05 Servo Gun Control-En

The Drive & Control Company
Rexroth PSI 6xCx
Servo gun control
Description of application Edition 05

1070087078
2/110 Bosch Rexroth AG PSI 6xCx | 1070087078 / 05
The data shown below is intended to describe the

product. If information on its use is provided,such
information represents application examples and
suggestions only. Catalog specifications are not
guaranteed properties. This information does not
release the user from performing his own
assessments and verifications. Our products are
subject to natural wear and aging.
E This manual is the exclusive property of Bosch

Rexroth AG, also in the case of intellectual proper
tyright applications. Reproduction or distribution by
any means subject to our prior written permission.
An example configuration is shown on the cover

page. The delivered product may therefore deviate
from the picture.
Language version of the document: EN

Original language of the document: DE
1070087078 / 05 | PSI 6xCx Bosch Rexroth AG 3/110
Contents
Contents
1 Regarding this documentation . . . . . . . . . . . . . . . . 5
1.1 Validity of the documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Additional documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Presentation of information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.3 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 General information on damage to property
and products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 General information on the "servo gun control" . . 15
5.1 Functions and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Firmware changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4 Special participating hardware components . . . . . . . . . . . . . . . 21
5.4.1 Command communication interface WIC (X7S) . . . . . . . . . . 21
5.4.2 Gun data module GDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4.2.1 Check the contents of the GDM . . . . . . . . . . . . . . . . . . . . . . 23
5.4.3 IndraControl VCP05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4.3.1 Select the desired timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4.3.2 Select the start menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.3.3 Select the start screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.3.4 Use the gun memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.3.5 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4.3.6 Force calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4.4 Alternative equipment for the communication interfaces . . 35
5.4.5 IndraDrive Cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4.5.1 Set the communication protocol . . . . . . . . . . . . . . . . . . . . . . 37
5.4.5.2 Set the drive slave address . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4.5.3 Set IP configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4.5.4 Important status messages . . . . . . . . . . . . . . . . . . . . . . . . . 39
6 Assembly and connection . . . . . . . . . . . . . . . . . . . . 41

6.1 Required communication connections and addresses . . . . . . 42
7 Commissioning the servo gun control . . . . . . . . . . 47

7.1 Basic requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2 Basic commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.3 Advanced commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.3.1 Geometry calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8 BOS user interface . . . . . . . . . . . . . . . . . . . . . . . . . 53

8.1 Programming: Servo gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Contents
8.2 Programming: Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.3 Diagnostics: Start Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.4 Diagnostics: Servo gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.5 Setup: Servo gun: General Gun . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.6 Setup: Servo gun: Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.7 Setup: Servo gun: Electrode maintenance . . . . . . . . . . . . . . . . 75
8.8 Setup: Servo gun: Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.9 Setup: Servo gun: General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.10 Setup: Servo gun: Temperature . . . . . . . . . . . . . . . . . . . . . . . . . 84
8.11 Setup: Servo gun: Synchron . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9 Important function schedules . . . . . . . . . . . . . . . . . 89

9.1 Weld schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.2 Teaching the joining level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9.3 Electrode change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.4 Tip dressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
9.5 Tip setting stroke execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.6 Open gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.7 Specify opening width (external robot axis) . . . . . . . . . . . . . . . 94
9.8 Referencing the gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.9 Change gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10 Diagnosis and fault messages . . . . . . . . . . . . . . . . 97

10.1 Timer messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.2 Drive control messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
11 List of tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
12 List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
13 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Regarding this documentation
1 Regarding this documentation

This section contains important information for using the documenta
tion.
" Familiarize yourself with the product before using it!
1.1 Validity of the documentation

The present documentation
For which product? • applies to the "Servo gun control" option of the PSI 6xCx weld timers
Target group? • is designed for Planning, assembly personnel, operators, commis
sioning, service technicians, plantoperators.
Topics dealt with? • provides information on
• Available components and their integration in relation to the timer
• Functions of the "Servo gun control" option
• Programming via BOS
• Commissioning
1.2 Additional documents

Several documents are available for the product, which must all be con
sulted to obtain all the necessary information.
" You may only commission the product when you have at least read
and understood the documentation marked with D.
Table1: Necessary and supplementary documents
Document
Title Document type
number
D PSI 6xxx: Weld timer with 1070080028 Instructions
Medium-Frequency Inverter
D PSI 6xxx.xxx xx: Weld timer with depending Instructions
Medium-Frequency Inverter, on type (type-specific
type-specific instructions instructions)
D PSG xxxx: 1070087062 Instructions
MF welding transformers
D PSG xxxx: Medium-Frequency depending Instructions
Welding Transformer, on type (type-specific
type-specific instructions instructions)
Rexroth GDM: Gun Data Module R911339735 Description of
application
Rexroth IndraControl VCP05.2 R911172348 Description of
application
BOS 6000 Online Help 1070086446 Reference
Rexroth IndraDrive Cs all
Motor documentation depending all
on type
Rexroth weld timer R911339734 Safety and user
Safety and user information information
Document
Title Document type
number
Rexroth PSG xxxx R911342242 Safety and user
MF welding transformers information
Safety and user information
Rexroth IndraDrive R911326738 Reference
Mpx-16 to Mpx-18 - Diagnostic
Messages
D: Necessary documentation
1.3 Presentation of information

Uniform symbols, terms and abbreviations are used throughout this
documentation, which are explained in the following sections.
1.3.1 Safety instructions

Safety instructions draw your attention specifically to potential hazards
or risks.
Where? We distinguish between the following places where safety instructions
may be required:
• Basic safety instructions:
They relate to general important matters and apply to the complete
documentation.
These safety instructions are provided in Sections 2 and 3 of the
instructions "PSI 6xxx: Weld timer with Medium-Frequency Inverter"
(doc. no.1070080028; also refer to page 5).
• Preceding safety instructions:
They refer to topic-related matters and are provided at the start of a
section or at the start of a whole procedure.
• Integrated safety instructions:
They relate specifically to a separate procedure step and are
provided right before the relevant step within the procedure.
Structure? A safety instruction is always structured as follows:
• Warning (only in case of personal injury)
• Signal word to indicate the danger level
• Type and source of danger
• Consequences of failure to observe
• Actions for averting danger.
Table2: Example for the structure of a safety instruction
Warning + SIGNAL WORD

Type and source of danger!
Consequences of failure to observe!
" Actions for averting danger.
" Further action(s) for averting danger.
Integrated safety instructions may be embedded in the format of the

environment so that there is no visual break in the action sequence.
They therefore may not necessarily use the layout shown in the
example, but they do use the indicated structure.
Danger levels? The safety instructions are classified according to danger levels
(danger classes). The signal word represents the danger level.
Table3: Danger classes according to ANSI Z535.6
Signal word Meaning

DANGER indicates a dangerous situation where death or serious
physical injuries will occur if it is not avoided.
WARNING indicates a dangerous situation where death or serious
physical injuries may occur if it is not avoided.
CAUTION indicates a dangerous situation where light to moderate
physical injuries may occur if it is not avoided.
NOTICE indicates a situation where damage to property or the
surrounding area may occur if it is not avoided.
Table4: Examples for classification of safety instructions
DANGER
WARNING
CAUTION
NOTICE
1.3.2 Symbols
The following symbols are used to mark passages in the text.
Table5: Symbols used
Symbol Meaning
Indicates a tip or piece of information, which helps to
ensure that the product is used and operated optimally
or provides a better understanding of interrelationships.
" Indicates something which must be complied
with/carried out.
· Indicates an (unsorted) list.
1. Indicates a (sorted) list or procedure steps where the
2. specified sequence must be complied with.
3.
1.3.3 Designations
The following designations are used in this documentation:
Table6: Designations
Designation Meaning
BOS Welding user interface
Bridge A bridge connects two segments in the network on the
layer 2 level (link layer) of the OSI model.
Gateway Switching device in the network.
IndraControl Hand-held programming device from Bosch Rexroth
VCP05
IndraDrive Cs Drive control system from Bosch Rexroth
IndraWorks Ds Software tool for parametrization and diagnosis of
the drive control systems from Bosch Rexroth
PE Protective earth. Protective conductor.
PG Programming terminal/welding computer.
PSG transformer-rectifier unit for PSI types.
Medium-frequency welding transformer 1000 Hz
PSI Programmable weld timer with inverter.
PLC Programmable logic controller.
WT Weld timer.
Also referred to as timer or module resistance weld timer.
1.3.4 Abbreviations
See section 13 from page 103.
Safety instructions
2 Safety instructions
" Please note the section with the identical name in the operating
(for document number, refer to table on page 5).
" If transformers from Rexroth are integrated in the gun used:
Please note the section with the identical name in the operating
instructions "PSG xxxx: MF welding transformers" (for document
number, refer to table on page 5).
" Please note the safety-relevant information in the documentation of
all drive components used.
Safety instructions
Notes:
General information on damage to property
3 General information on damage to property

and products
" Please note the section with the identical name in the operating
(for document number, refer to table on page 5).
Please note the section with the identical name in the operating
instructions "PSG xxxx: MF welding transformers" (for document
number, refer to table on page 5).
" Please note the relevant information in the documentation of all drive
components used.
General information on damage to property
Notes:
Scope of delivery
4 Scope of delivery
" Please note the section with the identical name in the instructions
"PSI 6xxx: Weld timer with Medium-Frequency Inverter" (for docu
ment number, refer to table on page 5).
Please note the section with the identical name in the instructions
"PSG xxxx: MF welding transformers" (for document number, refer
to table on page 5).
" Please note the relevant information in the documentation of all drive
components used.
Scope of delivery
Notes:
General information on the "servo gun control"
5 General information on the "servo gun control"

5.1 Functions and options
What does the servo gun control do?
In conjunction with the permissible components and the available
functions, it ensures quick and correct build-up of force on the gun
used.
The "servo gun control" adds the following primary functions to the
functions of the timer:
• Influencing the gun opening width
• Influencing the force between the two electrodes.
Functions for avoiding asymmetrical forces on the workpiece (gun
equalization) do not form part of the "servo gun control".
These functions must be provided on the robot side.
To operate multiple guns on one timer, an exchange coupling is
required on the robot side along with a docking system.
How does it work?

The opening width (stroke) and build-up of force on the welding gun are
influenced by a servo motor (gun pressure actuator) in conjunction with
the drive control "IndraDrive Cs" (via position, velocity and torque
control).
Via the command communication connection (WIC) on the timer, the
weld timer as the master has full control over the parametrization and
function of the drive control.
As a result, process-relevant functions and movement sequences for
an optimal welding schedule can be achieved easily via "servo
firmware" loaded in the timer.
Basic process schedule during welding
1. The timer sends the command to close the gun automatically to the
"servo gun control" once a welding schedule is started.
2. The path to the program-specific joining position is approached at
high velocity (positioning velocity) first of all until the start of a
parametrizable "search area".
The joining position can be set manually in advance via BOS or can
be determined automatically via teach sequence.
3. Once the search area is reached, the gun reduces its velocity to
prevent an electrode collision (contact velocity).
4. Once the sheet is reached, the timer checks
• that no tip is missing (when the "Geometry test" function is active)
• that the current sheet thickness lies within the permitted limits
(when the "Sheet thickness monitoring" function is active).
5. The stepper force parametrized in the weld program is built up and
the programmed force profile is run though if activated.
6. Once the hold time has elapsed, the gun opens again (including after
a welding fault), the timer reports "Weld Complete" and the current
status (e.g. Weld OK or not OK).
Benefits / advantages
• As both the welding process and the force generation are controlled
and monitored completely by the weld timer, optimal synchroniza
tion of current. time and force is possible. This shortens the cycle
times.
• A single user interface is sufficient for programming/diagnosis of the
weld timer and the servo gun control. This minimizes the induction
and training required.
• Gun parameters which can be imported via gun memory (GDM) en
sure problem-free, quick commissioning. This minimizes commis
sioning time.
• The entire gun-specific I/O communication between a separate gun
control and robot/PLC is no longer required. The whole process
communication is now carried out via the I/O interface of the weld
timer. This reduces the planning, installation and maintenance
required.
• Extensive monitoring functions help to monitor the welding process
and to document the process completely with no additional work.
This means that you can identify problems quickly in the electrode/
gun mechanism area (e.g. torn off tip, mechanical wear) and safe
guard your welding quality.
Functions
Modes • "Auto" mode:
Purpose: Specification of the desired movement profile for closing or
opening the gun and the program-specific force regulating variable
by the timer via command communication directly on the drive. This
means that the robot only has to select and start the weld program.
In this mode, the positioning movements of the gun axis, switching
points (switch from position to torque control) and the programmed
force value depend on program-specific settings and gun-specific
(electrode-specific) limitations in the timer. The maximum permitted
axis dynamics and the maximum permitted following distance must
be set in the drive control to suit the gun actuator options.
Commands received via BOS and HPG are ignored.
Requirements for a weld schedule: "Auto" mode and input "enable
positioning" = 1
• "Manual" mode:
Purpose: Manual access to functions of the servo gun control via
BOS6000 or IndraControl VCP05 (e.g. in connection with gun com
missioning, manual referencing, jogging the gun axis, gun warm-up
etc.). Commands received via the I/O interface are ignored.
• "Stop" mode:
Purpose: Suppresses all movements of the gun actuator. Is active
while "Close brakes" high signal is active on the timer input.
Monitoring functions • "Tip dress control" function

Purpose: For checking that the dressing length is correct after an
electrode tip dressing process.
This highlights any problems in the tip dresser blade area (e.g. blunt
tip dresser blade, force during tip dressing too low or too high).
For parametrization, see page 76.
• "Geometry test" function
Purpose: For checking for missing / incorrect tips, tips mounted
incorrectly, wear on the electrode shafts and irreversible bending of
the gun arms.
For parametrization, see page 77.
• "Force checking" function:
Purpose: For checking that the actual force is correct.
For parametrization, see "Force" parameter group, page 55.
• "Sheet thickness monitoring" function:
Purpose: For checking that the sheet thickness is correct.
For parametrization, see "Sheet thickness" parameter group
(page 55) and "Joining level" parameter group (page 54).
• "Tip wear monitoring" function:
Purpose: For checking for maximum permissible electrode wear
(max. permitted total wear on both tips!).
This enables the timer to report a physically necessary tip change to
the robot. For parametrization, see parameter "Max. wear of elec
trodes", page 76.
• "Gun identification" function:
Purpose: For reporting the differences in the gun IDs between the
timer and GDM data. This can be used to ensure that the docked gun
matches to the application. For parametrization, see parameter
group "Identification" (page 68) and the "Set Gun-Type" button.
• "Robot monitoring" function:
Purpose: Check the communication with the robot.
The timer monitors and reflects the input signal "watchdog signal
robot control". If the input status does not change at the latest after
500 ms, an entry is made in the BOS error log.
From this point on, movement commands are only accepted in
"Manual" mode. The fault can be reset via the I/O field or the user
interface.
Compensation functions • "Force calibration" function:
Purpose: Via force calibration, the drive control "learns" the link
between the motor current and the resulting force on the electrodes.
This is always necessary if no constantly connected force sensor is
available during operation to determine the actual force.
IndraControl VCP05 is required for force calibration.
• "Friction coefficient compensation" function:

Purpose: Ensures that any changes occurring after the force calibra
tion is complete (e.g. changes in the stiffness of the gun), have no
impact on the active electrode force.
Parametrization: not required.
The reference friction coefficient determined during force calibration
can be seen under "Diagnostics", "Servo gun" or "Last Weld", "Tip
positions" button ("Tip Position - Info Box" window) under "Mechani
cal basic load" (see page 80).
• "Dressing length output" function:
Purpose: Compensation of the wear-related changes in distance be
tween the tip contact surfaces and the workpiece using suitable
measures in the robot (e.g. TCP movement). The timer reports the
current dressing length of the tip of the fixed arm gun via the I/O inter
face on the outputs "Tip wear rate x". Parametrization: See "Gun
equalization share in dressing length" parameter, page 76.
Process functions • "External Robotaxis" function:
Purpose: Constant influence of the gun opening width simultane
ously with the other robot axes as controlled external robot axis
(e.g. 7 axis).
The robot outputs the calculated programmed position values of its
external axis in interpolator cycle via the I/O connection to the timer
and receives the actual position values of the gun axis in return. The
timer constantly passes on the programmed position values directly
to the drive via command communication.
In this mode, the current acceleration and velocity of the external ax
is depend on the programmed position values transferred in the fixed
time interval. The maximum permitted axis dynamics and the maxi
mum permitted following distance must be set in the robot to suit the
gun actuator options.
Conditions:
"Auto" mode and
"enable positioning" input = 0 and
"Programmed stroke position valid" input = 1.
A weld schedule is not possible if the function is active.
• "Sheet thickness detection" function:
Purpose: Automatically determines the sheet thickness.
See page 90.
• "Tip setting stroke" function:
Purpose: To create reproducible states when pressing newly
mounted tips on to the clamping cone.
The function is started with a positive edge on the timer input "Tip
setting stroke" and triggers the closing of the gun with subsequent
re-opening to the current active opening position (see page 54).
When the gun is closed, the force defined in the electrode-specific
parameter "Max. force in weld schedule" is active (see page 73).
• "Lubrication stroke" function:
Purpose: Motor lubrication.
Is started with a positive edge on the timer input "Lubrication stroke".
It triggers the opening of the gun to the maximum opening width and
subsequent movement to the current active opening position (see
page 54).
During the movement, the force defined in the electrode-specific

parameter "Max. force in weld schedule" is active.
When automatic lubrication is switched on, the timer reports that
motor lubrication is required after a definable number of strokes via
output signal "Request lubrication stroke". The robot must then bring
the gun into a collision-free position and can then trigger the
lubrication stroke via timer input "Lubrication stroke".
For parametrization, see "Lubrication stroke" parameter, page 78.
I/O signals • All I/O signals available in connection with the servo gun control can
be found in the type-specific instructions for the relevant timer.
5.2 Conditions
• PSI 6xCx
• Suitable timer and servo firmware version.
Where necessary, we will release firmware updates to optimize, im
prove or expand the function of the product. This document may
therefore contain descriptions of functions which require a firmware
update. For additional information on firmware, see section 5.3.
If the timer is supplied with servo gun control, the relevant latest
firmware packages are already integrated.
• Command communication connection (WIC) for real-time communi
cation with the "IndraDrive Cs" drive control.
See section 5.4.1 page 21.
If the timer is supplied with servo gun control, the necessary com
mand communication connection (WIC) is already integrated.
• Suitable interface module for I/O communication with the robot
For possible alternative equipment, see Fig. 7: page 35.
• Suitable interface module for communication with a computer with
the BOS 6000 user interface installed
• User interface BOS 6000 for parametrization, operation, diagnosis
and logging.
SW version required: from 1.42.1
Information on the user interface BOS 6000 is available in the
"BOS 6000 Online Help" (document number 1070086446; see also
page 5).
• IndraControl VCP05 for manual mode and force calibration FW
version required: > 115
• Optional:
Gun memory module (GDM) for fast commissioning of the servo gun.
• Optional:
"IndraWorks Ds" software if advanced diagnosis options are
required
5.3 Firmware changes

In this section, the user-relevant changes are listed with regard to the
published firmware versions.
Servo firmware axis controller:
FW version: 1070092568-AH (23.01.2014)
5.4 Special participating hardware components

" Detailed information on the timer, drive control and motor can be
found in the relevant product documentation (see Tab 1: page 5).
5.4.1 Command communication interface WIC (X7S)

Features:
• Requirement for the "servo gun control" function
• RJ45 socket for direct connection of the drive control "IndraDrive Cs"
via CAT-5 Ethernet cable
Function:
• Real-time data transmission between the timer and drive control
NS
X7S LINK
ACT
MS
Fig.1: Command communication connection X7S
NS LED for communication status (network status):

off: no command communication
yellow: initiating command communication
green: command communication active
red: fault
LINK LED for network detection (link):
off: no connection to the network
green: connection to network participant detected
ACT LED indicating data traffic (Activity):
Off: no data traffic
yellow, flashing: data transfer active
MS LED for status of the interface module (WIC):
off: IF module is not initiated
yellow: initiating IF module
green: IF module is initiated and working correctly
red: IF module reports fault
Information on any active faults can be found

• via diagnosis module on the drive control and on the timer
• via BOS 6000 in the "Error Table"
• via IndraControl VCP05
A list of all fault and status messages of the timer can be found in the
BOS 6000 Online Help. The Online Help also contains information
on remedies for the possible causes.
Information on fault and status messages of the drive control can be
found in the relevant product documentation.
5.4.2 Gun data module GDM

Features:
• Optional memory module for mounting on the gun
• For fast commissioning of the gun
• RJ45 socket for connection to X25 of the drive control
"IndraDrive Cs" via CAT-5 Ethernet cable
• Can only be written by the timer
Function:
• Non-volatile memory for important gun-specific data:
• Drive basic parameters
(BOS "Setup", "Servo gun")
• max. 10 counter statuses
(for stroke- or other user-definable component counters).
• Transformer parameters
(BOS "Programming", "Electrode")
• freely-definable gun-specific customer data
The transfer of the data from and to the timer can be triggered
manually via IndraControl VCP05 (see page 27) or via BOS6000.
1: 24 VDC
XFV 2: 0 V
PWR 3: PE
MS
NS
ACT 1: RxD-
2: RxD+
XFE 3: TxD-
4: TxD+
Fig.2: Gun data module GDM
PWR LED showing the supply voltage and FPGA status:

green: supply voltage of the GDM is ok
green/red flashing: GDM-FPGA is configured
MS LED for status of the gun memory module (module status):
green: GDM module is initiated and working correctly
red: GDM reports hardware fault
NS LED for communication status (network status):
green: connection to the timer detected during GDM
initialization
red: no connection to the timer during GDM
initialization
ACT LED indicating data traffic (Activity):
off: no connection to the network
green: connection to the network
green/red flashing: data transfer active
XFV Supply voltage fault
XFE Ethernet connection (from factory: IP adr.: 192.168.0.50 Port: 69).
The information flow is tunneled transparently to the timer by
IndraDrive via WIC.
Further information on the GDM is available in the product documen

tation (see Tab 1: page 5).
5.4.2.1 Check the contents of the GDM
NOTICE
Arbitrary settings of the communication interfaces
Arbitrary settings can cause significant problems in the connected
network!
" Therefore: never parametrize the settings arbitrarily!
" Ensure that the maintenance computer used
• is in the same subnetwork as the GDM
• does not collide with the IP address of the GDM
• is not configured as a bridge or gateway.
" Ask your system or IT professional if necessary.
To check the content of the GDM where necessary, connect the GDM to
a maintenance computer via point-to-point connection (see Fig. 3:), or
use the connection type according to Fig. 9: on page 44.
Gun memory
Maintenance GDM
computer
XFE
IP address: 192.168.0.50
Subnetwork: 255.255.255.0 Port: 69
Subnetwork: 255.255.255.0
Fig.3: Connection of maintenance PC on GDM for test
GDM firmware, gun, transformer and customer-specific data can then

be displayed via WEB browser.
For this, enter the following in the address line of your WEB browser:
http://192.168.0.50
If no connection can be established, try: http://192.168.0.50:69
5.4.3 IndraControl VCP05

Features:
• Required in conjunction with the servo gun control for force calibra
tion of the gun
• Optional for operation, diagnosis and commissioning of the timer on-
site
• RJ45 socket for connection to the timer via CAT-5 Ethernet cable
• The required supply voltage (24 VDC) can be obtained (separately)
from the timer (timer front side: X5).
Function:
• Operation of the servo gun in manual mode
• Starting the data transfer between the timer and gun memory GDM
(SST -> GDM; GDM -> SST) for commissioning purposes
• Display and acknowledgment of faults
• Display and amendment of frequently used timer parameters
(Access to the complete timer parametrization only via BOS6000)
5 4
6
3
Fig.4: IndraControl VCP05
1 Display area
2 Function keys F1 to F6. For calling up available functions.
3 Special keys. See below.
4 Sign keys.
- Definition of positive or negative input values
- Increment and decrement counter values
- Switch options (e.g.: + = On; - = Off)
5 Number keys. Enter numbers.
6 Navigation keys.
- Select input fields
- Select menu points or list lines
- Return to the next highest menu level
Functions of the special keys

Help For calling up a context-dependent help page.
Button pressed: help page is shown
Release button:help page disappears
Flashing LED: Prompt to call up the help page.
Switch between display and edit mode.
Yellow LED lit: Edit mode is active.
Input key.
Apply a data change in edit mode and switch to the next input field.
Display or close the Error Table.
Delete input fields.
Return to the next highest menu level.
End an active edit mode for this if necessary.
VCP05 firmware version > 115 is required to support all necessary

functions in connection with the servo gun control.
Further information on the VCP05 is available in the product docu

mentation (see Tab 1: page 5).
5.4.3.1 Select the desired timer
If the VCP05 is only used in conjunction with the servo gun control,
we recommend:
• Configure the connection table of the VCP05 with a single timer
and set the corresponding IP address to the value
"192.168.0.10". As every timer with servo gun control is set to this
IP address, you can connect the VCP05 to all timers with servo
gun control according to Fig. 8: on page 43 without having to
select a timer afterwards.
• Select the servo gun menu as the start screen for the VCP05.
Instructions on how to do this can be found in section 5.4.3.3 on
page 26.
If the VCP05 is not only used in conjunction with the servo gun con
trol, we recommend:
• Configure the corresponding IP address with "192.168.0.10" and
the timer name with "Servo" as the first timer in the connection
table of the VCP05 under <Connection Number="1">. As every
timer with servo gun control is set to this IP address, you can
connect the VCP05 to all timers with servo gun control according
to Fig. 8: on page 43 and then simply select the timer "Servo"
afterwards.
1. Press until the timer selection option appears.
2. Select the desired timer via the number keys or using the sign keys.
3. Press F6 to end the timer selection.
The VCP05 switches to the start menu.
5.4.3.2 Select the start menu
1. Press until the start menu appears:
Fig.5: Start menu of VCP
5.4.3.3 Select the start screen

A setting can specify whether the timer selection or the servo gun menu
is shown after certain events.
If the VCP05 is always used in conjunction with the servo gun control,
we recommend configuring "Servo gun" as the start screen:
1. From the start menu (see Fig. 5:), press the key sequence F6 F5 B.
2. Select the option "Servo gun" for the "Start screen" setting via sign
keys.
3. Press to exit the edit mode.
The servo gun menu now appears each time the VCP05 is started:
up
Fig.6: Servo gun menu of VCP

In the following text, the button sequences for reaching a specific

menu are always indicated as follows:
• blue / underlined:
The buttons only need to be pressed starting from the start menu
• black and bold:
The buttons must be pressed starting from the servo gun menu
Example text passage:
• Press the button sequence F5F6F6F4
5.4.3.4 Use the gun memory

If the optional gun memory module GDM (see page 22) is available,
gun-specific data can be transferred quickly between the timer and gun
memory module during gun commissioning.
This means that all required gun data can be parametrized in advance
in the gun workshop via BOS6000 and loaded into the GDM.
Once the gun has been transferred to the production plant, the required
data is then transferred from the GDM into the relevant destination timer
and triggers the transfer of the data to the drive control (BOS "Setup",
"Servo gun", "General Gun", "Activate data" button).
The functions for using the gun memory module GDM can be accessed
as follows:
1. Press the button sequence F5F6F1
2. Select the relevant electrode (= gun number) using sign keys.
3. To select the action, press
• F1 - Read Counter:
The values of all defined component counters (see page 56) are
loaded from the GDM into the timer and assigned to the selected
electrode.
• F2 - Write Counter:
The values of all defined component counters (see page 56) of
the selected electrode are loaded from the timer into the GDM.
• F5 - Read Data:
The values of all parameters for
- BOS "Setup", "Servo gun"
- BOS "Programming", "Electrode"
- the defined customer data
are loaded from the GDM into the timer and assigned to the
selected electrode.
" Check via BOS6000 whether a yellow triangle with
exclamation mark is shown in the bottom window area under
"Setup", "Servo gun", "General Gun". If it is, press the "Activate
data" key there. If process-relevant data is changed in the
drive during this process, referencing must be carried out
again.
The "Read Data" function can also be triggered via BOS6000 under
"Setup", "Servo gun", "General Gun" with the "GDM -> SST" button.
• F6 - Write Data:
The values of all parameters of the selected electrode from
- BOS "Setup", "Servo gun"
- BOS "Programming", "Electrode"
- and all defined customer data
are loaded from the timer into the GDM.
The "Write Data" function can also be triggered via BOS6000 under
"Setup", "Servo gun", "General Gun" with the "SST -> GDM" button.
4. Enter the password (741) via the number keys and acknowledge
with .
The relevant function is carried out with no further query.
5. Exit the edit mode via the key.
The yellow LED in the key must no longer be lit.
6. Press the key to return to the servo gun menu.
5.4.3.5 Manual mode

No constant position settings via digital interface (on the robot side)
are possible in manual mode.
Manual mode is required if manual access to the functions of the servo
gun control via HPG is required (e. g. in connection with gun commis
sioning, manual referencing, jogging the gun axis, gun warm-up etc.).
activate / deactivate Manual mode is activated automatically if you switch to one of the func
tion levels listed below. It is deactivated automatically as soon as you
leave this function level again or if the Ethernet connection of the
VCP05 is disconnected for longer than approx. 1 minute.
Manual mode can also be activated via BOS6000 under "Diagnos
tics", "Start Simulation" via the "Servo gun" parameter group.
Manual mode via VCP05 can then only be triggered again if the
mode is set to "Stop" via BOS6000 and manual mode has been acti
vated automatically again on the VCP05.
Requirements for starting the function:

• There is no error.
• The drive is in regulation
(display on diagnosis module IndraDrive Cs: AF)
The functions available in manual mode can be accessed as follows:

Function levels 1. Press the button sequence F5F6F6
The HPG now shows the following function levels:
• F1 Movements
• F2 Softstart
• F3 F-Calibration
• F4 Increm. Jog
• F5 Cont. move
• F6 Commands
Functions in manual mode 2. Then select the desired function from the button sequences listed
below.
WARNING
Strong electromagnetic fields during a weld schedule
Could cause malfunctions in pacemakers, other implants or
hearing devices!
" Ensure that persons who rely on or use these devices avoid
resistance-welding systems as far as possible.
CAUTION
Movements of the gun actuator
Risk of crushing!
" Ensure that neither people nor objects can be harmed by the
movements of the gun actuator.
" Ensure that enough space is available for the movements of the
gun actuator.
CAUTION
Weld spatters, hot surfaces
Risk of burns, eye injuries!
" Wear protective goggles to protect your eyes from flying weld
spatters or hot metal chips.
" Only wear flame-resistant work clothing.
• F1F1 Reference:
The gun pressure actuator is opened to its
mechanical end stop with regulated torque (see
parameter "Max. force at referencing", page 73) and
limited velocity (see parameter "Contact velocity",
page 73), then closed (tip-tip) and brought to the
current opening position (see page 54).
• F1F2 Position reset (after wear):
The timer determines the total tip dress length since
the last tip change via a closing sequence with
dressed tips.
• F1F3 Open Gun:

Triggers a positioning movement to the current active
opening position (see page 54).
• F1F4 Tip setting:
Triggers the closing of the gun with subsequent
re-opening to the current active opening position (see
page 54).
When the gun is closed, the force defined in the
electrode-specific parameter "Max. force in weld
schedule" is active (see page 73).
This means that newly exchanged tips are always
pressed onto the shafts in a reproducible way.
• F1F5 PosRes + EC (after tip change / before wear)
With undressed tips, the timer determines the current
tip - tip position with a closing sequence and com
pares this value with the parameter "Tip-tip pro
grammed position" if the geometry test is active (see
page 77).
• F1F6 Lubrication
Triggers the opening of the gun to the maximum
opening width and subsequent movement to the
current active opening position (see page 54).
During the movement, the force defined in the
electrode-specific parameter "Max. force in weld
schedule" is active.
• F2 F5 Start Weld on:
Triggers the start of the current selected weld pro
gram with the current selected force. The power unit
is triggered.
• F2 F6 Start Weld off (check gun force)
Triggers the start of the current selected weld pro
gram with the current selected force. The power unit
is not triggered.
This means that the gun force in the entire force work
range can be checked with a load cell.
• F3 F1F1F1 Calculate
Calculates the parameters for the calibration function
from the current table values and enters the data in
the BOS6000 database (external data recording).
• F3 F1F1F5 Up
Scrolls the calibration table one page towards the
start of the table.
• F3 F1F1F6 Down
Scrolls the calibration table one page towards the end
of the table.
• F3 F1F2 Check values
The calculated calibration parameters can be viewed
here and checked for plausibility. A "quality" value is
also shown as an evaluation of the calibration. This
quality value has no unit and should have a number
< 30. If larger values are shown, we recommend cali
brating the gun again.
• F3 F1F3 Delete table
Sets all table values to "0"
Calculation of calibration parameters is not possible
in this state.
• F3F6 Start F-Calibration:
Calibrate force. See section 5.4.3.6 from page 32.
• F4 F5 Jog Close:
Closes the gun by the current specified distance.
• F4 F6 Jog Open:
Opens the gun by the current specified distance.
• F5 F5 Start:
"Warms up" the motor and triggers the start of the
current selected weld program with the current
selected force until the continuous run is stopped
again. The power unit is not triggered during this
process.
• F5 F6 Stop:
Stopped an active continuous run.
• F6F1 Start change servo gun:
(servo gun control must be disabled)
The actuators are deenergized, the encoder and
temperature monitoring is switched off. The drive is in
"parked " state (display on diagnosis module
IndraDrive Cs: PA). The gun can be changed.
• F6F2 Stop change servo gun:
The drive is switched from "parked axis" state back to
normal mode (display on diagnosis module
IndraDrive Cs: Off or AF).
If the gun data is invalid/incorrect, the correct gun

data must be entered in the timer first of all via manual
parametrization by importing a suitable parameter file
or by reading out the GDM, and then sent to the drive.
Manual parametrization: see section 8.5 from
page 67
Parameter file import: via BOS menu path "File / Para.
data import/export / Import..."
Reading out GDM:
via BOS: see "GDM -> SST" button, page 70
via HPG: see section "F5 - Read Data" 27
Send to the drive: see "Activate data" button,
page 71.
5.4.3.6 Force calibration
Via force calibration, the drive control "learns" the link between the
motor current and the resulting force on the electrodes. This is always
necessary if no constantly connected force sensor is available during
operation to determine the actual force.
" Please note:
• As the force generation - particularly in relation to complex
welding tasks - is a quality-relevant parameter - the force
calibration must be carried out precisely.
• Without force calibration, the force cannot be generated
(correctly) and friction coefficient compensation (automatic
compensation of the changing gun stiffness) cannot be carried
out correctly.
NOTICE
Incorrect scaling values or arbitrary changes to the calibration
parameters
Possible damage to the gun or workpiece!
" Ensure that guns are only operated once they have been
calibrated correctly.
" Ensure that the correct electrode-specific data is active for the
relevant gun following a gun change. We recommend using the
GDM for this purpose and the automatic gun parameter check.
See the "Gun parameter check" parameter, page 70.
Required devices
• IndraControl VCP05
• Suitable calibrated force sensor
• We recommend using a socket for the force sensor. This means that
the sensor does not need to be held manually between the elec
trodes during the force calibration.
Conditions:
• The gun has been referenced.
• The gun is calibrated (see page 77).
Procedure for force calibration
1. Only with robot-controlled guns:
Move the gun into a suitable position (e.g. maintenance position).
The gun opening width must be sufficiently opened for the sensor to
be inserted.
2. Only with robot-controlled guns:
Move the gun into a neutral position. Otherwise, gravity has a nega
tive impact on the force calibration (and the friction coefficient com
pensation!).
• Neutral position of a X gun:
The gun arms span an area which is horizontal to the surface of
the earth.
• Neutral position of a C gun:
The direction of movement of the striking arm runs horizontal to
the surface of the earth.
3. Press the button sequence F5F6 F6F3F6
4. Switch to edit mode via the button.
The yellow LED in the button must light up.
The cursor flashes in the input field "Calibr.prog."
5. Enter the program number of the calibration program in use for the
current gun and press to apply the value.
6. Press B
The cursor flashes in the input field "F-Start:"
7. Enter the start force for the force calibration.
NOTICE
Start value too high and arbitrary value entry
Possible damage to the gun!
" The value to be entered can be found in the gun documentation or
the gun name plate (maximum force of the gun).
Press to apply the value.

8. Press B
The cursor flashes in the input field "F-End"
9. Enter the end force for the force calibration.

The input value should be selected so that it corresponds to the
smallest force used on the gun (incl. the force for dressing).
If in doubt, set the value to "1".
The system calculates the increment automatically.
10.Press F6 (Start F-Calibration) to start the calibration process.
The cursor flashes in the input field "F-Actual".
The "F-Cmd" input field shows the programmed value.
CAUTION
Risk of crushing!
" Ensure that the subsequent gun movement can not injure
anyone.
" Ensure that the force sensor is in the correct position.
11.Press F1 (Start) to close the gun with the relevant force.

12.Read the force actual value off the force sensor and enter the value
in the "F-Cmd" field.
13.Repeat steps 11. to 12. at least three times.
You can check which measurement is due to take place next in the
"No." field.
The current calibration step is shown in the "Step" field.
14.Providing at least one measurement has been carried out per pro
grammed force value (calibration step), you can switch to the previ
ous programmed force value (calibration step via F5 (S-1) and the
next programmed force value (calibration step via F6 (S+1).
15.Carry out steps 13. to 14. for all nine calibration steps.
16.Press F3 (Ready) to end the measurement input.
17.Check the displayed force calibration table via F5 and F6 to deter
mine whether all 9 calibration steps are assigned plausible values. If
not, the whole calibration process must be repeated!
18.If yes, press F1 (Calculate).
The timer now calculates the necessary calibration parameters and
reports the values to the BOS database (external parameter
change).
19.Check the "Scaling quality".
The smaller the value, the better the results of the calibration.
With a value > 30, we recommend repeating the calibration com
pletely.
20.Press the key four times to return to the servo gun menu.
5.4.4 Alternative equipment for the communication interfaces

The following interfaces can be used on X7E1 (ETH1) and X7E2
(ETH2) depending on your requirements:
PSI 6xCx.xxx
ETH1 (X7E1) ETH2
or
"LWL ProfiNet" module
or
AnyBus module AnyBus
"CC Ethernet module
100 Mbit" "ProfiNet IO"
"CC ProfiNet" module

or
The connection of the I/O communication with

the robot also takes place via the ProfiNet
interface module in addition to the BOS6000
computer connection.
"CC Ethernet 100 Mbit" module
Fig.7: Possible interface options of the PSI

For the Ethernet configuration of the interface modules shown, use

the "Anybus IPconfig" software.
For the installation file, see the BOS software package in the "Tools/
Anybus" folder.
For detailed information on the interface modules shown, see the

instructions "PSI 6xxx: Weld timer with Medium-Frequency Inverter".
5.4.5 IndraDrive Cs
For correct communication with the command communication interface
WIC (see page 21), IndraDrive Cs must be parametrized accordingly.
IndraDrive Cs usually comes correctly pre-configured.
For important IndraDrive Cs status messages, see section 5.4.5.4,

page 39.
Required communication settings

• Communication protocol: SERCOS 3
• Drive slave address: 1
• IP configuration 192.168.0.1 (see also Fig. 8: page 43)
5.4.5.1 Set the communication protocol
Conditions:
• IndraDrive Cs is switched on.
• Diagnosis module IndraDriveCs display reports "P -1" or "NRT"
Procedure:
1. Press the ENTER button on the diagnosis module.
The display shows: "Comm.Protocol".
2. Press the ENTER button again.
3. If "SERCOS 3" appears on the display, continue with step 6.
4. If "SERCOS 3" is not shown, press the ENTER button again.
The current entry flashes.
5. Press the buttons Y or B until "SERCOS 3" appears. Then press
ENTER to select this setting.
6. Press the "Esc" until "P -1" or "NRT" appears on the display again.
5.4.5.2 Set the drive slave address
Conditions:
• Communication protocol is "SERCOS 3".
Procedure:
2. Press B.
The display shows: "Slave Address".
3. Press the ENTER button.
4. If slave address "1" is shown, continue with step 7.
5. If slave address "1" is not shown, press the ENTER button again.
The current entry flashes.
6. Press the buttons Y or B until slave address "1" is shown.
Then press ENTER to select this setting.
7. Press the "Esc" until "P -1" or "NRT" appears on the display again.
5.4.5.3 Set IP configuration
Conditions:
Procedure:
2. Press B twice.
The display shows: "Ethernet".
The display shows: "FKM-Eng. X24-X25".
4. Press the ENTER button.
IP address 5. If "IP address: 192.168.0.1" is shown, continue with step 10.
6. If "IP address: 192.168.0.1" is not shown, press ENTER again.
The first numeric keypad flashes.
7. Press the buttons Y or B until the correct value is shown and then
press ENTER.
The second numeric keypad flashes.
8. Set numeric keypads 2 to 4 in this way.
The display shows "IP address: 192.168.0.1".
Subnet mask 10.Press B.
The display shows: "Subnet mask: 255.255.255.0".
11.If "Subnet mask: 255.255.255.0" is shown, continue with step 16.
12.If "Subnet mask: 255.255.255.0" is not shown, press ENTER again.
The first address block flashes.
13.Press the buttons Y or B until the correct value is shown and then
press ENTER.
14.Set numeric keypads 2 to 4 in this way.
15.Press the ENTER button again.
The display shows "Subnet mask: 255.255.255.0".
Gateway address 16.Press B.
The display shows: "Gateway address: 192.168.0.254".
17.If "Gateway address: 192.168.0.254" is shown, continue with
step 22.
18.If "Gateway address: 192.168.0.254" is not shown, press ENTER
again.
The first address block flashes.
19.Press the buttons Y or B until the correct value is shown and then
press ENTER.
20.Set numeric keypads 2 to 4 in this way.

21.Press the ENTER button again.
The display shows "Gateway address: 192.168.0.254".
22.Press the "Esc" until "P -1" or "NRT" appears on the display again.
5.4.5.4 Important status messages

bb Drive is ready for power on
(drive is deenergized)
Ab Drive is ready and has power
AF Drive is ready for regulation
(regulation enabled)
PM Drive is in "programming mode"
PA Drive is "parked"
(no regulation, no fault monitoring)
STO Drive is safely torque-free
(Safe Torque Off)
NRT Non Real Time mode
(drive is not working in real-time communication)
P-1...P3 Current phase during phase switch-up of the drive
Further information on fault and status messages of the drive control

can be found in the relevant product documentation.
Notes:
Assembly and connection
6 Assembly and connection

1. Ensure that the individual components used are integrated in the
overall system in accordance with the relevant product documenta
tion, are connected to suitable power supplies and are fused and ad
equately interference-suppressed in accordance with the valid
regulations.
2. Ensure that the communication connections of the individual
components used (e.g. Ethernet, ProfiNet) are in place and
available before a suitable configuration is carried out, but are not
yet connected.
3. Turn the system on.
4. Parametrize the communication interfaces used. Information on
parameterizing the communication interfaces can be found in
section 6.1.
5. Then connect the communication interfaces used according to the
specifications in Fig. 8: page 43 or Fig. 9: page 44.
6. Commission the servo gun control according to section 7 from
page 47.
6.1 Required communication connections and addresses
NOTICE
network!
" Therefore: never parameterize the settings arbitrarily!
" For configuring communication interfaces, use a computer that
• is only connected to the communication interface of the device
to be set
• is in the same subnetwork as the connected device
• does not collide with the IP address of the device to be set
• is equipped with suitable configuration tools
" The individual components used are or must be set to fixed, speci
fied IP addresses in conjunction with the servo gun control.
Automatic address allocation via a DHCP server is not permitted.
For specified IP addresses: see Fig. 8: page 43.
" Isolate the individual components used within a separate network

segment from the remaining network topology.
For this, the PSI must be equipped with 2 separate network modules.
For the main structure of the required network topology: see Fig. 8:
on page 43.
PSI 6xCx.xxx IndraDriveCs
* WIC:
fixed IP address Gun memory
192.168.0.99 GDM
WIC* X24
(X7S)
X25 XFE
ETH1 (X7E1) ETH2

IndraDrive Cs (X24): Gun memory GDM (XFE):
Fixed IP configuration. Fixed IP configuration.
IP address: 192.168.0.1 IP address: 192.168.0.50
ETH1: For important information Subnetwork: 255.255.255.0
Fixed IP configuration. on the correct Gateway: no entry
IP address: 192.168.0.10 configuration, see section DHCP: no
Subnetwork: 255.255.255.0 5.4.5 from page 37.
Gateway: no entry
DHCP: no
ETH2:
IP configuration, suitable for connection to the
robot (required for I/O connection via ProfiNet)
X5 and computer with installed BOS6000
VCP05
Fixed IP configuration.
IP address: 192.168.0.100
Subnetwork: 255.255.255.0
Gateway: no entry
DHCP: no BOS6000 computer Robot system
Fig.8: Required IP addresses of the individual components
NOTICE
Malfunctions in the command communication (WIC)
A different command communication connection method can
cause malfunctions in the interplay between the timer and the
drive control!
" Always connect via point-to-point connection!
In the figure on page 43, all network participants are isolated on the PSI
interfaces ETH1 and WIC from the remaining topology (ETH2) and
grouped via class C network in the IP area 192.168.0.x.
To enable access to all participants in the address space
192.168.0.x, e.g. for maintenance purposes or commissioning, it is
also feasible to connect PSI (ETH1), VCP05, IndraDrive Cs and
GDM at a dedicated switch, which the maintenance/commissioning
computer can simply be connected to when necessary. See the
following figure:
PSI 6xCx.xxx IndraDriveCs
Gun memory
GDM
WIC X24
(X7S)
ETH1 (X7E1) ETH2

X25 XFE
see Fig. on
page 43
X5 5-way switch
1 GBit
VCP05 Maintenance computer
Fig.9: Use of a dedicated switch
NOTICE
Merging of the network topology on ETH1 and ETH2
Merging can cause major faults in both network segments!
" Ensure that the switch shown in Fig. 9:does not serve any other
network participants.
NOTICE
network!
" Therefore: never parameterize the settings arbitrarily!
" Use a maintenance computer, which
• is only connected to the communication interface of the switch
shown (see Fig. 9:)
• is in the same subnetwork as the network users shown
(see Fig. 9:)
• does not collide with the IP address of the network user shown
(see Fig. 9:)
• is equipped with suitable configuration tools
Notes:
Commissioning the servo gun control
7 Commissioning the servo gun control

7.1 Basic requirements
... on the system in general • The servo gun must be docked on the robot, electrically connected
with the drive inverter and timer (motor power cable, -encoder cable,
primary and secondary transformer circuit, connections for current
measurement (KSR) and voltage measurement (UIR) where applica
ble, connection for transformer temperature monitoring) and the cor
rect tool data set activated for offsetting the mechanical gun data
(TCP, gun weight where applicable) on the robot side.
• The gun must have sufficient space for the movements of the gun
actuator.
... specifically on the gun • Correct status of the gun and electrode shafts.
• New tips are placed on the shafts and fixed in place loosely.
• Correct cooling on the gun (cooling tube, flow rate, supply tempera
ture).
... specifically on the timer • Basic commissioning of the system completed successfully.
Information on this can be found in the instructions "PSI 6xxx: Weld
timer with Medium-Frequency Inverter" (No. 1070080028) under
section "Commissioning".
• The conditions outlined in section 5.2 (page 20).
• Correctly configured, connected and active communication inter
faces. See section 6 from page 41
• Transformer and current calibration parameters with suitable
settings.
7.2 Basic commissioning

CAUTION
Risk of crushing!
" Ensure that no-one can be harmed by the movements of the gun
actuator.
This section outlines the actions required to carry out the basic commis
sioning of the servo gun control.
Once the basic commissioning has been completed successfully, the
drive is in regulation and the connected gun can be jogged open and
closed.
1. Check whether the "Servo gun" tab is shown via BOS under
"Programming", "Diagnostics" and "Setup" once the relevant timer is
selected.
If so, the function "Servo gun control" has been detected by the timer
firmware and can be parametrized via BOS.
If not, please note down the software version of your BOS (via
BOS 6000 cover page) and contact our service team.
2. Parametrize all basic settings of the servo gun control.

This data can be transferred to the timer in different ways:
via HPG and GDM • via HPG, if the GDM is present and has been written with the nec
essary data beforehand:
1. On the HPG, press the key sequence F5F6F1
2. Select the relevant electrode via sign key (= gun number).
3. Then press F5 (read data).
4. Enter the password (741) via the number keys and acknowl
edge with .
The relevant function is carried out with no further query.
5. Exit the edit mode via the key.
The yellow LED in the key must no longer be lit.
6. Press the key to return to the servo gun menu.
via BOS without GDM • via BOS6000, if no suitable basic settings already exist anywhere:
1. Select the relevant timer, followed by "Programming", "Elec
trode".
2. Select the relevant electrode/gun (2).
3. Adapt all the parameters and send the changes to the timer.
A description of all parameters is available in the Online Help.
4. Select "Programming", "Stepper".
5. Select a weld program which works with the relevant electrode/
gun.
6. Adapt all the electrode-specific parameters and send the
changes to the timer.
A description of all parameters is available in the Online Help.
7. Select "Setup", "Servo gun", "General Gun"
5 7
6 4
Fig.10: "Setup", "Servo gun", "General Gun"
8. Select the relevant electrode/gun (2).

9. Adapt all the parameters in all tabs (1) and send the changes to
the timer (4).
A description of all parameters is available from section 8.5
from page 67.
10.Press "Activate data" (6) to also send the changes to the drive
control.
11.Acknowledge the safety notice.
The drive control switches temporarily to "PM" (parametriza
tion mode) for a short time for the parametrization.
12.Acknowledge the completion message.
The new data is now active in the drive.
The yellow advisory symbol disappears.
13.If you also want to transfer the adapted basic settings of the
servo gun control to an existing GDM, start the transfer with the
"SST -> GDM" (7) button.
14.To export the adapted basic settings of the servo gun control to
a parameter file, first select the relevant timer, select the rele
vant electrode number (=gun number) via the BOS menu path
File / Para. data import/export / Export...", enter a clear file
name and acknowledge with the Ok button.
via BOS and GDM • via BOS6000, if the GDM is present and has been written with the
necessary data beforehand:
1. First select the relevant electrode/gun (2).
2. Start the transfer with the "GDM -> SST" (5) button.
3. Press "Activate data" (6) to also send the changes to the drive
control.
4. Acknowledge the safety notice.
5. Acknowledge the completion message.
via BOS and a suitable • via BOS6000 if a suitable parameter file is available:
parameter file
The destination timer name and destination electrode number
are included in the parameter file (SST-NAME;SUBINDEX;...)
and must be adapted if necessary.
1. First select the BOS menu path File / Para. data import/export /
Import..."
2. Select the relevant parameter file with the "..." button.
3. Confirm your selection with "Ok".
The data in the parameter file is imported into the relevant timer
under the corresponding electrode number. See information
above.
4. Select "Setup", "Servo gun", "General Gun" See Fig. page 49.
control.
3. Check whether the drive is in regulation (display on diagnosis module
IndraDrive Cs: AF).
If this is not the case, enable regulation (enabling switch on the robot
pressed?).
4. Reference the gun.
• Via BOS: see available commands from page 60
• Via HPG: see section 5.4.3.5 from page 28
The gun actuator can be jogged.
7.3 Advanced commissioning

Conditions:
• Basic commissioning is complete. See section 7.2 from page 47
• New status of the gun and electrode shafts.
• New tips are placed on the shafts and fixed in place loosely.
CAUTION
Risk of crushing!
actuator.
This section outlines the actions required to carry out the "advanced"
commissioning of the servo gun control.
Once the advanced commissioning has been carried out successfully,
the servo gun control is ready for welding.
1. Carry out tip setting stroke.

2. Carry out PosRes + EW (Position reset (before dressing)).
• Via BOS: not available
3. Adapt the parameter "Tip-tip programmed position" (= calibrate gun.
See page 77).
4. Reference the gun.
5. Only necessary with X guns: Carry out geometry calibration (see
section 7.3.1 page 52).
6. If "Start tip dress" is required: Dress electrodes.
7. If "Start tip dress" has been carried out (see step 6.): Carry out posi
tion reset (after dressing).
8. Only for guns where force calibration has not yet been carried out:
The gun is ready for welding.
7.3.1 Geometry calibration

This function compensates for deviations in the programmed position
values, which occur with X guns for design-related reasons.
Conditions:
• Gun is calibrated. See "Tip-tip programmed position" parameter
page 77.
Schedule:
1. Ensure that, under "Setup", "Servo gun", General Gun" in the BOS,
the parameters "Reference opening range" (see page 70) and "Inter
nal opening range" (see page 70) are set to "0".
2. Trigger Position reset (before dressing):
• via input signal S019 "Request reset position (before dressing)"
(see "Diagnostics", "Diagnostics I/O") - or -
• via PosRes + EW (Position reset (before dressing)). See section
5.4.3.5 from page 28.
3. Open the gun completely.
4. Alternatively, read off the internal gun opening width:
• via BOS under "Diagnostics", "Servo gun", display group "Main
stroke", "Position" field
• via HPG with key sequence F5F6F6F4
(in the top line next to "gun position":).
5. Enter the read off value in the parameter "Internal opening range".
6. Measure the current maximum opening width on the gun, or take the
value from the gun design drawing.
7. Enter the determined value in the parameter "Reference opening
range".
8. Send the changes to the timer with the "Data -> WT" button.
9. Press "Activate data" to also send the changes to the drive control.
10.Acknowledge the safety notice.
The drive control switches temporarily to "PM" (parametrization
mode) for a short time for the parametrization.
11.Acknowledge the completion message.
The yellow advisory symbol in front of the "Activate data" button
disappears.
12.If you also want to transfer the adapted basic settings of the servo gun
control to an existing GDM, start the transfer with the "SST -> GDM"
button.
13.Reference the gun.
Geometry calibration is active.
BOS user interface
8 BOS user interface

This section gives an overview of all servo-gun-specific areas of the
userinterface.
The areas are arranged as tabs within the individual fields of the BOS
("Programming", "Diagnosis", ...) and are only present if a timer is
equipped with "servo gun control".
The servo gun control is only supported from BOS versions > 1.42.1.
Information on the user interface is also available via the BOS 6000
online help.
8.1 Programming: Servo gun

All parameters in this dialog act on a program-specific basis.
Fig.11: ”Programming” field, "Servo gun" tab
"Positioning velocity" parameter

Defines for the selected program the velocity with which the arm gun
• moves to the start of the "search area" after the welding program is
started in position control (see Fig. 12: page 55)
• opens after Weld Complete.
Must be smaller than the "Max. closing velocity".
BOS user interface
"Opening position" parameter

Defines the position to which the gun opens in the following cases:
• after timer restart and subsequent referencing if the selected pro
gram is selected indirectly (with spot selection) via the robot or
• after Weld Complete of the selected program if the robot has not set
the "Programmed stroke position valid" signal since the last timer
restart.
NOTICE
Changes to the programmed opening position!
Risk of collisions between the gun and the surrounding objects!
" Note that the entered parameter value is only valid until the robot
sets the "Programmed stroke position valid" signal after a timer
restart.
After this point, the system always uses the programmed position
value specified by the robot with the active "Programmed stroke
position valid" signal.
"Milling Program" parameter

Off: The timer interprets the selected program as a weld pro
gram.
On: The timer interprets the selected program as a milling pro
gram.
For programs identified as a milling program:
• The program always runs without current once the program is
started.
• Once the program is complete, neither the output signal "Weld OK"
nor "Weld not ok" is set.
• As soon as the milling program is complete, the timer opens the gun
automatically and generates the "Weld Complete" signal. The robot
must then move the gun out of the tip dressing station.
Use the "Tip dress control" function (see page 76) to check the tip
dress.
"Joining level" parameter group
"Sheet thickness" parameter

Total material thickness on the welding position.
Serves as a reference for the sheet thickness monitoring ("Sheet
thickness" parameter group).
The value can be set manually via BOS and can also be determined
automatically via teach sequence with the "start teaching" signal. For
information on teaching the joining position, see section 9.2 page 90.
BOS user interface
"Search area" parameter group
"Main stroke" parameter

Defines the gun opening width from which switching takes place from
"Positioning Velocity" to "Contact velocity" to prevent a rebound impact
during contact.
" The value must be calculated so that the current friction coefficient
(measurement duration: 180 ms) is determined before the tips reach
the joining level.
Position before closing

(e.g. opening position)
Main stroke
Positioning velocity
Contact velocity
Sheet
thickness
Fig.12: Sequence of motions when closing the gun
"Sheet thickness" parameter group
"Monitoring" parameter
Switches the sheet thickness monitoring off or on.
"Upper/Lower tolerance" parameter
The gun must contact with the material within the specified limits. Other
wise, the schedule is aborted before the force is built up and the mes
sage "Sheet too thick/too thin" is generated.
The elasticity of the gun means that sheet thickness monitoring is not
practical for X guns.
The values are only shown if the parameter "Servo gun style" has the
value "Servo electrical" or "servo-pneumatic" and the sheet thickness
monitoring is switched on ("Monitoring" parameter).
Parameter group "Force"
"Monitoring" parameter
Switches the force monitoring off or on.
The gun force monitoring can be activated independently from the
gun force regulation.
BOS user interface
"Programmed value" parameter

Programmed value (reference value) for the force monitoring in kN
The value should be adapted on the "Base pressure value" parameter
(under the "Schedule" tab) or on the set pressure profile.
The parameter is only shown if the parameter "Servo gun style" has
the value "Servo electrical" or "servo-pneumatic" and the force moni
toring is switched on ("Monitoring" parameter).
"Upper/Lower tolerance" parameter

The gun must provide the force programmed under "Programmed
value" within the specified limits. Otherwise, the message "Sheet too
thick/too thin" is generated after the weld schedule.
The parameters are only shown if the parameter "Servo gun style"
has the value "Servo electrical" or "servo-pneumatic" and the force
monitoring is switched on ("Monitoring" parameter).
8.2 Programming: Counter

All parameters in this dialog act on an electrode-specific basis
(= gun-specific).
The timer provides 9 counters per gun, which can be used to monitor the
wear of freely definable components on the gun.
Once a weld program is complete, the timer increments all activated
counters on the corresponding electrodes (gun) by 1.
Parametrizable warning and max. limits can be used to generate
component-specific warning and end of life messages, which request
maintenance actions or replacement measures by the system operator
(examples: motor lubrication, change, maintenance, gun force check
etc.).
If the GDM is available, bidirectional transfer of all component coun
ters between the timer and GDM is possible.
This means that important information on a gun can be "passed on"
and used at the destination.
The standard counter names ("Value counter 1" to "Value counter 9")
can be adapted with the BOS configuration tool under the "Change
Texts" field according to requirements.
BOS user interface
Fig.13: "Programming” field, "Counter" tab
Deactivate counter To deactivate a counter, set the corresponding max limit to the value 0.
The current counter status and corresponding warning limit are retained
during the process, but the counter status is no longer incremented once
a weld program is complete.
Warning and end of life messages are no longer generated for the corre
sponding counter.
Set up and activate the counter Proceed as follows:
1. In the "Max limit" column, enter the counter status, which should trig
ger the "Weldgun component counter end of cycle: electrode x" mes
sage when reached.
Input value: > 0
2. In the "Warning limit" column, enter the counter status, which should
trigger the "Weldgun component counter warning: electrode x"
message when reached.
3. Press the "Set Counter" button.
The "Set Counter" window is opened.
4. Change the corresponding value counter.
5. Change the content of the corresponding additional info by entering a
suitable text.
6. Press the "Data ---> WT" button, enter a clear comment in the
comment field where applicable and acknowledge the data transfer
with "Ok".
The "Set Counter" window is closed.
The counter is now set up and active.
BOS user interface
"GDM -> SST" button

Load all counter data saved in the GDM into the electrode-specific
counter. Existing counter data is overwritten in the timer during this
process with no further query.
If the counter data was transferred correctly, the BOS outputs the
message "Function was finished successfully."
"SST -> GDM" button

Load all displayed counter data into the GDM.
Existing counter data in the GDM is overwritten during this process with
no further query.
If the counter data was transferred correctly, the BOS outputs the
message "Function was finished successfully."
"Data ---> WT" button

Saves data changes in the "Warning limit" and "Max limit" columns.
"Set Counter" button

Opens the "Set Counter" window.
Fig.14: "Set Counter" window
The following actions are possible here:

• Change the current counter status (e.g. to reset the counter after a
component has been replaced or maintenance work has been car
ried out).
An amended counter status can only be applied in the timer ("Data -->
WT" button) if the character sequence in the "Additional info" column
is also changed.
• Enter a character sequence (e.g. date etc.).
Is only possible after the relevant counter status has been changed.
BOS user interface
8.3 Diagnostics: Start Simulation

This field can only be selected if an online timer is selected as the
timer.
All data in the "Servo gun" parameter group acts on an electrode-spe
cific basis (= gun-specific).
All other data in this dialog acts on a timer-specific basis.
The following functions are possible with regard to the "servo gun con
trol":
• Set the modes "Auto mode", "Manual mode", "Stop" and "Force cali
bration mode"
• Trigger various commands when "Manual mode" is active.
Fig.15: "Diagnostics field", "Start Simulation" tab
"Mode" field
Shows the current active mode of the servo gun control.
"Operation mode settings" button
Attempts to set the mode currently selected via the "Mode" selection
field.
BOS user interface
"Mode" selection field
Mode selection.
To set the selected mode, press "operation mode settings".
Stop:
Selects the "Stop" mode.
"Stop" is required to "enable" the gun after "Manual mode" or "Force
calibration mode" has been set via BOS.
The gun can only be controlled via digital interface or VCP05 again after
"Stop" has been set.
Manual mode:
Selects "Manual mode" via BOS.
In "Manual mode", the commands available in the "Command" selection
field can be sent to the gun.
"Manual mode" can only be set if
• no gun change is active (servo gun control disabled)
• no "Manual mode" is active, which was triggered via VCP05.
Force calibration mode:

Selects "Force calibration mode" via BOS.
In "Force calibration mode" (operation only possible via VCP05), the
connection between the motor current and resulting electrode force is
determined - taking into account the current friction.
Only once force calibration has been carried out successfully can the
servo gun control convert a programmed force value to a correct elec
trode force.
"Execute command" button
Triggers the command selected via the "Command" selection field.

The button is only active if "Manual mode" has been set via BOS.
CAUTION
Risk of crushing!
" Ensure that neither people nor objects can be harmed by the
movements of the gun actuator.
" Ensure that enough space is available for the movements of the
gun actuator.
"Command" selection field
Command selection.
To trigger the selected command, press the "Execute command" button.
No Movement:
Dummy command. Does not trigger a movement.
BOS user interface
Reference:
Triggers a referencing sequence if the drive is in regulation. The gun
pressure actuator is opened to its mechanical end stop with regulated
torque (see parameter "Max. force at referencing", page 73) and limited
velocity (see parameter "Contact velocity", page 73), then closed (tip-
tip) and brought to the current opening position (see page 54).
Position reset (after wear):
The timer determines the total tip dress length since the last tip change
via a closing sequence with dressed tips.
Close gun:
Currently without a function.
Approach opening position:
Triggers a positioning movement to the current active opening position
(see page 54).
Approach position:
Triggers a positioning movement to the programmable target position.
Teach Joining Level position:
Triggers a movement sequence for determining the sheet thickness.
Determine transmitter offset main stroke:
Triggers the determination of the motor commutation offset.
If the transmitter offset data needs to be changed, this is signaled after a
few seconds with an exclamation mark in the footer (= ext. data change).
" In this case, switch to "Setup", "Servo gun", "Synchron" and press the
"Activate data" button.
This writes the new value in the drive control.
Determine transmitter offset gun equal.:
Tip setting:
Triggers the closing of the gun with subsequent re-opening to the current
active opening position (see page 54).
This means that newly exchanged tips are always pressed onto the
shafts in a reproducible way.
Mechanical test:
Lubrication:
Triggers the opening of the gun to the maximum opening width and
subsequent restart to the current active opening position (see page 54).
During the movement, the force defined in the electrode-specific
parameter "Max. force in weld schedule" is active.
Is used for lubrication.
BOS user interface
Force calibration:
Without function here. Trigger a force calibration via VCP05 if neces
sary.
Start change servo gun:
Without function here.
If necessary, trigger the gun change via digital interface or via VCP05.
Stop change servo gun:
Without function here.
If necessary, stop the gun change via digital interface or via VCP05.
BOS user interface
8.4 Diagnostics: Servo gun

This field can only be selected if an online timer is selected as the
timer.
Shows important status data of the servo gun control.
Fig.16: "Diagnosis" field, "Servo gun" tab
"Drive status" field
Contains error information after a servo gun error has occurred.
"Actual diagnostics code" field
Shows the status of the main stroke actuator.

Detailed information on the value shown can be found in the document
"Rexroth IndraDrive - Mpx-16 to Mpx-18 - diagnostics" (see Tab 1:
page 5).
The document is available as a pdf in the installation folder of
the BOS 6000 under "../Bosch Rexroth AG/BOS6000/help/
<language-specific folder>".
It may also be possible to call up the document directly via the F1
button.
BOS user interface
"Motor temperature" field
Current motor temperature.

Is only relevant with existing motor temperature sensors (see parameter
"Sensor configuration", page 85).
"Force" field
Current actual force.
"Motor current" field
Current motor current.
"Velocity" field
Current movement velocity of the tip of the striking arm gun.
"Position" field
Current position of the tip of the striking arm gun.
"Commanded position" field
Current specified command position of the tip of the striking arm gun.
"Max. tolerance model" field
Corresponds to parameter P-0-0098 of the drive control.

Deviation between the position command value and position actual
value.
Also known as the following distance.
BOS user interface
"Tip positions" button
Opens the "Tip Position - Info Box" window:
Fig.17: "Tip Position - Info Box" window
"Main stroke" field ("Actual" display group)

Shows the position of the main stroke inside the gun during which the
tips touched after the last tip dressing cycle.
Position value "0" refers to the linear position of the adjusting axis with
max. retracted stroke. It is set in the course of the referencing movement
in exactly the moment where the reaching of the fixed stop is detected.
"gun equalization" field ("Actual" display group)
"Main stroke" field ("New Electrode" display group)
Shows the position of the main stroke inside the gun during which new,
undressed tips touched.
"gun equalization" field ("New Electrode" display group)
"Tip wear" field
Electrode wear per tip since the last tip change.
"Last dress material removal" display group
"Main stroke" field:
Dressing length of the tip of the striking electrode arm during the last
dressing cycle.
"Gun equalization" field:
Dressing length of the tip of the fixed electrode arm during the last dress
ing cycle.
How the total dressing length is distributed over the tips of the striking
and fixed arm gun can be defined via the parameter "Gun equaliza
tion share in dressing length" ("Setup", "Servo gun", "Electrode main
tenance", parameter group "Tip dress control").
BOS user interface
"Main stroke" field ("Actual value mechanical test" display group)

"Gun equalization" field ("Actual value mechanical test" display group)
"Weld counter" field ("Lubrication interval" display group)
Number of welding sequences since the last lubrication stroke.
"Mechanical basic load" field
Reference friction coefficient in the unit Newton.
Is determined during the force calibration (measurement time lies in the
seconds range during this process).
Is used to compensate for a changing stiffness of the gun.
BOS user interface
8.5 Setup: Servo gun: General Gun

All parameters in this dialog act on an electrode-specific basis.
" To change data here, proceed as follows:

1. Change the relevant data.
2. Press "Data --> WT" (1) to apply the amended data in the timer.
control.
The system indicates this requirement by displaying the yellow
advisory symbol (3).
If process-relevant data is changed in the drive during this
process, referencing must be carried out again.
mode) for the parametrization.
3 2 1
Fig.18: "Setup", "Servo gun", "General Gun"

BOS user interface
"Servo gun style" parameter

Gun technology.
pneumatic:
This is a pneumatically moved gun, which is operated via proportional
regulating valve for force generation.
Servo electrical:
This is an electrically moved gun, which is operated via servo motor in
position and torque control.
servo-pneumatic:
This is a pneumatically moved gun, which is operated via adjustable
valve electronics in position and torque control.
Only the "Servo-electrical" setting is currently supported.
"Identification" parameter group
"Check gun ID" parameter

Switches the gun identification data check on or off. If the check is
switched on, differences in the gun identification data in the timer and
GDM data are reported.
" Only switch the function on if the GDM is used.
"Gun ID" parameter

Gun ID (hex.) for identifying the gun (gun serial number). Is saved in the
electrode-specific data of the timer and is only shown when "Check gun
ID" is switched on.
"Active gun ID" field
Gun ID (hex.) for identifying the gun (gun serial number). Is saved in the
GDM and is only shown when "Check gun ID" is switched on.
"Gun type" parameter
Customer-specific character string for identifying the gun type. This key
contains e.g. the manufacturer, mechanical design, actuators/sensors
used etc. in code. Guns of the same gun type are therefore always guns
with the same design.
Is saved in the electrode-specific data of the timer and is only shown
when "Check gun ID" is switched on.
"Active gun model" field
Customer-specific character string for identifying the gun type. Is saved
in the GDM and is only shown when "Check gun ID" is switched on.
"Motor serial no. (main stroke)" parameter
Customer-specific character string for entering/identification/logging
the serial number of the motor.
Must be adapted after the motor is replaced.
"Set act. Gun-ID" button

BOS user interface
"Set Gun-Type" button

Determines the relevant gun number based on the spot reference and
current specified spot extension and copies gun-specific data in to
the GDM.
The button is only active if you are logged on as administrator on
the BOS.
"Mechanical" parameter group
"Gun type" parameter
Design type of the gun (X gun, C gun).
The timer sets the output "Guntype X" or "Guntype C" on the digital inter
face depending on the setting.
"Gun equalization" parameter
Gun equalization: Function, which minimizes the asymmetrical
forces on the workpiece caused by the gun closing.
Only the "Without gun equal." setting is permitted.
" The gun equalization can be carried out via robot if necessary.
"Length of electrode arm" parameter

Length of the electrode arm in mm.
" For C guns, set the value to "1".
Lever arm
Length of electrode arm
(main stroke)
smax
Electrodes
Motor main
stroke
smax : max. travel based on the relevant motor stop
Fig.19: Design principle X gun
"Main stroke length" parameter

Length of the main stroke in mm.
See Fig. 19: Design principle X gun.
" For C guns, set the value to "1".
"Screw pitch main stroke" parameter

Screw pitch in mm.
Is required for converting the rotary motor movement into a linear path.
" The value can be found in the motor data sheet of the motor used.
BOS user interface
"Max. main stroke length" parameter

Maximum permitted stroke length of the main stroke in mm.
See Fig. 19: Design principle X gun: Smax
" The value can be found in the motor data sheet of the motor used.
"Reference opening range" parameter

Maximum opening width of the gun according to the design drawing or
measurement.
" Ensure that the value is set to "0" before the start of a geometry
calibration (only necessary with X guns ).
Information on the geometry scale can be found in section 7.3.1 from
page 52.
"Internal opening range" parameter

Maximum opening width of the gun according to the read position actual
value.
" Ensure that the value is set to "0" before the start of a geometry
calibration (only necessary with X guns ).
Information on the geometry scale can be found in section 7.3.1 from
page 52.
"Gun parameter check" parameter

Switches the check on all GDM data off or on following a change in the
"Change gun (disable servo gun control)" input signal. If the check is
switched on, differences between the timer and GDM data are reported
(message 192-10x).
" Only switch the function on if the GDM is used.
" To reset the message, establish data consistency between the timer
and GDM data.
Use the buttons "GDM -> SST" or "SST -> GDM" depending on the
desired adjustment direction.
"GDM -> SST" button
Loads all data saved in the GDM into the electrode-specific parameters.
Existing data is overwritten in the timer during this process with no
further query.
If the data was transferred correctly, the BOS outputs the message
"Function was finished successfully."
"SST -> GDM" button
Loads all gun data into the GDM.

During this process, the data in the GDM is overwritten with no further
query.
If the data was transferred correctly, the BOS outputs the message
"Function was finished successfully."
BOS user interface
"Activate data" button
Loads all data relevant for the drive into the drive control.
If this action is necessary, the BOS shows a yellow advisory symbol to
the left of the button.
If position-relevant data in the drive is changed during this action, the
gun must be referenced again afterwards (can be checked on the
output signal "gun referenced").
Applies data changes in the BOS database/timer.

BOS user interface
8.6 Setup: Servo gun: Movement


control.
3 2 1
Fig.20: "Setup", "Servo gun", "Movement"
"Max. closing velocity" parameter

Defines the maximum permitted positioning velocity of the gun.
BOS user interface
"Max. force in weld schedule" parameter

Defines the maximum permitted gun force.
If the programmed force is higher than this in a weld program, the force is
limited to this value.
The specified force is also used for the "Tip setting stroke" function
(see page 18).
NOTICE
Input values too high
Gun overload possible!
" Ensure that the input value is not higher than the maximum
permitted gun force.
The maximum permitted gun force can be found in the gun
documentation or on the gun name plate.
"Max. force at referencing" parameter

Defines the force from which the main stroke detects that the mechani
cal fixed stop is reached during referencing.
"Max. force at sheet search" parameter
Defines the force from which the main stroke detects that the joining
level is reached.
Must be higher than the current friction coefficient.
"Force in manual mode" parameter
Defines the force the main stroke works with in manual mode (e.g. during
jogging).
"Teach velocity" parameter
Defines the velocity with which the gun closes when learning the sheet
thickness (Teach In).
"Contact velocity" parameter
Defines the velocity with which the gun comes into contact with the sheet
within a weld schedule during the closing process.
NOTICE
Changes once force calibration is complete
Changes to the closing force!
" Ensure that the value is not changed once the force calibration is
complete. Otherwise, a new force calibration is required.
BOS user interface
"TCP-adjustment" parameter group
"TCP setpoint tracing" parameter

No function. Set the parameter to the value "Without".
Without:
No TCP-adjustment.
"Force monitoring" parameter group
"Force sensor" parameter

Off:
The current force actual value is determined indirectly via the motor
actual current and using the current/force characteristic curve
determined during force calibration.
On:
The current force actual value is determined directly via a connected
force sensor.
Force calibration is not required when a force sensor is used for force
monitoring.
"Force regulation through force sensor value" parameter
Off:
The force actual value required for force regulation is determined
indirectly via the motor actual current and using the current/force
characteristic curve determined during force calibration.
On:
The measurement of the connected force sensor is used for force
regulation.
The "Force sensor" parameter must be set to On for this.
If this action is necessary, the BOS shows a yellow symbol to the left
of the button.

BOS user interface
8.7 Setup: Servo gun: Electrode maintenance


control.
3 2 1
Fig.21: "Setup", "Servo gun", "Electrode maintenance"
BOS user interface
"Tip dress control" parameter group
"Tip dress control" parameter

Off: Switches the "Tip dress control" function off.
On: Switches the "Tip dress control" function on.
The "Tip dress control" function

• checks whether the tips were dressed by a defined amount during the
last tip dressing process following tip dressing and "Position reset
(after dressing)"
• checks whether the total dressing of both tips exceeds a maximum
permitted value following tip dressing and "Position reset (after
dressing)"
• defines the extent to which the tip of the fixed electrode arm is
involved in the total dressing.
The "Tip dress control" function does not control the tip dressing
process!
The tip dressing process must be controlled and parameterized in the
robot with corresponding macros (sequential process, number or du
ration of tip dresser rotations).
"Programmed value dressing length"

Defines by how many mm the tips must have been dressed in total
during the last tip dressing process.
If the determined dressing length lies outside the tolerance limits
outlined below, the timer resets the output signal "Tip dress Ok" and
reports a dressing error.
This check detects problems in the tip dresser/tip dress cutter area or
tip dressing processes which are parametrized incorrectly in the
robot.
"Upper tolerance dressing length" parameter

See "Programmed value dressing length" parameter
"Lower tolerance dressing length" parameter
See "Programmed value dressing length" parameter
"Max. wear of electrodes" parameter
Defines the maximum value in mm by which the tips may be dressed in
total.
If the determined dressing length exceeds the parametrized value, the
timer sets the output signal "Tip wear fault" and reports that the gun has
reached its maximum tip wear.
Both the output signal "Tip wear fault" and the output signal "End of
Stepper" should trigger a tip change cycle (travel to tip change posi
tion) on the robot.
"Gun equalization share in dressing length" parameter

Defines the percentage by which the tip of the fixed electrode arm is
involved in the total current dressing length.
The result is reported via the output signals "Tip wear rate x".
BOS user interface
"Geometry test" parameter group
NOTICE
Arbitrary changes
Problematic changes to the gun geometry are not detected!
" Ensure that the values are not changed arbitrarily.
"Geometry test" parameter

Off: Switches the "Geometry test" function off.
On: Switches the "Geometry test" function on.
The "Geometry test" function

• checks whether the current "tip-tip" position has changed in relation
to the "Tip-tip programmed position" parameter following a tip change
and "Position reset (before dressing)."
• reports the deviation on the outputs "Geometry x".
The following problems can result in a fault:
- tip missing
- incorrect tips (too short or too long)
- tips mounted incorrectly
- shaft faulty
- arm gun bent.
"Tip-tip programmed position" parameter
Position of the main stroke inside the gun with new guns, closed guns
and guns equipped with new tips.
Calibrate gun " To change data here, proceed as follows:
1. During the commissioning of the gun and before the parameter
value is set, ensure:
• That the arm guns are mechanically sound and correspond to
the original design data.
• New and suitable electrode shafts are mounted correctly.
• New, suitable and undressed tips are mounted correctly on the
shafts.
2. Trigger Position reset (before dressing):
• via input signal S019 "Request reset position (before dressing)"
(see "Diagnostics", "Diagnostics I/O") - or -
• via PosRes + EW (Position reset (before dressing)). See sec
tion 5.4.3.5 from page 28.
3. Use the "Act. Val. --> Prog. value" button in the "Geometry test"
parameter group to apply the current actual value in the parame
ter.
BOS user interface
The current actual value is shown in the "Tip Position - Info Box"
window (see page 79) in display group "New Electrode" under "Main
stroke".
4. Only necessary with X guns:
Carry out geometry calibration. See section 7.3.1 from page 52.
"Tolerance" parameter
Permitted deviation between the "Tip-tip programmed position" parame
ter and the "Main stroke" actual value under display group "New Elec
trode" in the "Tip Position - Info Box" window (see page 79). Large
deviations trigger the message "Geometry test error".
"Act. Val. --> Prog. value" button (Geometry test)
Applies the current value of display group "New Electrode" in the "Main
stroke" field ("Tip Position - Info Box"; see page 79) in the "Tip-tip pro
grammed position" parameter.
"Mechanical test" parameter group
"Lubrication stroke" parameter group

Off: Switches the "lubrication stroke" function off.
On: Switches the "lubrication stroke" function on.
The "lubrication stroke" function ensures an even lubrication of the mo
tor spindle by opening the gun completely and then moving it to the cur
rent active opening position (see page 54)
If activated, the function is always triggered after a programmable num
ber of weld schedules ("Lubrication interval") parameter.
An external enable is requested first of all on the timer side via the output
signal "Request lubrication stroke". The robot must then ensure that a
suitable system state is in place before triggering the function in the timer
via input signal "Lubrication stroke".
The function is usually only necessary with stationary guns. With
these guns, the lubricant can often only be brought to the relevant
active areas during a lubrication stroke due to the fixed lubricant
vessel position.
With robot-controlled guns, the movements of the robot usually
provide adequate lubricant distribution.
"Lubrication interval" parameter

Defines the number of welds after which the lubrication stroke should be
triggered.
BOS user interface
"Actual Value" button
Opens the "Tip Position - Info Box" window:
Fig.22: "Tip Position - Info Box" window
"Main stroke" field ("Actual" display group)

Shows the position of the main stroke inside the gun during which the
tips touched after the last dressing cycle.
"gun equalization" field ("Actual" display group)
"Main stroke" field ("New Electrode" display group)
Shows the position of the main stroke inside the gun during which new,
undressed tips touched.
"gun equalization" field ("New Electrode" display group)
"Tip wear" field
Electrode wear on both tips since the last tip change.
"Last dress material removal" display group
"Main stroke" field:
Dressing length of the tip of the striking electrode arm during the last
dressing cycle.
"Gun equalization" field:
Dressing length of the tip of the fixed electrode arm during the last dress
ing cycle.
How the total dressing length is distributed over the tips of the striking
and fixed arm gun can be defined via the parameter "Gun equaliza
tion share in dressing length" ("Setup", "Servo gun", "Electrode main
tenance", parameter group "Tip dress control").
BOS user interface
"Main stroke" field ("Actual value mechanical test" display group)

"Gun equalization" field ("Actual value mechanical test" display group)
"Weld counter" field ("Lubrication interval" display group)
Number of welding sequences since the last lubrication stroke.
"Mechanical basic load" field
Reference friction coefficient in the unit "Newton".
Is determined during the force calibration (measurement time lies in the
seconds range during this process) and then offset against the current
friction coefficient during every "Sheet search".
The signed difference is used to compensate for a changing stiffness of
the gun.
If this action is necessary, the BOS shows a yellow advisory symbol to
the left of the button.

BOS user interface
8.8 Setup: Servo gun: Motor


control.
3 2 1
Fig.23: "Setup", "Servo gun", "Motor"
"Main stroke" parameter group

• Configuration data of the main stroke motor.
" The data can be found in the motor documentation.
"Gun equalization" parameter group

• Currently without a function.
BOS user interface
8.9 Setup: Servo gun: General


control.
3 2 1
Fig.24: "Setup", "Servo gun", "General"
BOS user interface

" The data can be found in the motor/drive control documentation.

BOS user interface
8.10 Setup: Servo gun: Temperature


control.
3 2 1
Fig.25: "Setup", "Servo gun", "Temperature"
BOS user interface
"Sensor configuration" parameter

Available temperature sensors of the motor
"Motor warning temperature" parameter
Defines the motor temperature from which the warning "motor
overtemperature prewarning" is to be generated.
"Motor shutdown temperature" parameter
Defines the temperature from which the servo gun should be shut down.
Once the specified temperature is reached, the servo gun error "Servo
drive error main stroke" with "Motor overtemp. trip" appears in the BOS
error log and the output "Failure motor temperature" is set.

BOS user interface
8.11 Setup: Servo gun: Synchron


control.
3 2 1
Fig.26: "Setup", "Servo gun", "Synchron"
BOS user interface


BOS user interface
Notes:
Important function schedules
9 Important function schedules

This chapter contains information on the schedules of important func
tions which are controlled from the robot via digital interface. Auto mode
is therefore always required in these cases.
Schedules which are required as part of the servo gun commission
ing are outlined in section 7 from page 47.
CAUTION
Risk of crushing!
actuator.
9.1 Weld schedule

Conditions:
• "Auto" mode is active.
• Correct weld program has been selected.
Schedule:
1. Set "enable positioning" on the input.
2. Set "Start".
• The gun is first moved with position regulation until it reaches the
searcharea (parameter "Main stroke"; see page 55). Then it
searches the sheet with controlled speed.
• Once the sheet is reached, the timer checks
• that no tip is missing (when the "Geometry test" function is
active)
• that the current sheet thickness lies within the permitted limits
(when the "Sheet thickness monitoring" function is active).
• The programmed electrode force is built up.
• If none of the activated monitoring systems reacts, the selected
welding program is executed taking into account any programmed
force profile.
The electrode force is only monitored at the end of the weld schedule!
Information on the schedule of a weld program and the necessary
signal sequences are provided in the documentation of your timer.
• The gun opens.
For detailed information on the opening of the gun, refer to
section 9.6 from page 93.
9.2 Teaching the joining level

Purpose:
Automatic determination of the sheet thickness and taking over the data
into thecurrently selected weld program.
The procedure changes the "Sheet thickness" parameter (refer to
section 54).
If teach velocity is not desired, the sheet thickness can also be
entered manually via the BOS.
Conditions:
• The corresponding weld program has been selected.
• Workpiece is in a suitable position between the open electrodes.
Schedule:
1. Set "enable positioning".
We recommend "soft" switching the robot kinematics for the next two
steps (poss. in conjunction with a gun equalization function on the
robot side). This prevents irreversible bending of the sheet in the
welding position.
2. Set "start teaching".
The gun's speed is regulated and it is closed with limited torque
("Teach velocity" and "Max. force at sheet search" parameters; refer
to page 72).
When the configured torque limit value has been reached, the system
determines the sheet thickness, reports "teached position valid" and
stores the value in the timer under the program-specific parameter
"Sheet thickness".
"Max. force at sheet search" should be higher by at least a factor of
1.4 than the force required to overcome the staticfriction (current
friction coefficient value).
3. Set "teached position captured" to acknowledge the teaching of the
joining level in the timer.
The gun then opens again to the current set opening width.
4. Revoke "enable positioning".
9.3 Electrode change

The timer requests an electrode change by setting the output "End of
Stepper" or by resetting the output "Tip wear rate OK".
Conditions:
• Gun is in the maintenance position.
Schedule:
1. Set input "close brakes".
2. Place new tips on the shafts and fix in place loosely.
3. Reset the input "Close brakes".
The drive must now be in regulation (display on diagnosis module
IndraDrive Cs: AF).
5. Execute the tip setting stroke (see page 93).
Depending on the timer type, it may be necessary before
"Acknowledge, electrodes have been changed" to inform the timer
explicitly of the gun number (stepper) of the changed tips. See
type-specific instructions.
6. Set timer input signal "Acknowledge, electrodes have been
changed".
7. Set input "Request reset position (before dressing)". The timer deter
mines the current tip - tip position and compares this value with the
parameter "Tip-tip programmed position" if the geometry test is active
(see page 77).
It then reports that the process is complete via "Position reset com
pleted".
8. Reset input "Request reset position (before dressing)".
9.4 Tip dressing

The timer requests trip dressing via "Tip dress request".
Conditions:
• Optional:
A weld program is defined as a tip dressing program (see parameter
"Milling Program" page 54) and assigned to the relevant electrode.
• Optional:
The tip dress control (see page 76) is activated for the relevant elec
trode and parametrized correctly.
Schedule:
1. Select the matching tip dressing program for the electrode/gun and
move the gun correctly into the relevant initialized tip dressing station.
3. Start the tip dressing program.
Once the programmed times have elapsed, the gun is opened. The
timer then outputs the "Weld Complete" signal.
Depending on the timer type, it may be necessary before "Tips have
been dressed" to inform the timer explicitly of the number of the tip
dressed gun (stepper). See type-specific instructions.
4. Set timer input signal "Tips have been dressed".
The timer reacts with "Acknowledge tip dress detected".
5. Move the gun out of the tip dressing station and establish the suitable
system status. The gun must be able to close to the tip - tip position
without obstructions.
6. If the timer sets the output signal "Acknowledge tip dress detected",
set input "Request reset position (before dressing)". The timer deter
mines the total tip dress length since the last tip change and reports
completion via "Position reset complete".
7. Reset input "Request reset position (after dressing)".
9.5 Tip setting stroke execution

Conditions:
• A suitable system status has been established. The gun must be able
to close to the tip - tip position without obstructions.
Schedule:
2. Start the "Tip setting stroke" function with positive edge on the timer
input "Start tip setting stroke".
This triggers the closing of the gun with subsequent re-opening to the
current active opening position (see page 54).
9.6 Open gun

Conditions:
• A suitable system status has been established. The gun must have
sufficient space for the opening process.
• Input "enable positioning" is set.
In the following cases, the gun opens:

• after a positive edge on the input "open gun",
• during the Off Time (only relevant in timer repeat mode),
• at the end of each weld schedule (after the HLD) and
• after "Fault reset".
During the opening process, the main stroke is opened to the opening
width parametrized via BOS or specified by the robot via I/O. For more
information, see the parameter "Opening position" on page 54.
If the weld schedule has been aborted by the stop circuit of the weld
timer (e.g. during Emergency Stop), the gun can be opened after the
system is restarted via the input signal "Open gun".
9.7 Specify opening width (external robot axis)

Conditions:
Schedule:
1. Reset the input "enable positioning".
2. Specify the desired opening width binary-coded via the input signals
"Programmed stroke position x".
3. Set the input "Programmed stroke position valid".
The input signals "Programmed stroke position x" are now always
used as the data source. The gun actuator follows the position speci
fied on the data source.
4. To exit the current mode, reset the input "Programmed stroke posi
tion valid".
9.8 Referencing the gun

Purpose:
To determine the fixed reference point for the measuring system of the
gun pressure actuator. The system can only "convert" the measuring
system signals to an absolute position after this has taken place.
If no absolute encoders are used, referencing is always required after
switch-on or after a gun change.
The output signal "gun referenced" shows whether or not referencing
is required.
Conditions:
• A suitable system status has been established. The gun must have
sufficient space for the referencing process.
Schedule:
2. Set input "Request referencing".
The gun pressure actuator is now opened to its mechanical end stop
with regulated torque (see parameter "Max. force at referencing",
page 73) and limited velocity (see parameter "Contact velocity",
page 73), then closed (tip-tip) and brought to the current opening po
sition (see page 54).
3. The timer sets the output signal "Gun is referenced".
9.9 Change gun

Conditions:
• The gun is in a suitable position for changing.
• New status of the gun and electrode shafts.
Schedule:
1. Set input signal "Change gun (disable servo gun control)". The
actuators are deenergized, the encoder and temperature monitoring
is switched off.
The drive is in "parked " state (display on diagnosis module
IndraDrive Cs: PA).
2. The timer sets the output signal "Ready for gun change (servo gun
control is disabled)".
3. Change gun.
The gun must then be in mechanically perfect condition with correct
electrical connections.
4. Reset input signal "Change gun (disable servo gun control)".
The gun parameters are now - where activated - checked for validity
based on the gun ID (see parameter "Gun parameter check",
page 70).
If the parameters are valid, the power is connected again (display on
diagnosis module IndraDrive Cs: AF).
Otherwise, the power remains switched off and the system generates
a message stating that the wrong gun has been connected.
5. If the gun data is invalid/incorrect, the correct gun data must be en
tered in the timer first of all via manual parametrization or by reading
out the GDM and then sent to the drive.
• Manual parametrization:
See section 8.5 from page 67
• Reading out GDM:
via BOS: see "GDM -> SST" button, page 70
via HPG: see section "F5 - Read data" 27
• Send to the drive:
see "Activate data" button, page 71.
6. Reference the gun (see section 9.8, page 94).
7. Change electrodes (see section 9.3, page 91).
8. Execute the tip setting stroke (see page 93).
9. Adapt the parameter "Tip-tip programmed position" (= calibrate gun.
See page 77).
10.Reference the gun (see section 9.8, page 94).
11.Only for guns where force calibration has not yet been carried out:
Notes:
Diagnosis and fault messages
10 Diagnosis and fault messages
10.1 Timer messages

The timer reports specific servo gun errors in the form
"181−<subcode>".
Servo gun errors often do not occur in isolation, but in conjunction

with other messages.
In the event of a fault, therefore always take into account all
messages to get a better idea of the problem.
The diagnosis display on the front of the timer only shows the most
recent fault codes.
It is therefore best to consult the BOS or via VCP05 to view additional
active messages.
1. If not yet visible, bring the "Error Table" window to the foreground in
BOS6000.
The table contains a line for the relevant timer with the message
"Servo gun error" (2) and another message (1) where applicable.
2. Double-click (left mouse key) on the relevant line. The "Detailed Infor
mation - Fault Message" window opens.
1
2
Fig.27: Fault messages (example)
3. Ensure that the "Detailed Information - Fault message" window has

the focus and press the F1 button.
The system opens the Online Help. It contains a list of many
messages and their causes, complete with remedies.
Diagnosis and fault messages
You can also consult the fault log for further information on the active
fault:
Fig.28: Logging (example)
10.2 Drive control messages

Messages on the basic status of the drive control can be found
• via diagnosis display on the front of the drive control
• in BOS under "Diagnostics", "Servo gun" (see section 8.4 page 63).
Detailed information on this type of message can be found in the
document "Rexroth IndraDrive - Mpx-16 to Mpx-18 - diagnostics"
(see Tab 1: page 5).
The document is available as a pdf in the installation folder of the
BOS 6000 under "../Bosch Rexroth AG/BOS6000/help/
<language-specific folder>".
List of tables
11 List of tables
Table1: Necessary and supplementary documents . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table2: Example for the structure of a safety instruction . . . . . . . . . . . . . . . . . . . . . 6
Table3: Danger classes according to ANSI Z535.6 . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table4: Examples for classification of safety instructions . . . . . . . . . . . . . . . . . . . . . 7
Table5: Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table6: Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table7: Abbreviations and definitions of terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Notes:
List of figures
12 List of figures
Fig.1: Command communication connection X7S . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fig.2: Gun data module GDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fig.3: Connection of maintenance PC on GDM for test . . . . . . . . . . . . . . . . . . . . . 23
Fig.4: IndraControl VCP05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fig.5: Start menu of VCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fig.6: Servo gun menu of VCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fig.7: Possible interface options of the PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fig.8: Required IP addresses of the individual components . . . . . . . . . . . . . . . . . 43
Fig.9: Use of a dedicated switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fig.10: "Setup", "Servo gun", "General Gun" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Fig.11: ”Programming” field, "Servo gun" tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fig.12: Sequence of motions when closing the gun . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fig.13: "Programming” field, "Counter" tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fig.14: "Set Counter" window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fig.15: "Diagnostics field", "Start Simulation" tab . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Fig.16: "Diagnosis" field, "Servo gun" tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fig.17: "Tip Position - Info Box" window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fig.18: "Setup", "Servo gun", "General Gun" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fig.19: Design principle X gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fig.20: "Setup", "Servo gun", "Movement" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Fig.21: "Setup", "Servo gun", "Electrode maintenance" . . . . . . . . . . . . . . . . . . . . . . 75
Fig.22: "Tip Position - Info Box" window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Fig.23: "Setup", "Servo gun", "Motor" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Fig.24: "Setup", "Servo gun", "General" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Fig.25: "Setup", "Servo gun", "Temperature" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Fig.26: "Setup", "Servo gun", "Synchron" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Fig.27: Fault messages (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Fig.28: Logging (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Notes:
Abbreviations
13 Abbreviations
Table7: Abbreviations and definitions of terms
Abbreviation Meaning
%I General abbreviation for heat.
May be specified in %I (scale values) or
kA Scale values (%I)
With thyristor power units:
Measure for the electrical phase value.
For MF inverters: Measure for the pulse width.
AC Alternate current. Alternating current.
AE End of schedule. See FK.
BOS Welding user interface
BQR User interface for U/I controller
CAN Controller Area Network; data bus
CAT-5 Twisted pair cable type. CAT: Category.
Standard cable for local networks. Cat-5 cables are
designed for operating frequencies up to 100 MHz.
Cyc Cycles. Refer to P.
daN Deka-Newton. 1 daN = 10 N
DC Direct current.
dimmed The relevant object or its text is shown in gray. In this
state, the relevant function is inhibited, or cannot be
activated for reasons relating to the system.
EGB Electrostatically sensitive devices.
ELMO Electromotive.
EMC Electromagnetic compatibility
EP Single spot mode.
For automatic and manual systems
ESD Electro static discharge.
Abbreviation for all names that are related to electrostatic
discharge. e.g. ESD protection, ESD hazards.
ESZ Downslope time.
Time in which the %I decreases until the end of the
MainWLD.
FK Weld complete contact.
This signal is output when the weld schedule has been
completed.
FPGA Field programmable gate array.
FPO Freely programmable output.
Not available for all timers.
FQF Force quality factor.
Value for assessment of the welding quality derived from
the gradient of the counterforce to the electrodes during a
weld.
FW Firmware
Abbreviations
Gun equal. Gun equalization.
Function, which can compensate for unbalanced
electrode forces on the workpiece caused e.g. by the
weight of the gun or imprecise weld point position.
This can prevent unwanted deformation of the workpiece.
HLD Hold time.
Time after the last weld time in which the parts to be
welded can cool down.
HPG Hand-held programming device
HSA Main switch trip.
HW Hardware
Ignition. Ignition.
Firing pulses for triggering the power unit are switched on
and off.
IMP Number of impulses.
Number of impulses which make up MainWLD.
IP Internet protocol.
kA Kilo ampere (amperage)
kN Kilo-Newton (force)
KSR Constant-current regulation.
Keeps the current in the welding circuit constant.
KUR Constant-voltage regulation.
Compensates line voltage fluctuations.
LT Power unit (thyristor or inverter).
MC Monitoring contact.
e.g. for monitoring the pressure cylinder that closes
the electrodes ormonitoring of the electrode position,
e.g. "Close gun").
MF Medium frequency.
ms Milliseconds.
MV Magnet valve.
Drives the cylinders for closing the electrodes.
n. O.k. Not O.k.
NBS Mains load limitation control.
Monitors and influences the mains load.
NWI Post-warming pulse.
NWZ Post-heating time.
Also referred to as PstWLD.
O.k. O.k.
OFF Off time.
Time between two spot welds in which the magnet valve
is not driven. Relevant for "Repeat" mode only.
Option Round object on the user interface for switching
button a function on/off.
P Cycles (mains cycles, cycles).
At 50 Hz mains frequency: 1 P -> 20 ms.
At 60 Hz mains frequency: 1.P -> 16.6
PE Protective earth. Protective conductor.
Abbreviations
Per see P.
PG Programming terminal/welding computer.
PHA Heat value.
PLC Programmable logic controller.
PreWld Pre-weld.
Also known as PreWLD.
PSF Process stability.
Value for conformity between current resistance
characteristic and the resistance characteristic of
the reference curve.
PSG Transformer-rectifier unit for PSI types.
Medium-frequency welding transformer 1000 Hz
PSI Programmable weld timer with inverter.
PST Programmable weld timer with thyristor power unit.
PSZ Cool time.
Time between current impulses/blocks (1., 2., 3. CT).
RA Relay output.
Radio button Refer to "Option button".
REPEAT Repeat mode.
Mode for manually operated systems.
RJ Registered rack (standardized connector).
Connectors for telecommunication cables standardized by
the FCC (Federal Communications Commission).
RxD Receive Data (RxD) and Transmit Data (TxD) are
interface lines for receive and transmit data. The
receive and transmit data is sent between Data
Communication Equipment (DCE) and Data Transmission
Equipment (DTE) via these interface lines.
Slope Current slope.
Current increases/decreases from an initial to a final %I.
SQZ Squeeze time.
Time that runs before the weld time. The electrodes
squeeze the partsto be welded together.
STC Sheet thickness combination.
Function, which can be used to create sheet-thickness
specific reference curves instead of program-specific
reference curves.
Stepper %I stepping in order to compensate for electrode wear.
SW Software
TCP Toolcenterpoint.
Contact surface position of the electrodes of the
fixed arm gun in relation to the tool coordinate system.
The TCP moves due to the tip dressing of the electrodes.
This movement can be compensated for by adapting the
positioning of the robot.
Teach Process in which a desired position is determined and
saved for future use.
Temp. Temperature.
Abbreviations
Tool tip Explanatory text.
Appears when the mouse pointer remains on an input
field/object for amoment.
TxD Refer to RxD.
UIP Process quality.
Value for the welding quality derived from the resistance
characteristicof the current weld.
UIR UI regulation
UST Upslope time.
Time in which the %I increases from the beginning of
MainWLD on.
WIC Weld interface controller.
Module for bidirectional real-time communication between
the timer and drive control (command communication)
Wld Weld time.
We differentiate between PreWld (pre-weld time),
MainWld (main weld time) and PstWld (post-weld time).
All three weld times can be programmed with different
times and %I.
Impulses and slopes can only be programmed in the
MainWld.
WT Weld timer.
Also referred to as timer or module resistance weld timer.
ZD Gun pressure.
Force which generates the main stroke between the tips.
Index
14 Index
"A Force monitoring , 55
Abbreviations, 103 "Force monitoring" parameter group, 74
"Act. Val. --> Prog. value" button (Geometry test), 78 "Force sensor" parameter, 74
"Activate data" button, 71, 74, 80 Friction coefficient, 80
"Active gun ID" field, 68 Fx is blue/underlined?, 27
"Active gun model" field, 68
"Actual diagnostics code" field, 63 G
Actual force, 64 GDM, 22
"Actual Value" button, 79 GDM -> SST, 58
AE, 103 "GDM -> SST" button, 70
Geometry calibration, 52
B "Geometry test" parameter, 77
blue/underlined F keys?, 27 "Geometry test" parameter group, 77
BOS, 8 Gun data module GDM, 22
BOS user interface, 53 Gun equal., 103
Buttons (Fx) blue/underlined?, 27 "Gun equalization share in dressing length"
parameter, 76
C "Gun equalization" parameter, 69
Calibrate gun, 77 "Gun ID" parameter, 68
Calibrating the gun, 77 "Gun parameter check" parameter, 70
Check gun force, 30 Gun pressure actuator, 15
"Check gun ID" parameter, 68 Guntype (C/X), 69
Command, 60 "Gun type" parameter, 68, 69
Command communication (WIC), 106
Command communication interface (X7S), 21 H
"Commanded position" field, 64 HPG, 103
Commissioning, 47
I
Configuration data, Gun pressure actuator (moving I/O signals, 19
arm gun), 87 "Identification" parameter group, 68
"Contact velocity" parameter, 73
IndraControl VCP05, 24
Counter, 56
IndraDrive Cs, 37
IndraDrive Cs messages, 39
D
IndraDrive Cs status messages, 39
Damage to products, 11
Damage to property, 11 "Internal opening range" parameter, 70
"Data ---> WT" button, 71, 74, 80 J
Designations, 8 Joining level, 54, 90
Diagnostics code, 63 "Joining level" parameter group, 54
Diagnostics: Servo gun, 63
Diagnostics: Start Simulation, 59 L
Dress length, 65 "Last dress material removal" display group, 65
Drive status, 63 "Length of electrode arm" parameter, 69
"Drive status" field, 63 "Lower tolerance dressing length" parameter, 76
"Lubrication interval" parameter, 78
E "Lubrication stroke" parameter group, 78
EGB, 103
Electrode change, 91 M
EMC, 103 "Main stroke length" parameter, 69
ESD, 103 "Main stroke" field ("Actual" display group), 65, 66,
External robot axis, 94 80
"Main stroke" field ("New Electrode" display group),
F 65
Firmware changes, 20 "Main stroke" parameter, 55
Force, 64 "Max. closing velocity" parameter, 72
"Force" field, 64 "Max. force at referencing" parameter, 73
Force calibration, 32 "Max. force at sheet search" parameter, 73
"Force in manual mode" parameter, 73 "Max. force in weld schedule" parameter, 73
Index
"Max. main stroke length" parameter, 70 Setup: Servo gun: General Gun, 67
"Max. tolerance model" field, 64 Setup: Servo gun: Motor, 81
"Max. wear of electrodes" parameter, 76 Setup: Servo gun: Movement, 72
"Mechanical basic load" field , 66 Setup: Servo gun: Synchron, 86
"Mechanical test" parameter group, 78 Setup: Servo gun: Temperature, 84
"Mechanical" parameter group, 69 Sheet thickness, 55
Milling program, 54 Sheet thickness monitoring, 55
"Milling Program" parameter, 54 "Sheet thickness" parameter, 54
"Monitoring" parameter "Sheet thickness" parameter group, 55
(force), 55 SST -> GDM, 58
(sheet thickness), 55 "SST -> GDM" button, 70
Motor current, 64 Status information, 63
"Motor current" field, 64 Symbols, 8
"Motor serial no. (main stroke)" parameter, 68
"Motor shutdown temperature" parameter, 85 T
Motor temperature, 64 TCP, 105
Movement velocity, 64 "TCP setpoint tracing" parameter, 74
"Motor temperature" field, 64 "TCP-adjustment" parameter group, 74
"Motor warning temperature" parameter, 85 Teach, 105
"Teach velocity" parameter, 73
O Teaching the joining level, 90
Open gun, 93 "Tip dress control" parameter, 76
"Opening position" parameter, 54 "Tip dress control" parameter group, 76
Operating mode, 59, 60 Tip dressing, 92
operation mode settings, 59 Tip Position - Info Box, (window), 65, 79
Tip positions, (button), 65
P Tip setting stroke execution, 93
Parameter group "Force", 55 "Tip-tip programmed position" parameter, 77
PG, 8, 104 Tip wear, 65, 79
PLC, 8, 105 "Tip wear" field , 65
Programming: Counter, 56 Tolerance model, 64
Programming: Servo gun, 53 "Tolerance" parameter, 78
"Position" field, 64
"Positioning velocity" parameter, 53 U
"Programmed value dressing length", 76 "Upper tolerance dressing length" parameter, 76
PSG, 8 "Upper/Lower tolerance" parameter
PSI, 8 Force, 56
Sheet thickness, 55
R
Reference friction coefficient, 66 V
"Reference opening range" parameter, 70 VCP05, 24
Referencing, 94 Velocity, 64
"Velocity" field, 64
S
W
Scope of delivery, 13
"Weld counter" field ("Lubrication interval" display
"Screw pitch main stroke" parameter, 69
group), 66
"Search area" parameter group, 55
Weld schedule, 89
"Sensor configuration" parameter, 85
WIC, 21, 106
"Servo gun style" parameter, 68
WT, 8, 106
"Set Gun-Type" button, 69
Set IP configuration, 38 X
Set the communication protocol, 37 X7S, 21
Set the drive slave address, 37
Setup: Servo gun: Electrode maintenance, 75 Z
Setup: Servo gun: General, 82 ZD, 106
Notes:
The Drive & Control Company
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Tel. +49 9352 18 0
Fax +49 9352 18 8400
www.boschrexroth.com/electrics
DOK-PS6000-SERVOZANG**-AP05-EN-P

05 Servo Gun Control-En

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05 Servo Gun Control-En

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The Drive & Control Company

Rexroth PSI 6xCx

Servo gun control

Description of application Edition 05

The data shown below is intended to describe the

E This manual is the exclusive property of Bosch

An example configuration is shown on the cover

Language version of the document: EN

6 Assembly and connection . . . . . . . . . . . . . . . . . . . . 41

7 Commissioning the servo gun control . . . . . . . . . . 47

8 BOS user interface . . . . . . . . . . . . . . . . . . . . . . . . . 53

8.2 Programming: Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

9 Important function schedules . . . . . . . . . . . . . . . . . 89

10 Diagnosis and fault messages . . . . . . . . . . . . . . . . 97

12 List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Regarding this documentation

1 Regarding this documentation

1.1 Validity of the documentation

1.2 Additional documents

Table1: Necessary and supplementary documents

Regarding this documentation

1.3 Presentation of information

1.3.1 Safety instructions

Warning + SIGNAL WORD

Regarding this documentation

Integrated safety instructions may be embedded in the format of the

Table3: Danger classes according to ANSI Z535.6

Signal word Meaning

Table4: Examples for classification of safety instructions

Regarding this documentation

Table5: Symbols used

General information on damage to property

3 General information on damage to property

General information on damage to property

General information on the "servo gun control"

5 General information on the "servo gun control"

How does it work?

General information on the "servo gun control"

General information on the "servo gun control"

Monitoring functions • "Tip dress control" function

General information on the "servo gun control"

• "Friction coefficient compensation" function:

General information on the "servo gun control"

During the movement, the force defined in the electrode-specific

General information on the "servo gun control"

5.3 Firmware changes

General information on the "servo gun control"

5.4 Special participating hardware components

5.4.1 Command communication interface WIC (X7S)

Fig.1: Command communication connection X7S

NS LED for communication status (network status):

Information on any active faults can be found

General information on the "servo gun control"

5.4.2 Gun data module GDM

Fig.2: Gun data module GDM

PWR LED showing the supply voltage and FPGA status:

General information on the "servo gun control"

Further information on the GDM is available in the product documen­

5.4.2.1 Check the contents of the GDM

Fig.3: Connection of maintenance PC on GDM for test

GDM firmware, gun, transformer and customer-specific data can then

General information on the "servo gun control"

5.4.3 IndraControl VCP05

Further information on the GDM is available in the product documen

Further information on the VCP05 is available in the product docu