R911407604 01 PRC7X00.0900 en

Rexroth PRC 7x00-Lx/Wx-0900
Process Resistance Welding Control
Type-Speciﬁc Instructions Edition 01

R911407604
R911407604 | PRC 7x00-Lx/Wx-0900 Bosch Rexroth AG 1/24
Contents
1 Regarding this Documentation .......................................................... 3

1.1 Validity of the documentation .................................................. 3
1.2 Required and supplementary documentation .......................... 3
1.3 Display of information .............................................................. 4
1.3.1 Safety instructions ................................................... 4
1.3.2 Symbols ................................................................... 4
1.3.3 Designations ............................................................ 4
1.3.4 Abbreviations ........................................................... 5
2 Safety instructions ............................................................................ 5
3 General notes on damages to property and products ........................ 5
4 Scope of delivery .............................................................................. 5
5 Connection Diagram ......................................................................... 6
6 Input/output array ............................................................................. 8
6.1 Serial input/output field (Ethernet/IP)....................................... 8
6.2 Discrete 24 V inputs / outputs ............................................... 12
6.2.1 Discrete Inputs ...................................................... 12
6.2.2 Discrete Outputs .................................................... 13
6.3 Analog inputs / outputs .......................................................... 13
6.4 Other inputs/outputs: ............................................................. 14
7 Features ......................................................................................... 15
7.1 Special features..................................................................... 15
7.1.1 Tip Dress Management- Motor Control ................. 15
7.1.2 Forge Force Monitoring On ................................... 17
7.1.3 Isolation Contactor Control .................................... 17
7.1.4 Serial Input 3 “Global Adaptive Off“ ....................... 17
7.1.5 Serial Output 3 “Global Adaptive Enabled” ............ 17
7.1.6 Serial Inputs 64 through 143 “ASCII_0” through
“ASCII_9“ ............................................................... 18
7.1.7 Digital Pressure Feedback .................................... 18
8. Status codes ................................................................................... 18
9. Timing Diagram............................................................................... 19
9.1 Welding Sequence ................................................................ 19
9.2 Tip Dress Motor Control Management .................................. 22
9.3 Forge Force Monitoring ......................................................... 23
10. Annex ……………………………………………………………………..23
2/24 Bosch Rexroth AG R911407604 | PRC 7x00-Lx/Wx-0900
The data specified above serves to describe the

product. If information is also provided regarding
the use, it only constitutes application examples
and suggestions. Catalogue specifications are no
warranted properties. The information given does
not release the user from the obligation of own
judgement and verification. Our products are
subject to a natural process of wear and aging.
 This document, as well as the data,

specifications, and other information set forth in it,
are the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties
without its consent.
The title pages shows an exemplary configuration.

The supplied product may therefore vary from the
illustration.
The original instructions have been prepared in

English.
1 Regarding this Documentation
1.1 Validity of the documentation
This documentation applies to Rexroth PRC 7000 Process Resistance Welding Control.
The content belong to
• Connection (power supply)
• Functionality
of the Rexroth PRC7000 Process Resistance Welding Control.
This documentation is designed for technicians and engineers with special welding training and skills.
They must have knowledge of the software and hardware components of the weld timer , the power
supply used, and the welding transformer.
This documentation and the Rexroth PRC7000 Instructions contains important information on the safe
and appropriate assembly, transportation, commissioning, maintenance and simple trouble shooting of
Rexroth PRC7000 Process Resistance Welding Control.
 Read this documentation completely and particular the chapter "safety instructions" in the Rexroth
PRC7000 Process Resistance Welding Control Instructions and Rexroth Weld Timer Safety and
user information before working with the product.
1.2 Required and supplementary documentation

 Only commission the product if the documentation marked with the book symbol
is available to you and you have understood and observed it.
 The documentation is available in the mediadirectory with the link:

https://www.boschrexroth.com/various/utilities/mediadirectory/
You can find the documentation, if you insert in Search the Document number or search PRC7000
for example.
Table 1: Required and supplementary documentation
Title Document number Type of document
Rexroth PRC7000 Process R911172834 Instructions

Resistance Welding Control
Rexroth Weld Timer Safety and user R911339734 Safety and user
information information
Rexroth PRC7000 MGDM R911381901 Instructions
Rexroth PS6000 Wx / PRC7000 R911370699 Description of

Weld Timer and Welding Transformer application
with water cooling
Rexroth PSGxxxx MF-Welding 1070 087062 Instructions

Transformers
Rexroth PRI 7000 Online Help Reference

1.3 Display of information

In order to enable you to work with your product in a fast and safe way, uniform Safety instructions, symbols,
terms and abbreviations are used. For a better understanding they are explained in the following sections.
1.3.1 Safety instructions

For safety instructions refer to Table 1: Required and supplementary documentation Rexroth PRC7000
Process Resistance Welding Control Instructions and Rexroth Weld Timer Safety and user information.
1.3.2 Symbols
The following symbols mark notes that are not safety-relevant but increase the understanding
of the documentation.
Table 2: Meaning of the Symbols
Symbol Meaning
If this information is disregarded, the product cannot be
used and or operated to the optimum extent.
 Single, independent step

1. Numbered step:
2. The numbers specify that the Steps are completed one
3. after the other.
1.3.3 Designations
This documentation uses the following designations:
Table 3: Designation
Designation Meaning
ELMO Electromotive
FQF Force Quality Factor, Value for the welding quality, derived from the
characteristic of the counterforce to the tips during a weld.
IoT (Internet of Things) is a collective term for technologies of an

infrastructure that enables physical and virtual objects to work
together.
GDM Gun Data Module
IO Inputs, output, Process interface
KSR Constant current regulation
MOV Metal oxide varistor
PHA Phase angle
PRC 7000 Process Resistance Welding Control
PRI 7000 Process Resistance Welding Interface
PSG xxxx Medium-Frequency Welding Transformer 1000Hz
PSF Prozess stability
RPM Rotation speed

Q-stop Using the "Q Stop" function, the weld timer can detect any problems
occurring in the PSF, UIP or FQF parameters, which can be
signalled to the operator and/or the PLC. With the help of a program-
specific, configurable supervision, it must first be defined which PSF,
UIP and/or FQF values are to be detected as basically problematic
by the weld timer. The weld timer generally accounts for actual
values within the "conditional tolerance range" of the corresponding
monitored value only. In addition, you have to define the threshold for
the weld timer that has to be exceeded in order to actually signal the
problems occurred as an error. One differentiates between: •
program-specific Q Stop • component-specific Q Stop
STC TEACH Sheet Thickness Combination, teaching
UIP Process quality.
Value for the welding quality, derived from the resistance
characteristic of the current weld.

UIR UI control
WC Weld complete
WIC Weld Interface Controller (internal realtime bus)
WPS Resistance spot welding (process)
1.3.4 Abbreviations
For information on the abbreviations used in this documentation, refer to Table 1: Required and
supplementary documentation Rexroth PRC7000 Process Resistance Welding Control Instructions.
2 Safety instructions
For safety instructions, refer to Table 1: Required and supplementary documentation Rexroth
PRC7000 Process Resistance Welding Control Instructions and Rexroth Weld Timer Safety and user
information.
3 General notes on damages to property and products

For general notes on damages to property and products, refer to Table 1: Required and supplementary
documentation Rexroth PRC7000 Process Resistance Welding Control Instructions and Rexroth Weld
Timer Safety and user information.
4 Scope of delivery
For scope of delivery, refer to Table 1: Required and supplementary documentation Rexroth PRC7000
Process Resistance Welding Control Instructions.
5 Connection Diagram
Welding-Transformer
Mains
L3
L2
L1
V
U
(refer to Fig. 2 Mains
(refer to Fig.2 Mains
connection) connection)
XFE0
Ethernet
Port 0
XGSD1 SD-
PRI7000
Card and
Process
XFU1
interface
Micro-USB
Port 1
1 XFE1
0V extern 2 Universal
3 inte rfa ce
+24V I/O 4 slot
+24V fan 5 XDS1 Sta ndard
shield 6 Power supply, Any bus
Main switch release +24V 7 CC
stop circuit, ext.
+24V external 8
9 Fan, main
10 switch release
11
12 XFE2
13
Ethernet
14 Note:
on XDS1 is between pin 3 and pin Port 0
Second current sensor ISEK_1 1 10 the connection of a potential-
Second current sensor ISEK_2 2 free contact of the stop circuit
Second current sensor shield 3 prepared (refer to Rexroth
TEMP_1 +24V (digital) 4 PRC7000 Process Resistance
TEMP_2 +24V (digital) 5 XGM1 Welding Control instructions,
Transformer temperatur shield 6 XDS1).
Transformer XFS1
Secondary voltage USEK_1 7 The 24V supply for the I/O plugs
Secondary voltage USEK_2 8 Interface WIC
Secondary voltage shield 9 can be connected with XDS1 pin4 Port 1
10 and pin 11.
11 The 24V supply for the I/O plugs
12 should always be prepared.
The supply of the I/O plugs for
1 each XGD1/XGD2 and XGD3 will
2 be connected to the pins
3 (+24V_IO) and pin (0V_IO) (refer XFS2
PRESSURE_IN digital 4 XGM2 to Rexroth PRC7000 Process WIC
PRESSURE_IN_1 analog 5 Pressure Resistance Welding Control Port 2
PRESSURE_IN_2 analog 6 Interface instructions, XGD1-3).
7 The pins (+24V_IO) respectively
PRESSURE_IN 0V digital 8 pins (0V_IO) of the connectors
XGD1 and XGD2 are connected 24 V 24 V I/O supply
1 together in the device.
2 E00 Weld contactor closed
The supply shall be provided to E01 Tip Dress - RPM Sensor
3 XGD1 or XGD2 and XGD3.
4 XGD1 E02 Tip Dress - Motor Overload Tripped
Force sensor supply FORCE_24V XGM3 E03
5 Discrete
FORCE_IN_1 analog Force E04
6 inputs
FORCE_IN_2 analog 7 Interface E05
8 E06
Operate/Reset FORCE_RST digit. 9 E07
10 0V 0 V I/O supply
24 V
1 E08
2 E09
3 XGD2 E10
4 Discrete E11
5 E12
inputs E13
6 XGM4
7 Analog E14
8 Interface, E15
9 0V
High Speed
10 24 V 24 V I/O supply 2
11 inputs
A00 Close Weld Contactor
12 A01 Tip Dress Enable Circuit
13 Note: XGD3 A02 Gun 1, Transformer 1
14 A03 Gun 2, Transformer 2
15
Relay and contactors require Discrete
outputs A04 Gun 3, Transformer 3
16 RFI suppression A05 Gun 4, Transformer 4
E.g. free wheeling diode for small A06 Gun 5, Transformer 5
relays and contactors A07 Gun 6, Transformer 6
0V 0 V I/O supply 2
Fig. 1: Basic Weld Timer

PRC 7300 L1 / W1 PRC 7300 L2 / W2
Mains Mains
L1 400VAC - 500VAC -
480VAC 690VAC
L2 min. 35 mm2 min. 35 mm2
L3
U Welding Welding
Transformer Transformer
V min. 35 mm2 min. 35 mm2
PRC 7400 L1 / W1 PRC 7400 L2 / W2
Mains Mains
L1 400VAC - 500VAC -
480VAC 690VAC
L2
95 mm2 95 mm2
L3
U Welding Welding
Transformer Transformer
V 95 mm2 95 mm2
Fig. 2: Mains connection

6 Input/output array
6.1 Serial input/output field (Ethernet/IP)
Table 4: Serial inputs / outputs
No. Wort Byte Bit PRC7000 inputs PRC7000 outputs
0 1 0 0 Start 1 Weld Complete
1 1 0 1 Not used Not used
2 1 0 2 Weld Contactor Enable Not used
3 1 0 3 Global Adaptive Off Global Adaptive Enabled
4 1 0 4 Fault Reset Timer ready
5 1 0 5 Fault Reset with weld complete Weld Fault
6 1 0 6 Fault Reset with Reweld Without Weld Process Monitoring
7 1 0 7 Weld on external Weld on (with welding current)
8 1 1 0 Spot Number Bit 0 Not used
10 1 1 2 Spot Number Bit 2 Pressure inside tolerance area
11 1 1 3 Spot Number Bit 3 UI-regulation active
12 1 1 4 Spot Number Bit 4 UI-monitoring active
13 1 1 5 Spot Number Bit 5 Q-Stop
15 1 1 7 Spot Number Bit 7 Tip Dress Request
16 2 2 0 Spot Number Bit 8 Status Bit 0
32 3 4 0 Operate Force Sensor Pressure Output Bit 00

33 3 4 1 Calibrate gun resistance Pressure Output Bit 01
34 3 4 2 Not used Pressure Output Bit 02
40 3 5 0 End of component Acknowledgement end of component
41 3 5 1 Tip Dress Motor On Dressed Tip
42 3 5 2 Not used Tip Dress OK
43 3 5 3 Not used Tip Dress Sequence Running
44 3 5 4 Not used Programmable Output
45 3 5 5 Forge force achieved 3rd weld time active
46 3 5 6 Not used Pre Warning Tip Change
47 3 5 7 Not used Tip End Of Life
48 4 6 0 Reserved Reserved
60 4 7 4 Acknowledgment Tip Dressed Reserved
61 4 7 5 Acknowledgment Tip Changed Reserved
62 4 7 6 Not used Reserved
63 4 7 7 Not used Reserved
64 5 8 0 ASCII_0, Bit_0 Reserved

10 Bosch Rexroth AG R911407604 | PRC 7x00-Lx/Wx-0900
78 5 9 6 ASCII_1, Bit_6 New Tip & Dress Required
79 5 9 7 ASCII_1, Bit_7 New Tip
80 6 10 0 ASCII_2, Bit_0
81 6 10 1 ASCII_2, Bit_1
82 6 10 2 ASCII_2, Bit_2
83 6 10 3 ASCII_2, Bit_3
84 6 10 4 ASCII_2, Bit_4
85 6 10 5 ASCII_2, Bit_5
86 6 10 6 ASCII_2, Bit_6
87 6 10 7 ASCII_2, Bit_7
88 6 11 0 ASCII_3, Bit_0
89 6 11 1 ASCII_3, Bit_1
90 6 11 2 ASCII_3, Bit_2
91 6 11 3 ASCII_3, Bit_3
92 6 11 4 ASCII_3, Bit_4
93 6 11 5 ASCII_3, Bit_5
94 6 11 6 ASCII_3, Bit_6
95 6 11 7 ASCII_3, Bit_7
96 7 12 0 ASCII_4, Bit_0
97 7 12 1 ASCII_4, Bit_1
98 7 12 2 ASCII_4, Bit_2
99 7 12 3 ASCII_4, Bit_3
100 7 12 4 ASCII_4, Bit_4
101 7 12 5 ASCII_4, Bit_5
102 7 12 6 ASCII_4, Bit_6
103 7 12 7 ASCII_4, Bit_7
104 7 13 0 ASCII_5, Bit_0
105 7 13 1 ASCII_5, Bit_1
106 7 13 2 ASCII_5, Bit_2

107 7 13 3 ASCII_5, Bit_3
108 7 13 4 ASCII_5, Bit_4
109 7 13 5 ASCII_5, Bit_5
110 7 13 6 ASCII_5, Bit_6
111 7 13 7 ASCII_5, Bit_7
112 8 14 0 ASCII_6, Bit_0
113 8 14 1 ASCII_6, Bit_1
114 8 14 2 ASCII_6, Bit_2
115 8 14 3 ASCII_6, Bit_3
116 8 14 4 ASCII_6, Bit_4
117 8 14 5 ASCII_6, Bit_5
118 8 14 6 ASCII_6, Bit_6
119 8 14 7 ASCII_6, Bit_7
120 8 15 0 ASCII_7, Bit_0
121 8 15 1 ASCII_7, Bit_1
122 8 15 2 ASCII_7, Bit_2
123 8 15 3 ASCII_7, Bit_3
124 8 15 4 ASCII_7, Bit_4
125 8 15 5 ASCII_7, Bit_5
126 8 15 6 ASCII_7, Bit_6
127 8 15 7 ASCII_7, Bit_7
128 9 16 0 ASCII_8, Bit_0
129 9 16 1 ASCII_8, Bit_1
130 9 16 2 ASCII_8, Bit_2
131 9 16 3 ASCII_8, Bit_3
132 9 16 4 ASCII_8, Bit_4
133 9 16 5 ASCII_8, Bit_5
134 9 16 6 ASCII_8, Bit_6
135 9 16 7 ASCII_8, Bit_7
136 9 17 0 ASCII_9, Bit_0
137 9 17 1 ASCII_9, Bit_1
138 9 17 2 ASCII_9, Bit_2
139 9 17 3 ASCII_9, Bit_3
140 9 17 4 ASCII_9, Bit_4
141 9 17 5 ASCII_9, Bit_5
142 9 17 6 ASCII_9, Bit_6
143 9 17 7 ASCII_9, Bit_7

6.2 Discrete 24 V inputs / outputs
6.2.1 Discrete Inputs

Feedback Transformer 1 to 6
At the end of the scheduled squeeze time the six related I/O pairs “Transformer_X” and Feedback Transformer_X”
are checked. If the input and output have the same state the timer continues with weld time. If not the timer
extends (max. 1 second) squeeze time until the input and output corresponds. In case of not reaching this state
the sequence will be interrupted with an error message. The signal states are monitored until the initiation of Post-
Weld-Time. If the associated inputs and outputs do not the same state the sequence will be interrupted with an
error message. The error message “Transformer Faulted” will be displayed and requires a manual reset.
Table 5: Discrete inputs

Connection Nr Byte Bit Inputs
XGD1 0 0 0 Weld Contactor Closed
XGD1 1 0 1 Tip Dress – RPM Sensor
XGD1 2 0 2 Tip Dress – Motor Overload Tripped
XGD1 3 0 3 Feedback Transformer 1
XGD2 9 1 1 Tip Dress - Motor Current Tripped
XGD2 10 1 2 Not used

6.2.2 Discrete Outputs
Gun X, Transformer 1 to 6
A specific output will be turned on when a start sequence is initiated either by an fieldbus input or by software
command. The output will remain on until the next start sequence is received to select a new weld sequence.
The output is determined by the gun number assigned to the selected weld schedule. Gun range is assigned to
specific transformer outputs as follows in Table 6:
Table 6: Discrete Outputs

Gun Range Outputs
Gun 1 to Gun 20 Transformer 1
Table 7: Discrete Outputs

Connection No. Byte Bit Outputs
XGD3 0 0 0 Close Weld Contactor
XGD3 1 0 1 Tip Dress Enable Circuit
XGD3 2 0 2 Gun 1, Transformer 1
6.3 Analog inputs / outputs
Table 8: Analog inputs

Connection / Pin Inputs
XGM4 / 4, 5, 6 Not used
XGM4 / 12, 13,14 Not used
XGM2 / 5, 6 Analog Pressure Inputs
XGM3 / 6, 7, 8 Force Sensor Inputs
Table. 9: Analog outputs
Connection / Pin Outputs
XGM2 / 1, 2 Analog Pressure Outputs
XGM3 / 5, 9, 10 Force Sensor Outputs

6.4 Other inputs/outputs:
Table 10: Other inputs

Plug / Pin Inputs
XDS1 / 7 Main switch release +24V
XGM1 / 1, 2, 3 Secondary current
XGM1 / 4, 5, 6 Transformer temperature
XGM1 / 7, 8, 9 Secondary voltage
XGM2 / 4, 8 Digital Pressure Feedback
Table 11: Other outputs
Plug / Pin Outputs
XDS1 / 13 Shunt release
XDS1 / 14 Undervoltage release

7 Features
Schedule standard 1000 Hz (schedule parameters in milliseconds)
Fieldbus: Ethernet/IP
(Details refer to Table1 Required and supplementary documentation, Rexroth PRC7000 Process Resistance
Welding Control Instructions).
7.1 Special features

The welding controller features the following special features:
7.1.1 Tip Dress Management- Motor Control
For more details on the functions timing, refer to Appendix section 9, charts 1 to 7.
The following Inputs and Outputs are used from the Tip Dress Management:
Discrete input E_01 = “Tip Dress – RPM Sensor”

Discrete input E_02 = “Tip Dress – Motor Overload Tripped”
Discrete input E_09 = “Tip Dress – Motor Current Tripped”
Discrete output A_01 = “Tip Dress – Enable Circuit”
Serial input 41 = “Tip Dress Motor On”
Serial input 60 = “Acknowledgement Tip Dressed”
Serial input 61 = “Acknowledgement Tip Changed”
Serial output 15 = “Tip Dress Request”
Serial output 41 = "Dressed Tip
Serial output 42 = “Tip Dress OK”
Serial output 43 = “Tip Dress Sequence Running”
Serial output 46 = “Pre Warning Tip Change”
Serial output 47 = “Tip End of Life”
Serial output 78 = “New Tip & Dress Required”
Serial output 79 = “New Tip”
NOTE: Discrete input E_01 = “Tip Dress – RPM Sensor” is optional, with the option to enable/disable this feature
in PRI7000 interface under Tip Dresser. By default, this parameter is disabled – “Tip dresser with cycle counter”
is in Off state. When RPM sensor input is disabled, then Current Sensing Module becomes enabled - Discrete
input E_09 = “Tip Dress – Motor Current Tripped”.
Tip Dress RPM Sensor type required: Inductive proximity, 3-wire, PNP, N/O output, 10 to 30VDC operating
voltage range.
The Weld Controller is capable to control and monitor an external Tip Dress Device. Depending on the operation
mode, there are several sequences and possible error codes, which will be described in the following section.
The examples are based on the combination Robot and Weld Controller. Instead of the Robot, a PLC could
provide the communication to the Weld Controller as well.
If the selected active Spot Selection with assigned gun reaches the status “Tip Dress Required”, the Weld
Controller will activate the serial output 15 = Tip Dress Request = ON.
The Robot will then select a mill job task through the Serial Inputs 08 – 31 = “Spot number”. The robot will enable
Tip Dress Motor with Serial Input 41 = Tip Dress Motor On. This tells the Weld Controller to start the Tip Dress
Motor routine.
The Weld Controller will activate the Discrete Output A_03 = “Tip Dress – Enable Circuit” =”1”, which starts the
Tip Dress Motor. At the same time, the Weld Controller will activate the Serial Output 43 = “Tip Dress Sequence
Running” =”1”, which tells the Robot that the Tip Dress Motor has been started.
Depending on Tip Dress configuration (RPM sensor or Current Sensing Module), the Weld Controller will monitor
the Tip Dress Motor with two (2) possible combinations of (2) Inputs:
With RPM sensor enabled: The discrete Input E_01 = “Tip Dress – RPM sensor” will be monitored every second
in a way that if E01 stays in False “0” or True “1” state for 1 second, a fault would occur. The Error message
“Tip Dress Fault-Motor Tripped” will be displayed.
With Current Sense Module (CSM) enabled and (RPM sensor disabled): The discrete Input E_09 = “Tip Dress
- Motor Current Tripped” will be monitored in a way that if E09 registers True “1” state, a fault would occur. The
Error message “Tip Dress Fault-Motor Current Tripped” will be displayed.
In addition, if the discrete Input E_02 = “Tip Dress – Motor Overload Tripped” = “0” during dressing sequence,
a fault would occur. The error message “Tip Dress Fault – Current Overload Detected on the Electric Motor”
will be displayed.
If no faults are present then at the end of tip dressing routine, the Weld Controller will activate the Serial Output
42 = “Tip Dress OK” = 1 which indicates to the Robot that it is ready to open the gun. During this time Discrete
Output A_03 = “Tip Dress – Enable Circuit” is still on = 1.
The Robot will then acknowledge that the gun is open by providing serial input 60 = “Acknowledgement Tip
Dressed” then weld controller can turn off the Discrete Output A_03 = “Tip Dress – Enable Circuit” output = 0”.
If the “Acknowledgement Tip Dressed” signal is not received in parameter defined time window from the start of
tip dressing schedule, then a fault will occur. The error message “Tip dress motor-Time out” will be displayed.
As soon as the Serial Input 60 = “Acknowledgement Tip Dressed” is seen, the Weld Controller will activate the
Serial Output 41 = “Dressed Tip” = “1” to tell the Robot that the Tip Dress Sequence has been completed without
any errors. The Serial Output 41 “Dressed Tip” will be deactivated at the next Weld Schedules start.
When Serial Output 41 = “Dressed Tip” = 1 this will also reset:
• Serial Output 15 = “Tip Dress Request” = off = 0
• Serial Output 42 = “Tip Dress OK” = off = 0
• Serial Output 43 = “Tip Dress Sequence Running” = off = 0
When dressing sequence is complete, robot will then disable Serial Input 41 = “Tip Dress Motor On” to
Off = 0.
In case of an error during the Tip Dress Sequence, the Outputs for the Tip Dress control would change
as follows:
• Serial Output 41 “Dressed Tip“ off = 0

• Serial Output 42 “Tip Dress OK“ off = 0
• Serial Output 15 “Tip Dress Request“ on = 1
• Serial Output 43 “Tip Dress Sequence Running“ on = 1
• Discrete Output A_01 “Tip Dress – Enable Circuit“ off = 0
“Tip Dress Request” is a prewarning output for dressing and is active when wear counter reaches a warning
level (maximum wear count – warning wear count)
“New Tip & Dress Required” output is active (in addition to Tip Dress Request) when tip has been changed
(acknowledged by the robot) and Dress New Electrode parameter is enabled. Under these conditions, dressing
a new tip is required, otherwise, when attempting a weld, the controller will fault out with an error: “Tip Dressing
Necessary”.
“New Tip” output is active when tip has been changed (acknowledged by the robot) and Dress New Electrode
parameter is disabled. Under these conditions, dressing a new tip is not required and will allow to weld without
an error.
“Pre Warning Tip Change” is a prewarning output for tip change and is active when dress counter reaches a
warning level in the last dressing routine before tip change is required (maximum dress count – warning dress
count).
“Tip End of Life” output is active when both wear counter and dress counter are at maximum counts.
NOTE:
Every weld with current and without error will increment the wear counter.
Every valid dressing sequence will increment the dress counter and reset the wear counter.
When robot sends Serial input 60 = “Acknowledgement Tip Dressed”, the wear counter for selected tip is
reset.
When robot sends Serial input 61 = “Acknowledgement Tip Changed”, both the wear and dress counter for
selected tip are reset.
For more details on timing diagrams, refer to Appendix section 9, chart 5 and 6.
7.1.2 Forge Force Monitoring On

Forge Force Monitoring is enabled by default and configurable in PRI7000 interface under Global Parameters.
To disable this feature, switchTXT_ForgeForceMonitoringOn parameter to Off.
With Forge Force Monitoring On enabled, the robot must acknowledge at force status with Serial Input 45 –
“Forge Force Achieved“ during “3rd weld time active“ – Serial Output 45. If the signal is not received during 3rd
weld time active, then a fault will occur. The error message “Forge Force Not Achieved“ will be displayed.
For more details on timing diagrams, refer to Appendix section 9, chart 7.
7.1.3 Isolation Contactor Control

With Discrete Input E_01 = “Weld Contactor Closed“, weld controller will monitor the operation of the weld
contactor. A N.O. auxiliary contact on the weld contactor will be connected to this input. The input will be “on”
(24V) when the weld contactor is closed.
This input is checked at the end of Squeeze Time up to 250ms. If the Input is not “on” after 250ms, the weld will
be aborted and an error message displayed “Weld Contactor not closed“. A short Squeeze time may be delayed
by waiting for the feedback input.
Discrete Output A_01 = “Close Weld Contactor“ will be set with the receipt of a program start (internal or external)
, if serial Input 02 „Weld Contactor Enable“ is high and ignition is set. Output Close Weld Contactor will stay
energized until serial Input 02 is set low, or a fault occurs, or E-Stop occurs, or a timeout occurs.
A Timeout is defined as a period of time with no receipt of a “Start” signal. The timeout is set for 60 seconds.
Serial Input 2 = “Weld Contactor Enable“ must be maintained high to allow Weld Contactor control logic to
function. The input may be used to open the Weld Contactor as necessary, i.e., Tip Replacement. If this input
is low during the receipt of a program start (with ignition), an error message („No weld contactor enable“) is
displayed.
7.1.4 Serial Input 3 “Global Adaptive Off“

An active input forces programs with UI-measuring, UI-regulation and/or UI-monitoring a sequence in KSR-
measuring, KSR-regulation and/or KSR- monitoring without a reprogramming.
The input is level-active, for a normal operation it must be always low.
7.1.5 Serial Output 3 “Global Adaptive Enabled”

The output is only active if:
o “Voltage Measurement Active“ is on, and
o Input “Global Adaptive Off” is off (input is active), and
o Active Spot Reference has valid reference resistance curve recorded.
7.1.6 Serial Inputs 64 through 143 “ASCII_0” through “ASCII_9“

These numbers are added to the data of the welding log in order to allow for a subsequent allocation of the
information to a specific spot on a specific car body. The inputs will be interpreted as 8-bit ASCII characters. The
ASCII_0 through ASCII_9 characters corresponds to the first character of the name.
7.1.7 Digital Pressure Feedback
If pressure signal is not received by 5 seconds after receipt of start signal, an error message “No Welds
Pressure” is displayed.
8. Status codes
The current status code of the timer is outputted at the status code outputs according to the pending message.
The standard status messages are described in the PRI7000 Online help.
Application specific messages are shown in Table 8:
Tab.8: Application Specific Diagnostic Codes
Code Type Meaning Error Diagnostic Code
Error No Transformer Feedback 60003
Error Weld Contactor Not Closed 60004
Error No Weld Contactor Enable 60005
Error Forge Force Not Achieved 60006
Error Welding sequence without current 60008
Error No Weld Contactor Enable 60009
Warning Tip Dressing Requested 60030
Warning Tip Change Requested 60031

9. Timing Diagram
9.1 Welding Sequence

Start Welding can be executed by the robot in two ways: pulse input signal or maintained input signal.
Chart 1 illustrates pulse signal “Start 1“ (serial input 0) with falling edge executed before the end of sequence
“Weld Complete“ (serial output 0). “Weld Complete Duration Time” global parameter can be adjusted.
Chart 1:
Chart 2 illustrates maintained signal “Start 1“ (serial input 0) with falling edge aligning with the end of
sequence falling edge “Weld Complete“ (serial output 0). “Weld Complete Duration Time” global parameter
can be adjusted.
Chart 2:
NOTE:
It is recommended to operate the Start 1 signal as defined by Chart 2, so there is no potential of missing the
Weld Complete output due to “PLC scanning lags”.
Chart 3 illustrates Weld with Current with signal “Start 1“ (serial input 0) = 1 with “Weld Contactor Enable“ =
1 (serial input 2) and “Weld On External“ = 1 (serial input 7) to produce “Weld on with welding current = 1
(serial output 7).
Chart 3:
Chart 4 illustrates Weld without Current with signal “Start 1“ =1 (serial input 0) with
“Weld Contactor Enable“ = 1 (serial input 2) and “Weld On External“ = 0 (serial input 7)
to produce “Weld on with welding current = 0 (serial output 7) – weld without current.
Chart 4:
9.2 Tip Dress Motor Control Management

Chart 5 illustrates timing diagram for tip dress sequencing with parameter „Tip dresser with cycle counter“
enabled. The output TipDressInProcess is defined in mill job as a time duration and is executed by the robot
via spot number selection (serial inputs 08 – 31) and Tip Dress Motor On (serial input 41).
Chart 5:
Chart 6 illustrates timing diagram for tip dress sequencing with parameter „Tip dresser with cycle counter“
disabled. With RPM sensor monitoring disabled, discrete input E09 is monitoring for Current Sense Module
(CSM) high input.
Chart 6:
9.3 Forge Force Monitoring

Chart 7 illustrates timing diagram for Forge Force Function with parameter „ForgeForceMonitoringOn“
enabled. With monitoring enabled, Weld Controller is waiting for “Forge Force Achieved“ (serial input 45)
during “3rd weld time active“ (serial output 45).
Chart 7:
10. Annex
Basic Firmware: 1.11.9.0
Application: 1.8.10
Configuration: 1.6.4
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr a.Main
Germany
Tel. +49 9352 18 0
Fax +49 9352 18 8400
www.boschrexroth.com/welding
DOK-PRC700-PRC7X000900-IT01-EN-P

R911407604 01 PRC7X00.0900 en

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Rexroth PRC 7x00-Lx/Wx-0900

Process Resistance Welding Control

Type-Speciﬁc Instructions Edition 01

1 Regarding this Documentation .......................................................... 3

The data specified above serves to describe the

 This document, as well as the data,

The title pages shows an exemplary configuration.

The original instructions have been prepared in

1 Regarding this Documentation

1.1 Validity of the documentation

1.2 Required and supplementary documentation

 The documentation is available in the mediadirectory with the link:

Table 1: Required and supplementary documentation

Title Document number Type of document

Rexroth PRC7000 Process R911172834 Instructions

Rexroth PRC7000 MGDM R911381901 Instructions

Rexroth PS6000 Wx / PRC7000 R911370699 Description of

Rexroth PSGxxxx MF-Welding 1070 087062 Instructions

Rexroth PRI 7000 Online Help Reference

1.3 Display of information

1.3.1 Safety instructions

Table 2: Meaning of the Symbols

 Single, independent step

IoT (Internet of Things) is a collective term for technologies of an

GDM Gun Data Module

IO Inputs, output, Process interface

KSR Constant current regulation

MOV Metal oxide varistor

PHA Phase angle

PRC 7000 Process Resistance Welding Control

PRI 7000 Process Resistance Welding Interface

PSG xxxx Medium-Frequency Welding Transformer 1000Hz

PSF Prozess stability

RPM Rotation speed

STC TEACH Sheet Thickness Combination, teaching

UIP Process quality.

Value for the welding quality, derived from the resistance

characteristic of the current weld.

WIC Weld Interface Controller (internal realtime bus)

WPS Resistance spot welding (process)

3 General notes on damages to property and products

Fig. 1: Basic Weld Timer

PRC 7300 L1 / W1 PRC 7300 L2 / W2

PRC 7400 L1 / W1 PRC 7400 L2 / W2

Fig. 2: Mains connection

6.1 Serial input/output field (Ethernet/IP)

Table 4: Serial inputs / outputs

No. Wort Byte Bit PRC7000 inputs PRC7000 outputs

0 1 0 0 Start 1 Weld Complete

1 1 0 1 Not used Not used

2 1 0 2 Weld Contactor Enable Not used

3 1 0 3 Global Adaptive Off Global Adaptive Enabled

4 1 0 4 Fault Reset Timer ready

5 1 0 5 Fault Reset with weld complete Weld Fault

6 1 0 6 Fault Reset with Reweld Without Weld Process Monitoring

7 1 0 7 Weld on external Weld on (with welding current)

8 1 1 0 Spot Number Bit 0 Not used

9 1 1 1 Spot Number Bit 1 Not used

10 1 1 2 Spot Number Bit 2 Pressure inside tolerance area

11 1 1 3 Spot Number Bit 3 UI-regulation active

12 1 1 4 Spot Number Bit 4 UI-monitoring active

13 1 1 5 Spot Number Bit 5 Q-Stop

14 1 1 6 Spot Number Bit 6 Not used