Bosch BT220 User manual

Operating Terminal BT 220
Technical Information and Operation
PS 5000
101
Version

PS 5000
Operating Terminal BT 220
Technical Information and Operation
1070 080 037-101 (99.01) GB
Reg. No. 16149-03
E1999
by Robert Bosch GmbH, Erbach / Germany
All rights reserved, including applications for protective rights.
Reproduction or handing over to third parties are subject to our written permission.
Discretionary charge 20.00 DM

BT220 Technical Information and Operation
Contents
I
1070 080 037-101 (99.01) GB
Contents
Page
1 Safety Instructions 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Explanation of pictographs and symbols 1-1. . . . . . . . . . . . . . . . . . . . . . .
Warning of magnetic fields 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal use 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualified personnel 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retrofits and modifications by the user 1-5. . . . . . . . . . . . . . . . . . . . . . . .
Maintenance, repair 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and assembly 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units without Monitoring Contact ÜK 1-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Start Simulation 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Reset 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Working safely 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Overview 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Installation and Assembly 3-1. . . . . . . . . . . . . . . . . . . . . . . . . .
4 Electrical Connection 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Power Supply (X1) 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Lamp and Ready Outputs (X2) 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 RS232 Interfaces 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 RS485 Interface 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Operation 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Display and Acknowledge Events, if necessary 5-2. . . . . . . . . . . . . . . . .
5.2 Display / Change Internal Time Setting of the BT220 5-3. . . . . . . . . . . .
5.3 Set System Language 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Displaying / Changing Welding and Process Data 5-4. . . . . . . . . . . . . . .
5.4.1 Selection of Program and Weld timer 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.2 F2: Sequence 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3 F3: Monitoring 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.4 F4: Data of the Last Weld 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.5 F5: Slope 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.6 F6: Pressure Profile 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.7 F7: Stepper Diagnostics 5-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.8 F8: FPO_1 (freely programmable analog output) 5-15. . . . . . . . . . . . . . . . . . .
5.4.9 F9: Heat Correction 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
BT220 Technical Information and Operation
II 1070 080 037-101 (99.01) GB
5.5 Deleting the Message Memory 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Display Diagnostic Memory 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 Printing the Diagnostic Memory 5-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8 Deleting the Diagnostic Memory 5-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9 Adapting the BT220 Display 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.1 Setting the Message Display Mode 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.2 Setting the Flash Rate 5-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.3 Setting ”Automatic Message Scrolling” 5-26. . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.4 Display Parameters 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10 Testing the BT220 Keyboard 5-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11 Configuring the Printer Interface (X4) 5-29. . . . . . . . . . . . . . . . . . . . . . . . . .
5.12 Inhibiting the Control Function 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.13 Overview: BT220 Specific Functions and Parameters 5-33. . . . . . . . . . .
6 Maintenance 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Battery 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Reset 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Software release 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Appendix 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Information on the STK multi-contact interface board 7-1. . . . . . . . . . .
7.2 List of Figures 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Subject index 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BT220 Technical Information and Operation
Safety Instructions
1070 080 037-101 (99.01) GB 1-1
1 Safety Instructions
The product described hereunde was developed, manufactured and tested
in accordance with the basic safety stipulations of the EC Machine Directive.
You should nevertheless be aware of residual risks!
You should therefore read this manual before mounting, setting up, commis-
sioning or programming the system or working with this control system for
the first time.
Keep the manual in a place where it is easily accessible to all users!
Explanation of pictographs and symbols
The following warnings and notes may be attached to the individual hard-
ware components which are designed to inform the user of certain circum-
stances.
’ Warning of dangerous voltages!
’Components subject to electrostatic induction!
’Disconnect mains plug before opening!
’ Bolt for connection of the PE (protective earth)
conductor only!
’For shield conductor only!

Safety Instructions
BT220 Technical Information and Operation
1070 080 037-101 (99.01) GB
1-2
There is a certain hierarchy of warnings in this manual. The warnings are
printed in bold letters and marked by a warning sign at the margin.
The hierarchy of the warnings is as follows:
1. WARNING
2. ATTENTION
3. NOTE
WARNING!
The term WARNING will be used wherever danger is imminent.
The possible consequences may be death or severe injury (personal injury).
ATTENTION!
The term ATTENTION will be used wherever a dangerous situation is
possible.
The possible consequences include death, severe or light injury (personal
injury) damage to property or environmental hazards.
NOTE
The term NOTE will be used for making recommendations on the use.
Non-compliance with these recommendations may result in damage to
property, e.g. to the machine or the workpiece.
!

BT220 Technical Information and Operation
Safety Instructions
1070 080 037-101 (99.01) GB 1-3
Warning of magnetic fields
In the environment of resistance welding systems magnetic field strengths
have to be expected which usually are below the limits specified in VDE 0848
Part 4; in cases of doubt, the field strength must be measured.
WARNING!
When using manual welding guns, the limit values may be exceeded for the
extremities. In this case, additional work protection measures must be
taken.
WARNING for persons with cardiac pacemakers!
Warning signs should be posted for protecting persons with cardiac pace-
makers because the function of these devices may be disturbed (impulse
failure, total failure) and a negative influence on the pacemaker program-
ming or even a total program destruction may occur !!!
We recommend posting a warning of the type shown below at all entrances
to factory halls containing resistance welding equipment:
No entry for persons with cardiac
pacemakers!
Danger!
DIN 40023
!
!

Safety Instructions
BT220 Technical Information and Operation
1070 080 037-101 (99.01) GB
1-4
Normal use
In conjunction with the connected PS 5000 weld timer the Operating terminal
serves for the
‘Display and change of parameters
‘Display of faults, warnings and signals
It is only suitable for
‘industrial applications
in accordance with DIN EN 50082-2 of Electromagnetic Compatibility
(EMC).
It is not intended for any other use!
ATTENTION!
The use for purposes other than the intended use may result in personal
damage to the user or third persons or damage to the equipment, the work-
piece to be welded or other hazards.
Therefore, our products should only be used for their intended purpose!
Qualified personnel
This manual is designed for welding technicians and engineers with special
training and specific knowledge of the welding technology. They require pro-
found knowledge of the hardware components, the functions and the pro-
gramming of the welding equipment.
The term qualified personnel refers to
- engineering personnel familiar with the safety standards of the electrical
and automation technology.
- commissioning personnel entitled to commission, earth and label electri-
cal circuits and equipment/systems in compliance with the standards of
safety technology.
- operating personnel who have been instructed in operating installations
in resistance welding technology and who know the contents of the pres-
ent documentation as far as operation is concerned.
WARNING!
An exception are persons with cardiac pacemakers!
Due to the strong magnetic fields arising from resistance welding, the func-
tion of cardiac pacemakers may be disturbed. This may cause the death or
considerable health damages to persons with cardiac pacemakers!
Therefore, these persons should avoid the welding system.
Please note our comprehensive range of training courses. More information
is available from our training center (Phone: ++49 (0)6062 / 78258).
!

BT220 Technical Information and Operation
Safety Instructions
1070 080 037-101 (99.01) GB 1-5
Retrofits and modifications by the user
Our equipment has been designed and manufactured by us as a safe unit.
WARNING!
Retrofits or modifications may have negative effects on the safety of the unit!
The possible consequences include death, severe or light injury (personal
injury) damage to property or environmental hazards.
Therefore, please contact us prior to retrofits or modifications to the welding
system using third-party equipment. This is the only way to determine
whether these parts are suitable for use with our product.
Maintenance, repair
WARNING!
- Danger of life through electrical voltage!
Prior to any maintenance work - unless described otherwise - the sys-
tem must always be switched off! In the event of necessary measure-
ment or test procedures on the active system, the applicable safety and
accident prevention regulations must be strictly observed. In any case,
suitable insulated tools must be used!
- Danger of life through inappropriate EMERGENCY-OFF devices!
EMERGENCY-OFF devices must be operative in all modes of the sys-
tem. Releasing the EMERGENCY-OFF facility must by no means result
in an uncontrolled restart of the system!
ATTENTION!
- The right to perform repair/maintenance work on the timer compenents is
reserved to the BOSCH service department or to repair/maintenance
units authorized by BOSCH!
- Only use spare parts/replacement parts approved by BOSCH!
−If handled improperly, batteries may cause cauterization or explode!
Therefore:
Batteries must not be opened forcefully, recharged, soldered at the cell
body or thrown into fire!
- Only use original replacement batteries! Spent batteries or accumulators
must be disposed of as hazardous waste.
!
!

Safety Instructions
BT220 Technical Information and Operation
1070 080 037-101 (99.01) GB
1-6
Installation and assembly
ATTENTION!
- Please observe all applicable safety and accident prevention regula-
tions!
- Danger of damage to property through short-circuits!
When drilling or sawing out openings, metal burr may get inside modules
or plant sections that have already been installed.
Possible consequences include short-circuits and a destruction of the
equipment.
Therefore, all equipment should be well partitioned prior to any additional
work!
- The units, and especially the operating elements, must be installed so as
to be sufficiently protected against unintentional operation or contact.
- Connection and signal leads should be run so as to avoid disturbance of
any equipment functions by capacitive or inductive interference.
- Equipment designed for installation in housings or switch cabinets must
be installed in such enclosures before they may be used or operated!

BT220 Technical Information and Operation
Safety Instructions
1070 080 037-101 (99.01) GB 1-7
Units without Monitoring Contact ÜK
ATTENTION!
When the ÜK is permanently connected to +24V, the squeeze times are to
be selected long enough so as to ensure that the parts to be welded are opti-
mally pressed together before the weld time starts.
Start Simulation
ATTENTION!
If the equipment is started remotely, there results a program sequence
which can cause hazardous machine movements. So check before remote
start up that no one is in the danger zone of the welding equipment!
Fault Reset
WARNING!
- Danger of physical injury!
If the start signal is present on fault reset, the weld timer immediately
starts the program sequence! Hazardous machine movements may be
the result!
Therefore, before fault reset, you should make sure that there are no per-
sons in the danger zone of the welding equipment!
- Danger of bruises through electrode movement!
All users, line designers, welding machine manufacturers and welding
gun producers are obliged to connect the output signal of the Bosch weld
timer which initiates the electrode movement so that the applicable
safety regulations are complied with.
The risk of bruises can be considerably reduced by means of,
e.g., ‘two-handed start
‘guard rails
‘light barriers etc.
!

Safety Instructions
BT220 Technical Information and Operation
1070 080 037-101 (99.01) GB
1-8
Working safely
WARNING!
- During operation of the welding equipment welding splashes are to be
expected! The consequence may be injuries to the eyes or burns.
Therefore:
‘wear protective goggles
‘wear protective gloves
‘wear flame-retardant clothes
- Danger of injury at sheet metal edges and danger of getting burnt at the
parts to be welded!
Therefore: ‘wear protective gloves
NOTE
The strong magnetic fields arising in connection with resistance welding
may cause lasting damages to wrist watches, pocket watches, or cards with
magnetic stripes (e.g. EC cards).
Therefore, you should not carry any such items on you when working in the
direct vicinity of the welding equipment.
!

BT220 Technical Information and Operation
Overview
1070 080 037-101 (99.01) GB 2-1
2 Overview
NOTE
For comfortable programming and setting of parameters of the PS 5000 use
a PC with the welding software ”BOS 5000” installed. In normal operation of
the welding unit the complete function range of this package is not really re-
quired.
Because of this the BT220 is available to you as a stationary control ter-
minal of your PS 5000 (supported control types: PSS 5100.510 and
PSS 5200.510; please ask for other supported types).
It is designed for installation in the machine operating panel of the welding
unit. So faults, warnings and messages of the PS 5000 can be displayed in
clear text and basic welding data may be quickly and easily displayed or
changed.
Fig. 2-1: Front View BT220
This manual contains information on
‘the mechanics
‘the electrical connection and
‘the functions of the BT220.
ATTENTION!
Danger of malfunctions and damage!
Wrong installation and faulty connection can lead to unexpected or wrong
unit reactions and hence to hazardous situations. So please respect the de-
tails in the present manual.
Follow all the instructions in this manual (instructions are identified by the
sign ”’”). They are for your own safety and for problem-free commissioning.
‘Display of faults, warnings and messages of the PS 5000.
The BT220 can manage a maximum of 100 events present at the same
time in the message memory.
‘Display and modification of different welding and process data.
‘Diagnostic memory for max. 400 events (ring memory).
The contents of the diagnostic memory can be output via the serial
interface to a printer.
Functions

Overview
BT220 Technical Information and Operation
1070 080 037-101 (99.01) GB
2-2
‘BT220-1: with 1RS232 interface for the connection of
1 x PS 5000
or
1 x STK multi-contact interface board.
‘BT220-2: with 2 RS232 interfaces for the connection of
2 x PS 5000
or
1 x STK multi-contact interface board
and
1 x Report printer.
‘BT220-3/7: with 1RS485 and 1RS232 interface for the connection
of
1 x STK multi-contact interface board (RS485)
and
1 x Report printer (RS232).
‘STK x: Multi-contact interface board for the connection of max.
7 PS 5000 via RS232 interfaces. In the basic design the
STK is already prepared for the connection of 3
PS 5000. It can be easily retrofitted with additional
plug-in RS232 interface modules.
For communication with a BT220-x, the multi-contact
interface board is optionally available with a separate
RS485 or RS232 interface.
You can find more information on the multi-contact in-
terface board on page 7-1.
BT220-1
X1
X4
max. 15m 1st PS 5000
RS232
Fig. 2-2: Connection of a PS 5000
Constructions
Options
Application Examples

BT220 Technical Information and Operation
Overview
1070 080 037-101 (99.01) GB 2-3
BT220-2
X1
X5
max. 15m
X1
X4
max. 15m
1st PS 5000
2nd PS 5000
RS232
RS232
Fig. 2-3: Connection of 2 PS 5000
BT220-x
1st PS 5000 X1
2nd PS 5000
3rd PS 5000
4th PS 5000
5th PS 5000
6th PS 5000
7th PS 5000
Multi-contact in-
terface board
STK
X1
X1
X1
X1
X1
X1
Cable lengths for
- RS232 connections max.15m
- RS485 connections max.1000m
RS232
RS232
RS232
RS232
RS232
RS232
RS232
Channel 1
Channel 2
Channel 3
Channel 4
Channel 5
Channel 6
Channel 7
Channel 8
RS232
or
RS485
Fig. 2-4: Connection of max. 7 PS 5000 to BT220 via STK multi-contact interface board

Overview
BT220 Technical Information and Operation
1070 080 037-101 (99.01) GB
2-4

BT220 Technical Information and Operation
Installation and Assembly
1070 080 037-101 (99.01) GB 3-1
3 Installation and Assembly
The BT220 is intended for installation in a control panel, a control cabinet or
a front plate.
Weight: approx. 1.5 kg
Installation position: 0_to max. 90_slant
Installation type: in a desk or hinged frame, sealed as per IP 65
Degree of protection: IP 65 (front face); IP 40 (back face)
Dimensions: Required assembly cutout: 262 mm x 92 mm
Required installation depth: 110 mm
Front dimensions: 277 mm x 112 mm
Temperature: Operating temperature range: 0_C to +50_C
Storage temperature range: -30_C to +70_C
Air humidity: 20% to 80% rel. air humidity
’Please refer to the information in chapter ”Safety Instructions” relative to
installation and assembly.
’Install the BT220 so that ergonomic operation is guaranteed. Also the
operator must have a clear view of all moving machine parts at all times!
Remember how quickly the front panel can become dirty with an inclined
or horizontal installation.
’Avoid installation places which are exposed to direct sunshine (reduction
of display legibility; additional heat).
’Provide a minimum all-round clearance of 50mm for sufficient ventilation
and cable routing.
’Run all connection cables in loops, and use strain reliefs for all cables.
’Keep as far away as possible away from sources of interference, how-
ever at least 25cm. With strong magnetic fields we recommend the in-
stallation of partition plates.
’Only use silicon-free sealing, adhesive or insulating media.
max. 90°
Minimum allround
clearance of 50 mm
BT220
Fig. 3-1: Installation positions and distances

Installation and Assembly
BT220 Technical Information and Operation
1070 080 037-101 (99.01) GB
3-2
’Fix the BT220 with the 4 screw terminals. For this purpose, first insert the
BT220 into the assembly cutout and then engage the screw terminals in
the recesses on the top and bottom sides of the BT220 housing.
Then tighten the screw terminals.

BT220 Technical Information and Operation
Electrical Connection
1070 080 037-101 (99.01) GB 4-1
4 Electrical Connection
Supply inputs, outputs and interfaces are isolated from each other.
’Disconnect the unit from power before wiring the BT220.
’Make sure that the circuits of relays or contactors, which are installed in
the same installation room as the BT220 include the corresponding free-
wheeling diodes or RC spark-quenching devices.
15
69
X4
X1 X2 PE/Screening
X1: 24VDC power input
X2: Outputs (indicator lamps, ready state)
X4: RS232 interface for the connection of PS 5000, or STK multi-contact
interface board
Fig. 4-1: Connections on the BT220-1
15
69
X4 X5
X1 X2 PE/Screening
15
69
X1: 24 VDC power input
X2: Outputs (indicator lamps, ready state)
X4: RS232 interface for the connection of PS 5000 or report printer
X5: RS232 interface for the connection of PS 5000, or STK multi-contact
interface board
Fig. 4-2: Connections on the BT220-2
Remarks
BT220-2: If an STK multi-contact interface board is connected to X5, only a
report printer may be connected to X4.
Position of the Connec-
tions