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Bosch Manual REXROTH BOS6000 Users Manual PDF
Bosch Manual REXROTH BOS6000 Users Manual PDF
User Manual
Bosch Rexroth GmbH | Electric Drives BOS 6000 | 1070087074 / 01
and Controls
Validity The data specified above only serve to describe the product. 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.
Contents
Contents
Contents
Contents
Timer change.....................................................................139
Copy ..................................................................................140
Firmware change ...............................................................141
Para.-Data Import/Export (Parameter-Backup) .................143
Para.-Data Import/Export (Parameter-Restore).................144
Set Counter........................................................................145
Current calibration .............................................................146
Force calibration ................................................................147
Corresponding Programs...................................................148
Spot Comment...................................................................149
Detail Info...........................................................................150
Contents
Contents
Contents
In this chapter, you will find basic information concerning the BOS
6000 Help system.
Software version
Help version: 2.0 (10.05.2005)
Valid as of BOS software version: 1.14.5 (20.12.2004)
Copyright 2002-2006.
All rights reserved, including applications for protective rights.
10 Bosch Rexroth GmbH | Electric Drives BOS 6000 | 1070087074 / 01
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Activating Help
The Help system can be activated in different ways:
Show (Unhide)/Hide
• Shows or hides the left window area containing the “Content”,
“Index”, “Find” and “Favorites” tabs.
Previous (Back)
• While you navigate through the Help topics, the system
remembers all topics viewed in the order they have been called.
Previous (Back) jumps back one position towards the
beginning of the navigation path.
Next
• If Previous (Back) has been pressed at least once, Next jumps
forward one position towards the end of the navigation path.
Print
• Opens the ”Print help topics” window.
You can choose whether you only want to print the current Help
topic or its sub-topics as well (if existent). Then you confirm
your choice by pressing OK and follow your computer’s print
dialog.
12 Bosch Rexroth GmbH | Electric Drives BOS 6000 | 1070087074 / 01
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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. If no
exact entry match is found, the system will choose the lower
next keyword from the list according to the sort sequence.
4. Click on the Show (View) command button to view the
relevant description.
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Text 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 “Find” tab in the left window area.
3. For searching, enter the desired term(s) in the “Find term“ field.
If necessary, you may use the wildcard character “*” for any
possible string. The individual search terms can be logically
combined by the AND, OR, NEAR, NOT operators and the
bracket symbols “(“ and “)”. The search itself is not case-
sensitive, however, the operators have to be written in capital
letters.
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. Now, the relevant topics can be displayed by
double-clicking on a list entry or by clicking on the Show
(View) command button after having selected a topic.
14 Bosch Rexroth GmbH | Electric Drives BOS 6000 | 1070087074 / 01
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Use favorites
Topics that are frequently needed or especially important can be
included in the permanent Favorites list that is listed in alpha-
numerical order (and can even be given a different name there!).
Thus, after closing and re-opening the Help function, the topics of
interest are immediately displayed again.
Safety Instructions
Safety Instructions
This section contains important safety-related information.
Information concerning
• the mechanical construction
• the electrical connection (24V supply and I/O) and
• the functionality
of the hardware addressable via BOS is described more in detail in
the relevant manuals. There, you will also find safety information
that is important for product handling. Store this documentation in
a place to which all users have access at any time!
Safety Instructions
Symbols used
This symbol is used wherever insufficient or lacking
compliance with instructions may result in personal
injury.
DANGER
Safety Instructions
Proper use
Our weld timers
• serve for resistance welding of metals in connection with a
welding transformer and the appropriate power unit, and
• are suitable for operation in industrial environments in
accordance with the following standards: EN 50178, EN 60204-
1, EN 50081-2, EN 50082-2.
In residential environments, in trade and commerce as well as
small enterprises, class A equipment may only be used if it
does not inadmissibly interfere with other equipment.
Safety Instructions
Qualified personnel
The present documentation is designed for specifically trained
engineers with special knowledge of the welding technology. 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.
Such personnel are
• those who, being well trained and experienced in their field and
familiar with the relevant norms, are able to analyze the jobs
being carried out and recognize any hazards which may have
arisen
• those who have acquired the same amount of expert knowledge
through years of experience that would normally be acquired
through formal technical training.
Safety Instructions
Safety Instructions
Trademarks, copyright
• All trademarks of software installed on our products upon
delivery are the property of the respective manufacturers.
• Upon delivery, all installed software is copyright–protected. The
software may only be reproduced with our approval or in
accordance with the license agreement of the respective
manufacturer.
• Reverse engineering of our software/firmware is illegal.
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.
In order to work with the user interface, you need to have a rough
knowledge of the operating system (MS Windows 2000 or higher):
• operating the mouse and keyboard
• entering data with the keyboard into input fields, or selecting
data from lists.
• changing the size/position of a window, closing windows
• changing paths to folders via a dialog box if your settings differ
from the default.
Reference</LABEL ()
>
()
(Timer</LABEL>)
set-up</LABEL>
the BOS 6000 main
Schedule</LABEL>
window
Seq. Pg.2</LABEL>
(
Stepper</LABEL> Counter</LABEL
>)
General</LABEL>
Electrode</LABEL> calibration</LAB
EL>
1070087074 / 01 | BOS 6000 Electric Drives | Bosch Rexroth GmbH 25
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<LABEL
calibration</LAB
EL>
Thyristor-Unit-
Parameter</LABEL>
Diagnostics I/O</LABEL>
Timer-
Users Diagnostics
Information</LAB
I/O</LABEL>
EL>
Last
Weld</LABEL>
Start Simulation</LABEL>
Timer-
Information</LABEL>
Last Weld</LABEL>
Stepper curves</LABEL>
Tipdress curves</LABEL>
Fault-Setup</LABEL>
Communication</LABEL>
Correction</LABEL>
Reference</LABEL
>
(
( Info</LABEL>) Counter</LABEL
>)
table</LABEL>
overview</LABEL>
(
Overview</LABEL>
)
( Access
Level</LABEL>)
()
change</LABEL>
()
change</LABEL>
(
Import/Export (Para
meter-Backup) )
26 Bosch Rexroth GmbH | Electric Drives BOS 6000 | 1070087074 / 01
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(Para.-Data
Import/Export (Para
meter-Restore))
()
(
Programs</LABEL>
)
(Spot Comment)
Note: Many menu items can also be directly accessed via the
keyboard. The corresponding key codes are displayed
by the system to the right of the relevant menu text.
Note: If the menu items are not shown or are dimmed, the
function has not been enabled by the Administrator for
the user currently logged in.
File | Exit
Closes the BOS 6000 application (also possible by clicking on )
Edit | Programming
Switches to the topic “Programming” in the BOS 6000 main
window.
Edit | Diagnosis
Switches to the topic “Diagnosis” in the BOS 6000 main window.
Can only be selected if an online timer has been selected in the
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Edit | Setup
Switches to the topic “Setup” in the BOS 6000 main window.
Edit | Correction
Switches to the topic “Correction” in the BOS 6000 main window.
Edit | Autobackup
Opens/selects the ”Autobackup ” window.
Edit | Copy
Opens the Copy window
Edit | Login
Opens the Login window
Language
Immediately changes over to the selected language.
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Functions | Prewarning
Opens/selects the ”Prewarning ” window.
Functions | Protocol
Opens/selects the ”Protocol ” window.
Functions | Compare
Opens/selects the ”Compare ” window.
Help | Help
Opens/selects the Online help function.
Help | About
Displays information concerning BOS 6000, and concerning the
runtime libraries and the BOS6000.exe and BOSServ.exe used
when clicking on the “Module List” button.
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Login
Purpose:
• at program start:
• User login to system
• to set the desired language
(if enabled in configuration tool)
From the login, the system detects the functions of the user
interface to be enabled or disabled. Functions that are disabled are
not displayed or will be dimmed.
Username
Input the user name. Click on to select the desired user name
from the list of users.
Note: The user list can only be modified using the user
administration in the configuration tool.
User-Password
Enter the relevant password. An asterisk “*” will be displayed for
each character input.
Language
Timer Reference
Purpose:
• at program start:
• Display of basic communication parameters of all timers
assigned to the BOS 6000. For a description of the table
columns, also refer to window “Add/ChangeTimer”).
• to logon timers to BOS 6000 / delete timers from BOS 6000
• to define/change the ID and communication data of timers
• to export (Backup) timer data from the internal database, or
to import it into the internal database (Restore)
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OK command button
Closes the window.
Add/ChangeTimer
Purpose:
Timer name
Input of a unique timer name.
Several identical names are not permitted in Timer Reference.
Number of characters: min. 1, max. 48.
Prohibited characters: / | \ " ? * < > ' :
Acknowledge your input by pressing the Tab key.
Timer comment
Explanation text (optional).
Number of characters: max. 65.
Prohibited characters: ‘
Acknowledge your input by pressing the Tab key.
Channel
Communication port used.
Depending on the currently available hardware, the possible
communication interfaces can be selected from a list box.
IP address
Timer address within an Ethernet network.
In order to ping an IP address already entered in the timer
reference table, click on .
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Timer address
Timer address within a Field bus network.
Station
Station number of the timer within an INTERBUS network.
COM port
Defines the COM port (COM1, COM2) in connection with the V24
communication interface.
Operating mode
ONLINE:
When BOS 6000 is started, the system tries to establish a
connection with the timer under the given address.
OFFLINE:
In this mode, program preparations and programming exercises
can be made without a timer connected to the programming
terminal. The data of an offline timer is stored in the BOS 6000
internal database. Diagnosis or starting program execution is not
possible, however.
Software Version
Specification of the timer type and the necessary firmware version.
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Direction
When establishing connection with an online timer, the system
checks whether the data in the timer and in the database is
identical.
If it is not, you can define the desired response here:
• Selection:
The system will offer a selection of further activities.
• Timer -> DB:
Default. Timer data is transmitted to the database. Current
actual values and counter statuses will not be transmitted.
• DB -> Timer:
Special case. Database data is transmitted to the timer. Actual
values and counter statuses stored in the database will not be
transmitted.
• FW-MODE:
Special case. Database data is transmitted to the timer. Actual
values and counter statuses stored in the database will also be
transmitted.
Connection set-up
Purpose:
• at program start:
• Status/error display
- Connection set-up to the online timers
- Data match between the data in the database and in the
timer
- Database initialization for new offline timers
Select the desired direction of the data match in this dialog and
confirm your selection by hitting OK.
The data match will start as soon as you have acknowledged
the query by hitting OK.
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Programming
Within the BOS 6000 main window, the “Programming“ menu
(selection by symbol ) offers the following options:
Programming: Schedule
Start-Inhibit (P)
If preset with the value “On”, execution of the program in question
is not permitted. Thus, for example, it is possible to prevent a
program that is not in use or to which no meaningful parameters
have been assigned from starting.
Note: The power unit will not be energized unless the following
conditions are met:
Parameter “Weld/No weld (P)” = “On” and
Parameter “Weld/No weld (Global)” = “On” and (if
existent)
the “Weld external” input signal has been set.
Schedule
Defines the desired sequence mode of the relevant program.
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Single:
A high level at the start input initiates the welding schedule (or
welding program) exactly once, starting with the pre-squeeze time
(Pre Sqz).
For the next program start, the Start signal has to be switched off
and back on.
Repeat:
The weld timer initially responds to the start signal as in "single
spot" mode and starts the welding schedule.
If the start signal is still present after the end of the hold time
(HLD), the solenoid valve signal will be switched off and the
electrode gun is opened.
The Off time (OFF) runs. During this time, the operator can pull on
the welding gun towards the next spot.
After the end of the OFF time, the solenoid valve will be energized
again, and the welding schedule will be restarted - this time
beginning with the SQZ.
This schedule will be repeated for as long as the start input is high.
Seam:
Offers 2 fixed, sequential heat blocks (1st and 2nd heat block) for
each start event, with the possibility of programming the duration
and amount of current separately for each block.
During the 2nd heat block, the weld time (WLD) and a cool time
(2.CT), if programmed, will be repeated for as long as the start
input remains high.
When the start signal becomes low, the timer will cancel the actual
current pulse and start the hold time (HLD).
Monitoring
Defines the desired monitoring mode of the relevant program. For
activation/deactivation of monitoring, refer to parameter "Current
monitoring".
Standard:
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Mixed:
The rms value is measured separately for each heat block,
compared to the relevant Reference current of a weld time and
monitored by separate tolerance bands (for the 1st, 2nd and 3rd
heat block). Any cool times programmed will not be accounted for
in the actual value generation for the individual heat blocks.
This results in a greater transparency of the individual heat blocks,
however, the amount of data to be processed becomes larger.
Regulation
Defines the desired regulation mode of the relevant program.
Standard:
The Regulation mode predefined for the 2nd heat block is
applicable to all 3 heat blocks.
Mixed:
The regulation modes of all 3 heat blocks can be defined
individually and independent of each other.
Electrode
Defines the electrode (gun) to be used by the relevant program.
The counts to be incremented by the timer in the course of the
relevant program is also determined by this setting.
Spot-Repetition
Turns the “Spot repetition” function on/off for the relevant program.
When spot repetition has been activated, the welding program
concerned is automatically repeated once if Current monitoring
has been activated and would respond by issuing the "Low
current" or "No weld current" error messages.
This function may possibly save user interventions.
Pre Sqz
The Pre Sqz is processed immediately following the Start signal in
all three Sequence Modes ”single spot”, “repeat”, and “seam”.
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At the beginning of Pre Sqz, the timer activates the solenoid valve
signal to initiate the closing movement of the electrode gun. No
current flows during this period of time.
The Pre Sqz precedes the SQZ in order to ensure that the
electrode gun is completely closed even in the event of a long
travel, e.g., with manual guns.
When welding repeated spots, the Pre Sqz will only be processed
for the first spot of the series.
SQZ
During the SQZ, the working pressure of the electrodes is built up.
The electrode gun must be entirely closed at the end of SQZ. No
current flows during SQZ.
The following signals may prevent processing of the SQZ with
individual timer types
• Pressure contact
• Pressure feedback from pressure control valve
• NBS release
PreWld
Period of time for preheating the parts to be welded with the Pre
Weld kA.
If preheating is not desired, this parameter can be set to 0.
The maximum permitted period of time can be limited using the
"Programming" menu, tab "General".
Also refer to 1.CT“.
1.CT
Serves to reduce stress in the parts to be welded after the PreWld.
The welding gun remains closed within the 1.CT. There is no
current flow.
Slope
Turns the “Slope” function on or off.
When slope is active, the %I can be automatically sloped in the
2nd heat block.
This “Slope” function is defined via the following parameters:
UST (Slope-Time)
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Start-Slope-Current
DST (Down-Slope-Time)
End-Slope
UST
Acts in conjunction with the "Slope" function.
Period of time during which the current is linearly changed from the
programmed Start-Slope-Current to the Main weld current if the
“Slope“ function is active.
The UST always starts at the beginning of the 2nd heat block and
is not interrupted by any cool times programmed in the 2nd heat
block (refer to 2.CT).
WLD
Period of time during which the parts are welded together with the
Main weld current taking a possibly activated Slope into account.
The maximum permitted period of time can be limited using the
"Programming" menu, tab "General".
For more information, also refer to 2.CT“.
DST
Acts in conjunction with the "Slope" function.
Period of time during which the %I is linearly changed from the
programmed Main weld current to the End slope if the “Slope“
function is active.
The DST always ends at the end of the 2nd heat block and is not
interrupted by any cool times programmed in the 2nd heat block
(refer to 2.CT).
2.CT
With active pulse operation (Parameter "Impulse" has been
assigned a value greater than 1) this cool time serves to reduce
the stress in the parts to be welded after the WLD and separates
the individual pulses (duration of a pulse: corresponding to the
WLD).
The welding gun remains closed within the 2.CT. There is no
current flow.
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Impulse
Activates the impulse mode if assigned a value greater than 1.
If impulse mode has been deactivated, the duration of the 2nd heat
block exactly corresponds to the WLD.
If impulse mode is active, the WLD is repeated corresponding to
the value programmed for “Impulse”. This is the only case in which
the 2.CT is also active. The duration of the 2nd heat block now
depends on the number of WLD and the number of 2.CT.
3.CT
Serves to reduce stress in the parts to be welded prior to the
beginning of the PostWeld. The welding gun remains closed within
the 3.CT. There is no current flow.
PostWeld
Period of time for post-heating the parts to be welded with the . In
this way, the parts to be welded can be prevented from cooling
down too quickly (due to the electrodes cooling).
If post-heating is not desired, this parameter can be set to 0.
The maximum permitted period of time can be limited using the
"Programming" menu, tab "General".
Also refer to 3.CT.
HLD
Period of time for cooling down the parts to be welded.
The welding gun remains closed during the HLD. There is no
current flow.
At the end of the HLD, the weld has been completed. The timer
resets the “solenoid valve” signal. The welding gun is opened.
If necessary, the weld complete contact (WC) is output.
OFF
Period of time until the next SQZ during which the gun is open in
Sequence mode "Repeat" and can be pulled to the next spot to be
welded..
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Pre Weld kA
Desired base current during the PreWld.
In kA or %I, depending on the Regulation mode programming .
The maximum permitted %I is limited in the ”Programming” menu
using the “Electrode” tab (via parameter “Upper current limit”).
Start-Slope-Current
Desired base current at the beginning of the UST.
In kA or %I, depending on the Regulation mode programming .
The maximum permitted %I is limited in the ”Programming” menu
using the “Electrode” tab (via parameter “Upper current limit”).
End-Slope
Desired base current at the end of the DST.
In kA or %I, depending on the Regulation mode programming .
The maximum permitted %I is limited in the ”Programming” menu
using the “Electrode” tab (via parameter “Upper current limit”).
Pst Wld kA
Desired base current during the PostWeld.
In kA or %I, depending on the Regulation mode programming .
The maximum permitted %I is limited in the ”Programming” menu
using the “Electrode” tab (via parameter “Upper current limit”).
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Reference current
The parameters “Ref. current” serve as separate command values
for monitoring the individual heat blocks.
The weld timer compares the measured actual rms current values
(shown in the "Act. ref. current" fields) with these programmed
values and interprets them as “good” or “bad” with respect to the
relevant tolerance limits.
Unacceptable actual values result in a fault message if the relevant
Current Monitoring function has been activated.
Regulation mode
Defines the desired regulation mode for the relevant program,
taking parameter "Regulation" into account.
PHA
Programming the phase angle of thyristor power units or the pulse
width of medium-frequency inverters. Programmed %I values will
be interpreted as command values for the power unit and input as
%I.
No regulation is active. The resulting current exclusively depends
on the conditions of the secondary circuit. A current sensor is not
necessary.
If a current sensor is available, it can be used to display the actual
current and for Current monitoring.
KSR
Activates constant-current regulation.
Programmed %I values will be interpreted as command values for
the %I controller and input as kA values.
Unless blocked by parameter "Control stopped", current regulation
is activated. For this reason, the resulting current is largely
independent of the conditions of the secondary circuit. A current
sensor must be available.
The Current monitoring function can be separately activated.
Please note that actual current values are not monitored for
programmed tolerance bands unless current monitoring is
switched on!
Current monitoring
Repeat factor
For a description, refer to parameter "conditional tolerance band".
The display fields right of the repeat factor (MIX … tolerance band
error) indicate the number of consecutive welds already recorded
within the conditional tolerance band.
Pressure stepping
The “Pressure stepping” function automatically changes the
pressure value (electrode force) between two consecutive phases
(start phase and stepping phase) depending on the current
program, the count and the tip dress counter.
It is enabled or disabled for the respective electrode parallel to the
"Stepper" function via parameter "Stepper" (refer to "Programming"
menu, tab "Stepper").
It depends on the parameter settings whether or not the (enabled)
function is eventually active:
Pressure profile
Turns the “Pressure profile” function on or off.
If this function is active, pressure changes can be input during
execution of the relevant welding program.
The pressure profile including the pressure value and pressure
time can be programmed in 10 steps (parameters "Force x.PV"
and "Time x.PT").
It starts with the squeeze time (SQZ) and ends with the hold time
(HOLD). If the total of the pressure times is longer than the entire
schedule duration from the Squeeze time (SQZ) until the Hold time
(HOLD), the pressure profile will be cut off at the end of the Hold
time. Afterwards, only the Base pressure value) will be active.
Force x.PV
Pressure values (force in kN) for the "Pressure profile" function.
The corresponding time spans are defined in parameter "Time
x.PV".
Time x.PT
Periods of time (in ms) during which the corresponding pressure
value ("Force x.PV") is output in conjunction with the "Pressure
profile" function.
Off-time
Acts in conjunction with the "freely programmable output" function.
Parameters 1.Off-time, 2.Off-time and 3.Off-time serve to define a
maximum of 3 periods of time during which the freely
programmable output is reset.
On-time
Acts in conjunction with the "freely programmable output" function.
Parameters 1.On-time, 2.On-time and 3.On-time serve to define a
maximum of 3 periods of time during which the freely
programmable output is high.
Reference time
Reference time (in ms) for the "Time monitoring" function.
Note: The actual time (time span from the beginning of the
PreWld until the end of the PostWeld including all cool
times) is displayed immediately after the end of the
relevant welding program in the "Diagnosis" menu, tab
"Last Weld".
Tolerance standard
+/- tolerance (in ms) for the "Time monitoring" function.
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Programming: Stepper
Using the Set counter command button, the Count and the
Dressing-counter of the relevant electrode can be manipulated.
Refer to sect. "Set counter".
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%I Step.-Value
Displays the currently active %I stepping as a percentage of the
base %I.
Monitor Step.-Value
Displays the currently active stepper value for the Reference
current in % of the base reference current (Monitor stepper).
Press. Step.-Value
Displays the currently active Pressure stepping as a percentage of
the base pressure value.
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%.
The start phase is normally very small (approx. 5 – 50 spot welds)
and only has to be programmed for special applications, e.g.,
galvanized sheets.
In combination with tip dressing, the start phase may be used to
“run-in” a new electrode.
Counts
Indicates the current Counts of the relevant electrode.
New electrodes always start with a Count of 0. The actual count is
incremented by the program-specific Count-Factor after each spot
welded.
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Maximum count
Effect when dressing has been deactivated
(for activation/deactivation, refer to parameter Dressings"):
Defines the End of Stepper 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.
Prewarning Count
Defines the number of counts prior to the End of Stepper for which
the “Prewarning” signal is to be output for the relevant electrode.
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Dressings
Indicates how often the relevant electrode should be dressed in
the course of its life cycle (including first tip dress. Refer to "Dress
new electrode").
Dress-Request
Defines the number of counts prior to the "Maximum Count" for
which the “Tip dress request” signal is to be output for the relevant
electrode.
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Stepper
If activated, the “Stepper”, “Dressing” and “Dress new electrode”
functions have been enabled for the electrode in question and
operate according to their parameter settings.
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.
Programming: General
Max. %I correction
Defines the maximum %I correction (increase) of the relevant
timer (refer to "Correction" menu, tab "Correction", parameter "%I
correction (x)").
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Min. %I correction
Defines the maximum %I correction (decrease) of the relevant
timer (refer to "Correction" menu, tab "Correction", parameter "%I
correction (x)").
Max. Pressure-Correction
Defines the maximum pressure correction (increase) of the
relevant timer (refer to "Correction" menu, tab "Correction",
parameter "Pressure correction (x)").
Min. Pressure-Correction
Defines the minimum pressure correction (decrease) of the
relevant timer (refer to "Correction" menu, tab "Correction",
parameter "Pressure correction (x)").
Start-Inhibit (T)
If programmed as “ON”, starting any program of the selected timer
will initiate the error message “Start inhibited".
Note: The power unit will not be energized unless the following
conditions are met:
Parameter “Weld/No weld (P)” = “On” and
Parameter “Weld/No weld (Global)” = “On” and (if
existent)
the “Weld external” input signal has been set.
Control stopped
If programmed as “On“, this function will inhibit KSR mode (refer to
parameter "Regulation mode") for all programs of the relevant
timer. 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.
Monitoring stopped
If programmed as “On“, this function will prevent a response of
Current monitoring for all programs of the relevant timer. 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.
Choose parity
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 not the “Program selection xx” input signals
have been properly transmitted.
Possible settings:
• Off: no parity check.
• Even: Parity check on.
The number of active input signals “Program selection xx” must
be even if the “Parity” input signal is not high.
• Odd: Parity check on.
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.
In connection with the WC signal, also refer to parameters "WC
Period" and "WC Start time".
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..
WC Start time
Influences the time when the WC is output.
• Input = 0:
The positive edge of the WC will be simultaneously output at
the end of HLD.
• Input > 0:
The positive edge of the WC is delayed by max. 1000 ms with
respect to the end of HLD.
• Input < 0:
The positive edge of the WC will be output before the end of
HLD. This allows you to reduce constant delays in the
subsequent handling sequence.
Although 1000 ms can be maximally programmed as the time
period for accelerating the WC, this time must always be shorter
than the currently programmed HLD.
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Fade-out time
Note: The programmed fade out time is identical for all weld
times and for all welding programs! Therefore, you
should make sure that the fade out time is always
shorter than the shortest programmed weld time.
Trail current
Note: This setting is identical for all weld times and for all
welding programs.
Current supervision
Programming: Electrode
%I Limitation
Limits the maximum permissible %I values for the electrode in
question.
Note: The value input must not be lower than the value of
parameter “%I Prewarning ”.
%I Prewarning
Defines the current in %I for the relevant electrode which is to
trigger a %I Prewarning.
1. Halfcycle limit
Limits the phase angle of the 1st halfcycle within the welding
schedule (= transformer inrush current) to the value input for the
relevant electrode.
This parameter is relevant and displayed for equipment with
thyristor power units only.
Toroid sensitivity
Specifies the toroid sensitivity (in mV/kA) of the current sensor for
the relevant electrode (gun).
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2. Toroid sensitivity
Electrode range
Current at 0% I
Current at 50% I
Type (transformer)
Note: This parameter is only relevant for weld timers of the PSI
6000 series.
Supervision (diodes)
If activated, the high-current diodes in the transformer’s secondary
circuit will be monitored for excessive junction temperatures.
For this purpose, the system checks - with reference to a cooling
water temperature of 30 degrees Centigrade - whether the
(internally calculated) junction temperature of the diodes (value
displayed in field "Diode temperature") exceeds the "Switch-off
temperature" configured. If yes, the welding sequence is
immediately aborted.
Type (diodes)
Diode temperature
Displays the calculated junction temperature of the high-current
diodes during the last weld performed with the relevant electrode
(gun).
Mains voltage
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.
Conversion-Factor
Determines the slope of a linear characteristic that defines the
resulting gun force as a function of the force influencing variable
(refer to "Programming" menu, tab "General, Parameter"Mode
Pressure Output") parameter.
The following relationship applies in general:
F(St) = <Conversion factor> x St + <Zero-adjust>
where F is the resulting force in kN and St the force-influencing
variable.
Examples:
Input value “1”: the timer converts a programmed force into the
force-influencing variable at a 1:1 ratio using a 45 degrees
characteristic.
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Zero adjust
Determines the offset by which the linear characteristic (refer to
parameter "Conversion-Factor") intersects with the force axis (F).
Programming: Thyristor-Unit-Parameter
Note: Entries in the “Thyr.” field are only possible if the timer is
capable of driving several power units in parallel.
Thyristor-Unit-Type
Thyristor-Unit temperature
Ignition Type
Software-Version (Thyristor-Unit-Parameter)
Displays the firmware version.
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Diagnosis
Within the BOS 6000 main window, the “Diagnosis“ menu (which is
called up by the icon) offers the following choices:
Inputs / Outputs
Returns the current status of these signals.
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.
Signal status:
0: Signal is low (white background)
1: Signal is high (green background)
• If the signals are shown in binary format, you can click on a bit
field in order to display the signal number, signal type and
signal name in line “Description”. transmitted via the field bus
“discrete”: present at a hardware input/output
”internal”: is influenced/generated within the timer
The timer can be reset to “Ready” state and the WC contact can
be output by hitting the Reset with WC command button.
When hitting Reset with Reweld, the timer will be reset to “Ready”
state after a current fault of the type “Low current” or “no weld
current …”, and the faulty welding schedule will be restarted if the
start signal is still present.
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Diagnosis: Timer-Information
The timer can be reset to “Ready” state and the WC contact can
be output by hitting the Reset with WC command button.
When hitting Reset with Reweld, the timer will be reset to “Ready”
state after a current fault of the type “Low current” or “no weld
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current …”, and the faulty welding schedule will be restarted if the
start signal is still present.
Setup
Within the BOS 6000 main window, the “Setup“ menu (which is
called up by the icon) offers the following choices::
You can transfer all stepper curves to the timer by hitting the
Apply command button.
• The final point (%I change of 100% with a count of 100%) refers
to parameter "Pressure at end of 1.Stepper-Phase" for the
pressure, to parameter "%I at end of 1.Stepper-Phase" for %I,
and to parameter "Reference current at end of 1.Stepper-
Phase" for the reference current.
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• The starting point and the end point of a curve (white points) are
always fixed.
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.
You can transfer all data displayed to the timer by hitting the Apply
command button.
• The final point (%I change of 100% with a count of 100%) refers
to parameter "Pressure after last dressing" for the pressure, to
parameter "%I after last dressing" for %I, and to parameter
"Reference current last dressing" for the reference current.
• The starting point and the end point of a curve (white points) are
always fixed.
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.
Setup: Fault-Setup
Setup: Communication
Subnet mask
Subnet mask stored in the flash memory of the Ethernet adapter.
For more information concerning Ethernet, please refer to our
documentation on “Programming field buses”:
Standard gateway
IP address of the standard gateway stored in the flash memory of
the Ethernet adapter.
For more information concerning Ethernet, please refer to our
documentation on “Programming field buses”:
SMTP Address
SMTP address stored in the flash memory of the Ethernet adapter.
For more information concerning Ethernet, please refer to our
documentation on “Programming field buses”:
Port Number
Port number stored in the flash memory of the Ethernet adapter.
For more information concerning Ethernet, please refer to our
documentation on “Programming field buses”:
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Address mode
Address mode Comment
DEF_IP_SWITCH If Anybus switch bank == 0:
IP, subnet and gateway from flash
If Anybus switch bank != 0:
Low-Byte IP from Anybus switch bank, High-IP from
Basic address switch, Subnet and GATEWAY from
object
ALL_IP_SWITCH If Basic switch banks == 0:
as LOW_AB_IP_SWITCH.
If Basic switch banks != 0:
IP = Basic switch banks,
subnet and gateway from object
NO_IP_SWITCH always: IP, subnet and gateway from object
LOW_AB_IP_SWITCH If Anybus switch bank == 0:
IP, subnet and gateway from flash
If Anybus switch bank != 0:
Low-byte IP from Anybus switch bank:
High-IP == 192.168.0.X
Subnet == 255.255.255.0
GATEWAY == 0.0.0.0
LOW_CPU_IP_SWITCH immer: Low-Byte IP from CPU switch bank,
High-IP, Subnet and GATEWAY from object
MIX_IP_SWITCH always: Low-Byte IP from CPU switch bank,
High-IP from Basic address switch,
Subnet and GATEWAY from object
Baudrate
Baudrate
Automatic
Fixed 10 MBd
Fixed 100 MBd
Mode
Mode
Automatic
Fixed, simplex
Fixed, duplex
MAC-Adress
Display of the worldwide unique MAC address of the Ethernet
adapter.
For more information concerning Ethernet, please refer to our
documentation on “Programming field buses”:
DIP switch
Displays the setting of the IP-ADR switch bank (on the front side of
the Ethernet adapter) in decimal format.
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Correction
Within the BOS 6000 main window, the “Correction“ menu (which
is called up by the icon) offers the following choices::
Correction: Correction
Purpose:
%I Correction (Prg.)
Corrects the demanded %I of the relevant program by the
percentage indicated.
The permissible correction value also depends on parameters
"Max %I-Correction" and "Min %I-Correction" within the
"Programming" menu, tab "General "".
The %I correction (Prg.) and the %I correction (Elec.) act in
addition to each other.
%I Correction (Elec.)
Corrects the demanded %I of all programs using the electrode
displayed by the percentage indicated.
The permissible correction value also depends on parameters
"Max %I-Correction" and "Min %I-Correction" within the
"Programming" menu, tab "General "".
In order to enter correction values for other electrodes, you must
select a spot/a program that has been assigned to the desired
electrode as described above.
The %I correction (Prg.) and the %I correction (Elec.) act in
addition to each other.
Pressure-Correction (Prg.)
Corrects the electrode force (“base pressure value” parameter) of
the relevant program by the percentage indicated.
The permissible correction value also depends on parameters
"Max Pressure-Correction" and "Min Pressure-Correction" within
the "Programming" menu, tab "General "".
The Pressure correction (Prg.) and the Pressure correction (Elec.)
act in addition to each other.
Pressure-Correction (Elec.)
Corrects the electrode force (“base pressure value” parameter) of
all programs using the electrode displayed by the percentage
indicated.
The permissible correction value also depends on parameters
"Max Pressure-Correction" and "Min Pressure-Correction" within
the "Programming" menu, tab "General "".
In order to enter correction values for other electrodes, you must
select a spot/a program that has been assigned to the desired
electrode as described above.
The Pressure correction (Prg.) and the Pressure correction (Elec.)
act in addition to each other.
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Spot Reference
Purpose:
Spot name
Input of a unique spot name.
Several identical names are not permitted in Spot Reference.
Number of characters: max. 48.
Prohibited characters: '
Sched
Number of the program used to weld the spot.
WT
Name of the timer used to weld the spot.
Timer comment
Timer comment entered in Timer Reference.
Comment 1 to comment x
Comment field for describing the spot weld. The number of
comment fields can be specified in a configuration tool parameter.
Comments for a spot can be displayed by clicking on the icon
in the BOS 6000 main window (refer to window “Spot Comment".
Prewarning
Purpose:
Update
To update the display manually.
Normally, the display is automatically updated once per minute
(parameter can be set in configuration tool), and this setting should
not be altered for reasons of performance.
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Detail Info
Can only be activated if precisely 1 electrode has been selected.
In addition to displaying information about all important counter
statuses (counts, spot counter, dressing counter), the system also
indicates the maximum count and the maximum dressings of the
electrode in question.
The following activities are also possible with respect to the
currently selected electrode
- acknowledge tip change
- set counts and dressing counter manually.
Electrode changed
Can only be activated if at least 1 electrode has been selected.
Acknowledges an electrode change for all electrodes selected.
The counts, spot and dressing counters of the electrodes in
question are set to 0.
Error table
Purpose:
Network overview
Purpose:
Protocol
Purpose:
Error protocol:
contains all events occurred with the exception of weld faults, data
changes by the user and actual values.
Weld fault protocol;
only includes the weld faults occurred.
Data change protocol:
contains all events by which data were changed.
Weld current protocol:
contains all schedules that have been started including all
important command values and actual values.
ID
Sequential numbers of the protocol entries.
Date/Time
Time the entry was made.
Timer name
Name of the timer (as assigned in Timer Reference) that caused
the protocol entry.
Description
Cause of entry in plain text.
Addition
Additional message. Depending on fault, it includes the program or
electrode number; or other causes of the fault in the event of
welding faults.
Fault
Checkmark means: Protocol entry is defined as a fault.
Program
Program in which the weld fault occurred.
Monitor status
Message of the current monitoring function.
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Reference current
Current value that is the basis for monitoring.
Programmed time
Maximum permitted time span between the program start and the
end of the hold time (HLD) in ms.
Entry is only made if time monitoring is active.
Actual time
Actual time span between the program start and the end of the
hold time (HLD) in ms.
Entry is only made if time monitoring is active.
Count
Count status of the relevant electrode at the time of occurrence of
the fault.
Spot-Name
Spot name (as assigned in the Spot Reference table) for which the
weld fault occurred.
Parameter
Parameter that has been modified.
Prog./Elec.Nr.
Number of the program in which the parameter was changed,
or
number of the electrode that is affected by the modified parameter.
Old
The parameter value prior to the data change.
New
The parameter value after the data change.
Unit
Physical unit of the modified parameter.
Station number
Username
Username performing the data change.
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Comment
Comment text that was entered on the occasion of a data change.
Number
Number of the last welding program executed.
Spot-Name
Name of the spot (as assigned in the Spot Reference table)
welded.
Count
Count status of the relevant electrode at the time the schedule was
executed.
Count in %
Relevant electrode wear (in %) at the time the schedule was
executed.
Monitor status
Message of the current monitoring function in connection with the
weld executed.
Schedule
Status of program schedule.
Addition
Additional message concerning the weld executed.
Spot Repet.
Setting of the “spot repetition” parameter used for the schedule.
Monit.-Mode
Setting of the “monitor” parameter used for the schedule.
tDem.s
tAct.s
RegStd
Setting of the “regulation” parameter used for the schedule.
iDem.11
Setting of the “reference current” parameter used for the PreWld of
the schedule (in kA).
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iAct.1
Actual current measured in the PreWld (in kA).
regulation1
Reg1
Setting of the “regulation mode” parameter used for the PreWld of
the schedule.
iDem.12
Setting of the “reference current” parameter used for the WLD of
the schedule (in kA).
iAct.2
Actual current measured in the WLD (in kA).
Reg2
Setting of the “regulation mode” parameter used for the WLD of
the schedule.
iDem.13
Setting of the “reference current” parameter used for the PostWeld
of the schedule (in kA).
iAct.3
Actual current measured in the PostWeld (in kA).
Reg3
Setting of the “regulation mode” parameter used for the PostWeld
of the schedule.
PHA Std
PHA1
Mean phase value in the PreWld (in %I).
PHA2
Mean phase value in the WLD (in %I).
PHA3
Mean phase value in the PostWeld (in %I).
Compare
Purpose:
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Parameter Overview
Purpose:
FTP-Upload
Purpose:
Filename
Name of the zip file containing all html files necessary for the
relevant timer in compressed format. The path and the filename
can be modified for the selected timer using the … command
button.
Backup
Purpose:
Restore
Purpose:
Autobackup
Purpose:
WT
Timer name for storing the data via the autobackup function.
Date/Time
Time at which the autobackup will be/has been performed for the
first time for the timer in question.
Filename
File name under which the timer backup data is stored in the target
directory.
Next schedule
Next time the autobackup will be performed for the timer in
question.
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Last cycle
Time at which the autobackup has been performed for the last time
for the timer in question.
Status
gray: no backup has been made so far
green: backup was properly made in the last cycle.
Delete
Deletes a selected line without further queries. The relevant timer
is no longer taken into consideration for the autobackup.
All timers
First deletes all existing lines, then queries the time of the first
backup and the desired backup interval
OK
Activates the autobackup function and closes the window.
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Timer change
Purpose:
Copy
Purpose:
Firmware change
Purpose:
Timer type
Timer type including firmware version as defined in the Timer
Reference.
File
File name of the firmware to be loaded into the memory of the
relevant timer using the Load FW command button.
To select a firmware file, please click into the corresponding field.
Click on the … command button and select the desired firmware
file.
Status
red: no firmware has been loaded to the timer memory.
green: firmware has been/is being loaded.
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Load FW
Load the firmware file displayed in the “File” column to the RAM of
the corresponding timer. Welding can be continued during the
firmware load. This process will only be performed for the timers
selected via the appropriate checkboxes.
Change
Copies the firmware loaded into the timer RAM to the timer’s flash
memory. This process will only be performed for the timers
selected via the appropriate checkboxes.
If no firmware has been loaded into the memory of the relevant
timer using the Load FW command button, the Change command
button appears dimmed.
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Set Counter
Purpose:
Current calibration
Purpose:
Benefits:
Force calibration
Purpose:
Benefits:
Corresponding Programs
Purpose:
If the background color of the “Spot name” list box in the BOS
6000 main window changes to yellow, several spots are welded
with the program displayed in the “Program” input field.
By clicking on the icon, you can then display all of these spots
in the “Corresponding Program” window.
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Spot Comment
Purpose:
Detail Info
Purpose:
Stepping
Display of the electrode status in plain text.
Counts
Indicates the current Counts value for this electrode (= Counts).
Spots
Indicates the number of spots already welded by this electrode (=
spot counter).
Dressings
Indicates how often the electrode has already been dressed (=
Dressing Counter). Start tip dressing is not accounted for in this
case.
Max. Count
When dressing has been deactivated (Dressings = 0.0):
indicates the maximum permitted electrode count. Can be
configured in window"Programming: Stepper".
When dressing is active (Dressings > 0.0):
indicates the maximum permitted electrode count between 2
dressing cycles. Can be configured in window"Programming:
Stepper".
Dressings
Indicates how often the electrode may be dressed until the end of
stepper. Can be configured in window"Programming: Stepper".
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Electrode changed
Acknowledges an electrode change for the electrode displayed.
The counts, spot and dressing counters of the electrode in
question are set to 0.
Set counter
Sets the counts and dressing counter of the electrode displayed.
Cancel
Close “Detail Info” window.
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How to …
How to …
In this section, you will learn how to carry out important activities
within BOS 6000. The descriptions are focused on the handling
and operation of the software.
The BOS 6000 user interface and the BOS 6000 server application
(BOSServ.exe) running in the background are closed.
How to …
Note: BOS 6000 can no longer access a timer that has been
deleted. Parameter input, diagnosis and logging are not
possible for deleted timers!
Ö Do not delete any timers from BOS 6000 which you will still
need for programming or diagnosis, or for which continuous
logging is necessary!
How to …
How to …
How to …
1. In the BOS 6000 main window, select the Edit | Copy menu
item from the menu bar. The “ Copy” window will be displayed.
Note: At this point, the data has not been copied yet!
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How to …
How to …
2. First, select the relevant zip file using the … command button
and confirm your selection by hitting Open.
3. From the right list box, you select the timer whose data record
in the internal database is to be replaced with the contents of
the zip file and confirm your selection by hitting OK.
In the “Import Record Set Comparison” window, the system
displays important information concerning the backup selected
and the specified target timer record set.
4. Hit the OK command button to start the restore procedure.
For more details, refer to window “ Connection setup".
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How to …
How to …
4. In the “Detail view” tab, you will see the details of the
differences. Sort the table according to your needs.
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How to …
How to …
How to …
3. Use the tabs to select whether the access level of a menu item
(“Menu” tab) or a command button (“Button” tab) is to be
modified in the calling window.
The “Table” tab is only available in conjunction with a pop-up
menu which can be activated by right-clicking in the calling
window.
4. Select the line containing the relevant object and click on to
select the desired access level. If is not displayed, press
the Cursor-right key.
Only those users whose access level is identical to or higher
than the access level just assigned will be able to access the
object accordingly in the future.
5. Repeat the last two steps in order to assign all relevant objects
the desired access levels.
6. Confirm the current settings by hitting the Update button.
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How to …
How to …
Sort tables
Most tables can be sorted according to any criteria.
• Numerical columns will be sorted in numerical order by the
system.
• Columns containing strings will be sorted in alpha-numerical
order.
ascending: descending:
Filter tables
Some tables (in which the Show filter command button is offered,
e.g., in some logging tables) can be conveniently filtered according
to topics. When filtering is active, only those table lines are
displayed/printed/exported that meet the filter criteria selected.
The filter topics are dynamic, i.e., all entries in a column are
automatically included in a list box by the system which also
avoids redundant entries. Filters are activated by selecting an
entry from one or several list boxes.
How to …
How to …
How to …
How to …
Procedure
... if several parameters have been changed one after the other:
How to …
How to …
How to …
How to …
How to …
How to …
How to …
1. In the BOS 6000 main window, select the Edit | Timer Change
menu item.
The “ Timer change” window will be displayed.
How to …
4. Switch the defective unit off, safely isolate it from supply, and
replace it.
5. Make the necessary switch settings on the new unit (e.g. ADR
switch, NEXT/END switch for Interbus network).
6. Turn 24V logic supply on the unit on.
7. Select the Timer Change command button from the “Timer
change” window.The complete timer-specific record set will
now be automatically copied from the BOS 6000 internal
database to the timer.
Wait for the status messages at the end of the data
transmission (“Function was finished successfully.”).
8. Repeat force and current calibration.
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How to …
Procedure:
1. In the BOS 6000 main window, select the Edit | Firmware
Changing menu item. The “ Firmware Changing" window will
be displayed:
How to …
How to …
Reset faults
Note: As an alternative to the method described here, the
errors that occurred last can also be reset in the
“Diagnosis“ menu, tabs “Start Simulation" or "Timer
Info".
2. Select the line that contains the relevant fault (left click or
cursor keys “up”/”down”).
3. Call up the Detail information (double click or “Enter” key).
Functions of the command buttons offered here:
182 Bosch Rexroth GmbH | Electric Drives BOS 6000 | 1070087074 / 01
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How to …
How to …
How to …
How?
Conditions:
How to …
Procedure:
2. Enter suitable %I values for the 2 test welds into the two %I
fields.The upper %I value should not exceed the working range
of the welding equipment (refer to conditions listed above).
The lower %I value should be in the lower working range of the
welding equipment and should be at least 20 %I lower than the
upper value.
By activating check box “Store values”, you can cause the
timer to present the values input without the need to re-enter
them when calibration is repeated for the relevant electrode.
3. Select a suitable calibration program.
Check whether the appropriate electrode number is displayed!
4. Click on OK command button.
The next window of the current calibration function will be
shown.
5. Move the sensors of the reference ammeter to the proper
position and check the setting of the reference ammeter.
6. Close the electrode gun.
How to …
How to …
How?
Conditions:
Procedure:
How to …
How to …
How to …
1070087074 / 01 | BOS 6000 Electric Drives | Bosch Rexroth GmbH 191
and Controls
Fault messages
Fault messages
Please note:
Stop / No 24V
Fault messages
Control stop
Possible cause Remedy
Function that is influenced by the Customer-specific application
“Ready” input
Fault messages
External Over-Temperature
(External Device Over Temperature Fault)
Possible cause Remedy
Message of an external temperature
input:
Cable between timer and Check cable/connector
temperature sensor broken
Insufficient cooling Check cooling circuit
Excessive welding %I/duty cycle Reduce welding %I, shorter duty
cycle
Fault messages
Battery-Low
Possible cause Remedy
The voltage of the timer’s buffer Replace battery
battery has dropped
Memory deleted
Possible cause Remedy
All data has been deleted from this
timer:
New firmware was copied to timer: Copy data
Battery is low or defective Replace battery and copy data
No schedule programmed
Possible cause Remedy
Wrong program selected Check program selection
Invalid spot selection Check spot selection
Invalid parameters in selected Check value range of the following
program parameters: power unit number,
electrode number, program number
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Fault messages
Hardware Fault
(Hardware Fault - Replace Timer / Inverter)
Possible cause Remedy
Defective module Replace module or timer
A module is detected during power- Replace module
up which does not match the
firmware:
A firmware was copied to the timer Copy proper firmware to the timer
which is not permitted for the
existing hardware
Fault messages
I/O-Bus Fault
(Serial I/O Bus Fault)
Possible cause Remedy
The serial I/O module has signaled Replace I/O module or timer
a bus error to the timer
Half-Cycle Monitoring
(Transformer Half cycling Fault)
Possible cause Remedy
During the welding process, two
subsequent half-cycles with the
same polarity were detected:
Synchronization voltage too low Check synchronization voltage
Thyristor unit defective Check thyristor unit and fuses
Fault messages
Fuse in power unit defective Check all fuses of the power unit, or
replace power unit
Synchronization OK
Possible cause Remedy
Welding power has been None: This message only appears in
reconnected. the log
Also refer to Sync / Power Fault
Start Inhibited
(Weld scheduled stopped)
Possible cause Remedy
The schedule of the selected Enable program at the programming
program was inhibited: terminal (“Start-Inhibit” parameter)
Check program selection, select
proper program
Fault messages
Timer switched on
Possible cause Remedy
24V supply was reconnected
Control reset was triggered from the
GUI
Fault messages
No Weld external
Possible cause Remedy
External weld signal was Check signal at the Weld external
deactivated input
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Fault messages
Weld external
Possible cause Remedy
External weld signal was activated None: This message only appears in
the log
No Weld internal
Possible cause Remedy
Weld signal switched off at Check setting at the programming
programming terminal terminal (“Weld/No weld (Global)”
parameter)
Weld internal
Possible cause Remedy
Internal weld signal activated None: This message only appears in
the log
No stroke, no weld
Possible cause Remedy
Schedule without ignition and Input signal “Schedule with stroke,
without solenoid valve (gun does with weld” is low
not close)
Fault messages
End of stepper
Possible cause Remedy
The specified electrode has reached
the End of stepper condition
Fault messages
End of stepper
Possible cause Remedy
The weld timer was stopped by End Replace electrode
of stepper
Electrode changed
Possible cause Remedy
The electrode change was None: This message only appears in
acknowledged externally the log
Stepper exceed
Possible cause Remedy
An external request was made to Replace electrode
exceed the end of stepper
Prewarning reached
Possible cause Remedy
The specified electrode has reached
the Prewarning condition:
The count value has reached the The electrode will soon reach the
programmed wear until Prewarning End of stepper condition
Dress-Request reached
Possible cause Remedy
The specified electrode has reached
the Dress-Request condition
The count value has reached the Dress electrode
programmed wear until Dress-
Request
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Fault messages
Dressing necessary
Possible cause Remedy
The specified electrode has
exceeded the Dress-Request
condition
The count value has exceeded the Dress or replace electrode
programmed wear until dress
request
Electrode dressed
(Stepper tip dressed)
Possible cause Remedy
The electrode tip dress was None: This message only appears in
acknowledged externally the log
Tipdress prewarning
Possible cause Remedy
The specified electrode has reached The cutter blade should be replaced
the Tipdress Prewarning condition soon
Fault messages
condition:
Fault messages
Cutter1: Emergency-Stop
Possible cause Remedy
The stop circuit of the weld timer Check weld timer stop circuit
was opened during dressing Check connectors and cables
Fault messages
Cutter2: Emergency-Stop
Possible cause Remedy
The stop circuit of the weld timer Check weld timer stop circuit
was opened during dressing Check connectors and cables
Fault messages
Note: The message will be active until the electrode has been
replaced!
Fault messages
No voltage 1.HW
Possible cause Remedy
No primary voltage was measured Check KUR connectors and cables
in KUR mode
No Weld
Possible cause Remedy
Weld signal was switched off during
the schedule
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Fault messages
No current …
Possible cause Remedy
Electrodes not closed Check closing mechanisms (robot,
machine)
No electrical contact at the point to Check position and pressure of
be welded electrodes
Contamination of sheets Clean sheets
Sealant used Check conductivity
Low Current …
Possible cause Remedy
Current measured is below
tolerance band:
Tolerance band too small Check tolerance band
Programmed value too high, e.g., Check programmed value, stepper
because of stepping values
Contamination of electrodes Repeat weld, clean electrodes
Contamination of sheets Repeat weld, clean sheets
Bad electrode positioning Improve positioning
Welding transformer underrating Change over or replace welding
transformer
Over Current …
Possible cause Remedy
Current measured exceeds
tolerance band:
Programmed value step-change to Select broader tolerance band,
lower %I values reduce programmed value step-
changes
Handling of different sheet Use several programs with different
thicknesses or sheet layers parameters
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Fault messages
Fault messages
Diode defect
(Transformer Diode Defective)
Possible cause Remedy
A defective welding diode is
detected in “Measurement:
Secondary” mode due to the
saturation current peaks caused by
the welding transformer that has
been shorted by the defective diode:
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Fault messages
Overcurrent or Earth-fault
(Transformer Diode Defective)
Possible cause Remedy
The inverter output current is in
excess of 110% of the maximum
current, or there is a major earth
leakage current (no personal
protection):
The transformer supply line or the Replace transformer supply line or
welding transformer has a short- welding transformer
circuit or an earth fault
Output current too high In PHA mode, the current may
become too high. Reduce %I or work
in KSR mode
For weld times above 1s, currents at Change over to “Measurement:
the power limit and ”Measurement: Primary” mode for currents with a
Secondary” mode, the integrator for duration of more than 1s
current measurement may drift off,
pretending a lower actual current to
the inverter, which results in an
overcurrent response due to the
regulation mode
Fault messages
Driver-Fault
(Transistor Fault or External Short Circuit Fault)
Possible cause Remedy
A fault was detected in the IGBT
power transistor control which
indicates a short-circuit or overload.
Defective power transistor inside Replace timer
inverter, or external short-circuit, if
the fault can only be reset by cycling
power to the unit.
if the fault can simply be reset,
please call technical service
Fault messages
Fault messages
2 off via output “Main switch 2”, but and main switch
the signal at input “Weld contactor 2
closed” is still high after 100 ms
Fault messages
Fault-Reset
Possible cause Remedy
ALL faults have been reset None: This message only appears in
the log
Welding-Fault Reset
Possible cause Remedy
Welding faults have been reset None: This message only appears in
the log
Slave error
Possible cause Remedy
Display in master-slave operation Check slave
that the slave inverter is not ready
Read error from slave
Reset error in slave
Fault messages
Fault messages
Fault messages
Fault messages
Error US measurement
Possible cause Remedy
Fault in ultrasonic measurement Refer to additional fault message
Fault messages
Fault messages
The spot weld was automatically Use “Fault Reset with WC”.
repeated after Fault Reset with
Reweld
Fault messages
Fault messages
PSQ ok
Possible cause Remedy
No faults in the ultrasonic system None: This message only appears in
(PSQ) the log
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and Controls
Glossary
Glossary
AC
Alternating Current.
Base %I
Programmed current in kA or the phase value in %I for a weld time.
It is defined as 100% and serves as a basis for calculating the %I correction and
%I stepping.
CAN
Controller Area Network.
Data link between the ultrasonic controller board and the front-end
Check box
Square object used to activate/deactivate a function. A group of check boxes is
used for an “m from n” selection.
Configuration tool
Separate program for the administrator that may be used to adjust many features
of BOS 6000 to your specific requirements.
Count
Refer to Counts.
Count factor
Program-specific value that can be configured in “Programming: Stepper”
window.
When a welding program is executed, the counts are incremented by the value of
the count factor.
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Glossary
Counts
Electrode-specific counter. Indicates the current Counts value of an electrode.
In contrast to the spot counter, the counts are not incremented by the fixed value
of 1 for each spot welded, but rather by an adjustable, program-specific count
factor.In this way, the electrode count can be exactly recorded even when
welding different sheet thicknesses or materials.
CT
Cool time.
DC
Direct Current.
dimmed
The relevant object or a part of it is shown in gray color. In this condition, the
relevant function is blocked or cannot be activated for reasons immanent to the
system.
double click
Move mouse pointer to the desired element, shortly press the left mouse button
twice and release it immediately afterwards.
drag
Move mouse pointer to the desired element, press and hold down the left mouse
button and move the mouse.
The mouse pointer drags the element along as it moves.
Drag the element to the desired location and release the left mouse button.
Dressing counter
Electrode-specific counter. Indicates how often the electrode has already been
dressed (first tip dress not included).
DST
Down-slope time.
ED
Duty cycle.
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and Controls
Glossary
Front-end
Electronic equipment used in connection with ultrasonic welding.
HLD
Hold time.
HTML
HyperText Markup Language.
%I
Phase value (%I). Programmed %I for PHA mode.
Icon
Small symbols shown by the system instead of windows or entire applications.
In connection with the safety instructions, the icons draw the reader’s attention to
specially important safety issues.
I/O
Input/Output.
IP
Internet Protocol.
IP address
Address of a timer that communicates with BOS 6000 through an Ethernet
network. The address consists of four numbers between 0 and 255 each
separated by dots. Also refer to our documentation on “Programming field buses”,
no. 1070 087005.
kA
kilo-Amps.
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Glossary
Keyboard control
Operating the BOS 6000 via the keyboard.
Refer to shortcuts.
kN
kilo-Newton.
KSR
KonstantStromRegelung (constant-current regulation).
Drives the power unit so as to ensure that the programmed current is reached in
the secondary circuit.
KUR
Constant-voltage regulation.
Link
Blue, underlined text. A left-click on this text will open a new window or invoke a
function.
List box
List containing options for selection.
Menu
List containing a number of commands/functions for selection.
Menu line
Line containing a number of commands/functions for selection.
Mixed mode
In contrast to Standard mode, the PreWld, WLD, PostWeld are treated
separately for the purpose of monitoring and regulation.
mouse click
Move mouse pointer to the desired element, shortly press the left (unless
specified otherwise) mouse button once and release it immediately afterwards.
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and Controls
Glossary
ms
Millisecond.
mV
Millivolts.
NBS
Mains load limitation control.
Function designed to prevent an overload of the welding network caused by
simultaneous welding of several timers.
OFF
Off time.
PHA
Non-regulated timer mode as compared to KSR and KUR.
The welding %I (programmable as %I) is determined by the phase value (of
thyristor power units) or the pulse width (of medium-frequency inverters).
Popup menu
Menu that appears after a right click at the mouse pointer position.
PSI
Weld timer with integrated medium-frequency inverter.
PSQ
Ultrasonic quality assurance system.
PST
Weld timer with integrated thyristor unit.
PSU
Separate medium-frequency inverter unit (without integrated control logic).
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Glossary
Radio button
Round object used to activate/deactivate a function. A group of radio buttons is
used for a “1 from n” selection.
Scrollbar
A bar at the right and/or bottom margin of an object (e.g., a window or a list box).
By moving it, you can shift the contents of the object (e.g., in order to display
more information).
Shortcuts
Many commands/functions can be invoked by pressing a key or by pressing
several keys simultaneously.
In order to trigger a key combination, you first have to press and hold down one of
the keys Ctrl, Alt or Shift, then press the key indicated after “+”, and finally
release both keys.
Important shortcuts:
Alt+<x> To select menu items via the keyboard. <x>:
Wildcard character for the character underlined
in the relevant menu text.
Alt+Esc Brings the next currently active application into
the foreground.
Alt+F4 Closes the active window
Alt+Space bar Opens the system menu
Alt+Cursor down Opens/closes a list box selected.
Alt+Cursor up
Alt+Tab Selects a currently active application and
brings it into the foreground.
Print Copies the current screen display to the
clipboard
Enter key Executes a command.
End In text/number field: Places the cursor behind
the last character.
In list box: Selects the last entry in the list.
F1 Calls up the Help function
F10 Selects the first item in the menu bar.
Space bar Selects or deselects an element from within the
checkbox
Cursor down Selects an element from a list box, or
Cursor up increments/decrements the numerical value
displayed.
Home In text/number field: Places the cursor in front
of the first character.
In list box: Selects the first entry in the list.
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and Controls
Glossary
Slope
Linear %I change in the form of a current slope.
Spot counter
Electrode-specific counter. Indicates the number of spots already welded by the
respective electrode.
In contrast to the counts, the spot counter is incremented by the fixed value of 1
for each spot welded.
The spot counter is only displayed below “spots” in the “Detail-Info” window.
SQZ
Squeeze time.
Standard mode
In contrast to Mixed mode, the PreWld, WLD, PostWeld are treated jointly for the
purpose of monitoring and regulation.
Status line
Is located at the lower margin of the BOS main window and contains the following
information:
Name of the parameter that can be modified in the current input field (containing
the cursor) and its applicable input limits (important for dynamic limit values, e.g.,
due to %I stepping).
Timer communication status:
green: online, blue: offline, red: fault
Date, time and key conditions.
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Glossary
UST
Up-slope time.
WLD
Weld time. Time in which the power unit is activated. Three different weld times
can be set in the timer:
PreWld Warming-up time. For heating up the parts to be welded.
WLD: Main welding time.
PostWeld: Post-heating weld time. Prevents parts from cooling down too quickly
The duration and %I of all 3 weld times can be configured separately. The PreWld
and PostWeld are optional.
WT
Weld timer.
Other names include, e.g., timer, module, controller module, etc.
Title bar
The horizontal bar on the upper edge of a window or dialog that shows the title of
the window or dialog and the command buttons for maximizing, minimizing or
closing the window, if available.
Is dimmed, for example, for those windows which are not active.
Tool tip
When the mouse pointer remains motionless on an input field/object for a
moment, a relevant explanation appears in a small window.
ÜK
Monitoring contact
US
Ultrasonic.
USR
Ultrasonic control
Glossary
WC
Weld complete contact.
Signal that is output by the weld timer after a welding schedule. It normally
causes the robot to move on to the next spot weld.
Whether weld complete is output for faultless welds only or independent of the
welding result can be selected in parameter “WC with error".
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Glossary
1070087074 / 01 | BOS 6000 Electric Drives | Bosch Rexroth GmbH 235
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Index
Index
Counts 67 DST 49
Current at 0% I 85
Current at 50% I 85 E
Current calibration 147
Current Measurement Range Exceeded 216 Edit | Autobackup 29
Current measurement range exceeded… 210 Edit | Copy 29
Current measuring/Current supervision 80 Edit | Correction 29
Current monitoring 53 Edit | Export record set 29
Cutter blade changed 204 Edit | Firmware changing 29
Cutter1 Edit | Login 29
Cutter not running 204 Edit | Oscilloscope function 29
Dressing process aborted 204 Edit | Programming 28
Emergency-Stop 205 Edit | Setup 29
Max. mill duration exceeded 204 Edit | Timer change 29
Motor protection trip 205 Electrode changed 202
Temperature fault 204 Electrode dressed 203
Cutter2 Electrode life tipdress 203
Cutter not running 205 Electrode range 84
Dressing process aborted 205 Electrode/Stepper 46
Emergency-Stop 206 End of stepper 201, 202
Max. mill duration exceeded 205 End of Stepper (refer to maximum counts) 68
Motor protection trip 206 End-Slope 52
Temperature fault 206 Enter/change spot references 172
Error table 124
Error US control loop 221
D
Error US measurement 220
Data download started 194 Exit BOS 6000 153
Define access levels for individual objects 163 Export parameter data to ASCII file 175
Delete spot references 173 Export spot reference 171
Delete timers from BOS 6000 154 Export spot reference to an Excel file 171
Deleting topics from the Favorites list 15 Export timer data (backup) 158
Description of the symbols in the menu lines 11 Export Timer Reference 156
Detail Info 151 ext. data change 169
Diagnosis 97 Extend stepping request 201
Diagnostics I/O 98 Extended electrode life Near End of Stepper
Last Weld 107 201
Start Simulation 102 Extended electrode life/Waiting 71
Timer-Information 105 external data change 169
User Diagnostics I/O 101 External Over-Temperature 193
Diode defect 212
Diode Over Current 211 F
Diode temperature 90
DIP switch 116 Fade-out time 78
Display spot comments 173 Fault messages 191
Displaying the topics in the Favorites list 14 Fault-Reset 216
Dress new electrode 71 File | Exit 28
Dressing necessary 203 File | Para. data import/export | Export … 28
Dressing-Curve (Programming, Seq. Pg.2) 59 File | Para. data import/export | Import … 28
Dressing-Curve (Programming, Stepper) 69 Filter tables 166
Dressings 70 Find
Dress-Request 70 Text 13
Dress-Request reached 202 Find keyword 12
Driver-Fault 213 Firmware change 142
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and Controls
Index
Index
Index
Index
Trail current 79
Transformer temp too high 193
Turns ratio (Thyristor-Unit-Parameter) 95
Type (diodes) 88
Type (transformer) 85
Type of connection (transformer) 86
U
Upgrade the timer firmware 179
Upper current limit 82
Upper tolerance band 54
US measuring loop fault 224
Use favorites 14
USP communication error 224
USP hardware fault 223
USP not calculated 221
USP temperature too high 223
USP too high 222
USP too low 222
UST 49
W
WC (Diagnosis, Start Simulation) 105
WC Period 77
WC Start time 77
WC with error 77
Wear per component 71
Weld Contactor Gun 1 Did Not Open 215
Weld Contactor Gun 1 Open 214
Weld Contactor Gun 2 Did Not Open 215
Weld Contactor Gun 2 Open 214
Weld external 200
Weld internal 200
Weld program chosen 104
Weld time too long… 211
Weld time too short… 211
Weld without Command 192
Weld/No weld (Global) 74
Weld/No Weld (P) 44
Welding-Fault Reset 216
Why 17
Width of a table column 166
With stroke, with weld 200
Without regulation, without monitoring 209
WLD 49
Z
Zero adjust 93
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and Controls
Index
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 (0)93 52-40-50 60
Fax +49 (0)93 52-40-49 41
service.svc@boschrexroth.de
www.boschrexroth.com
Printed in Germany
1070087074 DOK-PS6000-BOS6000****-AW01-EN-P