits the maximum permissible electrode force values for the electrode (gun) in question. In order to determine the maximum configurable values, the system strips the Final values of active stepper data configured or the maximum permissible pressure correction data out from the input value. Example: Input value: Maximum pressure stepping: Max. Possibility of damaging guns. CAUTION Before pressure calibration has been properly carried out, there is no defined correlation between the programmed force and the resulting force at the electrode gun. For thisthe reason, the value input cannot protect gun unless pressure calibration has been properly completed. CAUTION The value is automatically determined by the timer in the course of pressure calibration and entered in this parameter. By making arbitrary changes of the parameter value the defined correlation between the value input and the resulting force at the electrode gun will be lost. Therefore, you should never make any arbitrary changes to the value displayed. A feedback transformer is used for voltage measurement with the KUR regulation mode. Enter the turns ratio of this transformer in this parameter. Thyristor-Unit-Type Note: This parameter is not available for all timer types. Adjusts the timer to the power unit connected. Possibili ty of derives damage sadditional to the plant!important The timer CAUTION information from this parameter that is necessary for safe operation. Thyristor-Unit temperature Note: This parameter is only available for timers with an external power unit. Indicates the type of temperature contact at the power unit. Ignition Type Note: This parameter is only relevant for connection of CNOMO power units. It is needed to set the control method for the AC power unit. Standard (Burst): Default CNOMO (Pulse): Special case Possibili ty of damage s to the plant. The timer derives additional important information from this parameter that is CAUTION necessary safeshould operation. Therefore, foryou never make any arbitrary changes to the input value. Timer t ype (Thyri stor -Unit-Pa ramete r) Returns the exact timer type. Note: The “Diagnosis” menu can only be activated for online timers. Note: For information concerning the Status line, refer to “Explanations“ section. Progra m (display field in “ Diagnosis” menu) Shows the program number currently active at the digital inputs as a decimal number. For this purpose, all signals are cyclically updated and displayed either in binary format (line by line from left to right, starting with the lowest signal number) or one below the other (in table format), depending on the type of display selected. Note: In contrast to the other tabs, customized names (set by the configuration tool) are used for the signals in this case. Therefore, please make sure that there is noone in the hazard zone when the welding program is started or the WC contact is deliberately output. Possibili ty of imm ediate welding sc hedule start afte r “ Fault reset with rewe ld”. DANGER If the start signal is present when a fault is reset with reweld, the timer will immediately start repeating its program run. Welding will be repeated. Therefore, please make sure that there is noone in the hazard zone when fault reset with reweld is started. Possibili ty of imm ediate machine movements after “ Fault Rese t with WC”. DANGER If the start signal is still present at “Fault reset with WC”, the timer will set the “WC” output signal as soon as the fault has been reset. This may result in machine movements. DANGER Under certain conditions, the timer will automatically extend the SQZ before proceeding to WLD (waiting for pressure contact or pressure feedback). Therefore, you should ensure that no-one enters the hazard zone for as long as the messages “No Schedule” (“Interval” field) or “OK” field) are not displayed in the “Actual(“Status” Cycle” area. The timer can be reset to “Ready” state and the WC contact can be output by hitting the Reset w ith WC command button. Status (Diagnos is, Start Simulation Additional information concerning the active interval. Last weld program cho sen Display of the program no.Start wi th ign itio n (Diagnosi s, Start Simulation. Start without ignition (Diagnosis, Start Simulation). Radio button “Off”: a WC signal previously given by the “On” radio button is removed. Timer type (Dia gnos is, Timer-I nfor mation) Display of the exact timer type of the relevant timer. Software- Versi on (Diagnosi s, Timer-I nfor mation) Displays the firmware version of the relevant timer. Addi ti on (Diagnosis, Timer-Inf mation, concerning Timer) the timer message displayed. Additionalorinformation Displays either the program number, electrode number, or an additional message text. Interval (D iagnosi s, Timer-I nfor mation) Indicates the section of the welding schedule that is currently being processed by the timer (schedule display). Status (Diagnosi s, Timer- Information, Actual Cycle) Additional information concerning the active interval. Program (Dia gno sis, Timer-I nfor mation) Number of the program that was last started in the relevant timer. Diagno sis: Last We ld Note: First you have to select the relevant timer - indirectly via the “Spot-Name” field, or - directly via the “Timer” field. You can transfer all stepper curves to the timer by hitting the Appl y command button. Each curve (0 to 9) influences the I, reference current and pressure and defines the desired change of all these quantities subject to the electrode count during the stepping phase. Select the desired curve in the “Curve number field. A total of 8 intermediate points are available between the starting point and the end point for influencing the curve characteristic. For this purpose, you must drag the black points with the mouse to the desired position, or enter the corresponding values right below the “I change” and the “Count Value” parameters. For reasons of plausibility, count values can only be entered in ascending order into the input fields from left to right. Linear interpolation will be carried out between any 2 intermediate points. In a first approximation, these curves approximately resemble the shape of an e-curve, rising sharply in the beginning and becoming flatter afterwards. The actual shape of a I stepping curve is an experimental value. Normally, it does not really depend on the actual heat value, or the electrode shape used by a welding program, but rather the electrode alloy and the parts to be welded. You can transfer all data displayed to the timer by hitting the Appl y command button. Each curve (0 to 9) influences the I, reference current and pressure. Based on the curve, the timer defines the change of all quantities specified after a dressing cycle subject to the electrode count. The change will remain constant until the next dressing cycle (stepper function). It will act in addition to a change generated by the Stepper-Curve Select the desired curve in the “Curve number field. Again, the optimum curve shape is an experimental value which depends on the type of electrode maintenance concept. A linear adjustment (ramp) may be used as an initial approximate value. Setup: Fault-Setup Note: First you have to select the relevant timer - indirectly via the “Spot-Name” field, or - directly via the “Timer” field.