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PSI6000 Inverter
Hardware and
BOS6000 Software
Klaus Klick
DCC/SVC15
Version 1.36.0
System overview Pg 7
Welding Sequence Pg 10
Hardware configuration Pg 13
Timer standard configuration Pg 15
Timer Name & I/O configuration Pg 17
Software communication Pg 22
Ethernet configuration Pg 23
BOS 6000 Software Pg 25
Programming page Pg 29
Icons Pg 30
Welding Sequence Pg 31
Programming exercise Pg 35
Copy Parameter Pg 36
Copy Programs / Timer Pg 37
Current Monitoring Pg 46
Extended Welding Sequence / Pressure Profile Pg 52
Electric Drives and Controls 2
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We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
Contents Page 2
Heat Stepper Pg 53
Heat Stepper & Tip dressing Pg 55
General set-up Pg 56
Electrode set-up Pg 58
Power Unit set-up Pg 62
I/O Diagnosis Pg 63
Simulate Start Pg 66
Timer Information Pg 67
Last Weld Pg 68
Plant Layout Pg 69
Log In / Compare Pg 72
Protocols Pg 76
Overview Pg 80
Error Table Pg 81
Pre-Warning F2 Pg 83
Correction Pg 87
Electric Drives and Controls 3
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We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
Contents Page 3
Force Calibration Pg 89
Current Calibration Pg 96
Set Up Heat Stepper Curves Pg 106
Set Up Tip Dresser Curves Pg 107
Backup Pg 108
Restore Pg 111
Help Page F1 Pg 116
How to extract spatter data Pg 118
System Overview
Mains Input
Optional Voltage-Feedback
Current-Feedback
Welding Gun
Welding
Gun
Electric Drives and Controls 6
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Overview PSI6000 Inverter and Transformer
Primary sensors
for KSR
Inverter output
500V 1000Hz to the
Gun
UIR Connections
F = Force [kN]
I = Current [kA]
t = time [ms]
Weld Current
Electrode 1
Contact-resistance Electrode-Sheet1
Sheet 1 Material-resistance 1
Contact-resistance Sheet-Sheet
Sheet 2 Material-resistance 2
Contact-resistance Electrode-Sheet2
Electrode 2
Electrode-Force F [kN]
Current I Q = R x I² x t
[kA]
Electric Drives and Controls 9
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BOS6000 & PSI6000 Weld Control
Hardware Familiarisation
7.) 2x PST6250.333L1
9.) Fuses
Side View
Welding controls
PSI6300.100L1
PSI6300.333L1
PSI6300.350L1
PSI6300.773L1
PSI63C0.357L1
PSI63S1.259L1
Transformers
PSG6130
Electric Drives and Controls 14
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We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
Timer Configuration PSI 6100.201L1
Profibus I/O
Serial Com
Parallel I/O
24 Volts internal /
external supply, see
next page.
External pressure
control to prop valve
Secondary current
feedback,
Transformer temp
feedback.
Output to the
Electric Drives and Controls
transformer 15
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24volts Distribution
Internal links
The fans are normally located at the rear of the panel, forcing air
to be driven across the fins of the heat sink.
+24volt feedback, from the prop valve, tells the welding control
that the demanded pressure has been reached, this then allows
robot control to give the command to close the gun and allow the
weld schedule to commence.
If no prop valve is used, then +24volts and 0volts must be
supplied to pin 4 & 2 !!
Electric Drives and Controls 18
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We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
Transformer Feedback
Software Communication is
normally via a specific
communications card, via
Interbus / Ethernet…etc.
You can also connect directly
to individual timers via the
serial port, X1
The General tab will A further Ensure that the IP address you select does not
now become visible configuration screen exactly match the IP address of the Timer, the
will appear last digit should be different
Select Properties
Select Internet Protocol (TCP/IP) then OK
Programming
The spot number, program
and communication status is
found at the top of program
page, as well as the drop
down menu’s
Spot reference
Comments
Rights
Administration
Timer
reference
Overview
Spot reference
Table
Program Page
Correction
(Parameter data) Diagnosis
Set-up
Electric Drives and Controls
(i/o interface)
28
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We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
Sequence
Monitoring parameters
are only shown, if
kA-monitoring is “ON”
Programming
Programming
The sequence screen allows
the user to see the
programmed weld Program
parameters at a glance Timer
Pressure
Weld time
Squeeze Weld current Hold
Step1: Prog1 – 2
Step2: Prog3 – 5
Using the Copy feature from the main menue, you have all Options
to copy any data from the weld timers.
Regulation:- Mix or
Standard
Monitoring:
Mix or Standard
Standard mode: the actual
current is determined by the
complete weld cycle including
any cool times
Mix mode: the actual current
is determined by the individual
weld times
Electrode:
0 – 31 different electrodes
can be selected, dependent
on your firmware version
Reweld:
If this function is activated
and a low weld current
occurs with the start signal
still high, the control will
automatically attempt to
reweld the program, if the
weld is low again a weld
fault is output.
Note:- if there is no current,
then a reweld will not be
activated
Electric Drives and Controls 42
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Sequence
Impulse:
This function indicates how
many times the weld 2, cool 2
function is repeated during one
weld sequence.
Current monitoring:
1
Repeat factor, is the number
2
of consecutive welds allowed
3
in the conditional permissible
4
tolerance band;
if this occurs, the actual
figure is displayed here
2
3
Ref, kA is the
programmed reference
current
Act. Ref. kA is the
actual current
achieved
Average PHA is the
actual Phase angle
required to achieve the
required current
3.) 1.)
2.)
Electric Drives and Controls 47
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Spot table
4.)
Heat increase %
in the lifetime of
electrode caps
Heat stepper:-
activation on/off
Warn Wear:-
Wear factor:- Number of welds
individual welds can be before the end
given a greater or of the max-life,
lesser “weighting”, that pre-warning
Max Wear:-
dependent on the becomes active
actual wear to the tips The number of welds over which the (50)
heat is stepped (incremented)
Wear/comp:- The
number ofElectric
welds taken
Drives and Controls 51
to complete
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rights reserved
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Heat Stepper
Heat increase
% between tip
dresses
Max Wear:-
The number of welds over which the
heat is stepped (incremented)
Please note:-
The Max life is
calculated by the
multiplying
(Max Wear x tip dress Tip Dress Steps:-
steps) + Max Wear The number of dress
steps (10)
i.e. (500 x 10) + 500 =
5500 welds
Dress-Request:- The
number of welds before
the max wear that the tip
Heat increase dress request output is
% between tip activated
dresses
Max Wear:-
Dress new Electrode:- The number of welds over which the i.e. 5450 welds
The weld is heat is stepped (incremented) (500)
inhibited, until the gun
is dressed,
Electric Drives and Controls 53
immediately after the
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electrode
We also retain sole power of disposal, has
including all rightsbeen
relating to copying, transmission and dissemination.
General set-up
A measuring loop check is a verification of the current sensor in the secondary circuit.
On : Measuring loop test active, sensor faults are detected. .
Electric Off : Measuring
Drives and Controls loop test not active, sensor faults are not detected. 54
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General set-up
The Fade out time parameter is used to suppress the natural
current rise at the beginning of the weld time for current
measurement
The %I Prewarning
parameter indicates the heat
value (in scale divisions SKT)
for which an imminent %I
limitation is to be detected for
the electrode displayed.
Upper currrent limit is the
maximum programmable set
limit of the current in the
individual electrode
Bosch sensors have been
adjusted to 150 mV / kA.
When using third-party
sensors, the appropriate
transmission ratio can be
programmed using the For details on the
Toroid sensitivity parameter measuring range,
see the next sheet
Timer type:-
Software / Firmware
Version:-
Start signal;
this is a signal sent from
the robot, to initiate the
start of a weld sequence
depending on the
program- /spotselection.
At the position
Start with Ignition
click once in the “On” tab
The timer will now execute
a weld
Weld current
protocols are
activated from the
Timer reference
page on start up.
If this option is
NOT selected this
page and the UIR
Monitoring page
will not show any
data.
F2
The information held on this page,
can be critical for
identifying
1. Wear on the caps
2. Number of remaining parts
3. Electrode status,
1. Green : - healthy
F2
The information held on this page,
can be critical for identifying
1. Wear on the caps
2. Number of remaining parts
3. Electrode status,
1. Green : - healthy
2. Orange: - Tip dress
required
F2
The information held on this page,
can be critical for identifying
1. Wear on the caps
2. Number of remaining parts
3. Electrode status,
1. Green : - healthy
2. Orange: - Tip dress
required
3. Yellow: - Prewarning
active
F2
The information held on this page,
can be critical for identifying
1. Wear on the caps
2. Number of remaining parts
3. Electrode status,
1. Green : - healthy
2. Orange: - Tip dress
required
3. Yellow: - Prewarning
active
4. Red: - End of stepper
life
Electric Drives and Controls 84
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Correction
7) If you want to
change the values,
place a tick in the box
before you type in the 9) Press the OK
new values. The button to enter the
changes will then be next screen
stored for the next time
the routine is entered.
Electric Drives and Controls 97
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Current Calibration
Communications page
shows confirmation of
the Ethernet address,
with the subnet mask.
7. Click Continue to
complete the
restore function
Electric Drives and Controls 113
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Help page F1
F1
F1
116
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How to extract the spot table from the BOS6000
software
Click on add
117
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How to extract the spot table from the BOS6000
software
118
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We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
How to extract the spot table from the BOS6000
software
119
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We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
How to extract spatter data from the BOS6000
software
120
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How to extract spatter data from the BOS6000
software
This screen will be shown.
Select the configuration of the data, Spot name
or program No
Select a date and time from the drop down
menu, this will be the start of the data to be
extrapolated.