Bosch Rexroth PS5000 Operating instructions

Rexroth IndraControl VCP 20
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
Rexroth PS5000 / PS6000
Operating And Diagnostic Terminal
BT 6.190
1070087068
Edition 01
Commissioning And Operating Instructions

II Electric Drives
and Controls
Bosch Rexroth AG BT 6.190 1070087068 / 01
Rexroth PS5000 / PS6000
Operating and Diagnostic Terminal BT6.190
Commissioning and Operating Instructions
DOK-PS6000-BT6.190****-IB01-EN-P
This manual provides information about the
Dconstruction, assembly, connection and
Doperation of the BT 6.190 operating and diagnostics terminal.
Description Release
Date
Notes
DOK-PS6000-BT6.190****-IB01-EN-P 03.2005
EBosch Rexroth AG, 2004
Copying this document, giving it to others and the use or
communication of the contents thereof without express authority, are
forbidden. Offenders are liable for the payment of damages. All rights
are reserved in the event of the grant of a patent or the registration
of a utility model or design (DIN 34−1).
The specified data is for product description purposes only and
may not be deemed to be guaranteed unless expressly confirmed
in the contract. All rights are reserved with respect to the content
of this documentation and the availability of the product.
Bosch Rexroth AG
Postfach 11 62
D-64701 Erbach
Berliner Straße 25
D-64711 Erbach
Tel.: [phone]
Fax: [phone]
Dept.: BRC −WS/VTR
Title
Type of Documentation
Document Typecode
Purpose of Documentation
Record of Revisions
Copyright
Validity
Published by

Electric Drives
and Controls
IIIBosch Rexroth AGBT 6.1901070087068 / 01
Contents
Contents
Page
1 Safety Instructions 1−1. . . . . . . . . . . . . . . . . . . . . . .
1.1 Possible Safety Markings on the Product 1−1. . . . . . . . . . . . . . .
1.2 Safety Instructions in this Manual 1−2. . . . . . . . . . . . . . . . . . . . . .
1.3 Intended Use 1−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Qualified Personnel 1−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Installation and Assembly 1−6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Electrical Connection 1−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Operation of the Product 1−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Retrofits and Modifications by the User 1−9. . . . . . . . . . . . . . . . .
1.9 Maintenance, Repair 1−10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10 Working Safely 1−11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.11 CE mark 1−12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.12 Documentation, software release and trademarks 1−13. . . . . . .
2 Overview 2−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Assembly and Connection 3−1. . . . . . . . . . . . . . . .
3.1 BT 6.190 built−in unit 3−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Dimensions and assembly 3−1. . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Connection 3−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 BT 6.190 −hand−held terminal (BT 6.190 HPG) 3−7. . . . . . . . .
3.2.1 Connection 3−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Operation 4−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Overview of BT 6.190 operating elements 4−2. . . . . . . . . . . . . .
4.2 Overview of main menu items and their functions 4−4. . . . . . . .
4.3 Select main menu items and navigation in
sublevels 4−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Quick mode 4−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 List of parameter numbers for
direct selection mode 4−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Special operation functions 4−13. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 Display error messages 4−13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2 Selecting the system language 4−13. . . . . . . . . . . . . . . . . . . . . .
4.5.3 Setting the LCD contrast 4−14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.4 Inhibiting operating functions (changing codes) 4−15. . . . . . . .
4.5.5 Display data from the last weld 4−17. . . . . . . . . . . . . . . . . . . . . .
4.5.6 Display I/O signals 4−18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.7 Programming the welding current times 4−19. . . . . . . . . . . . . . .
5 Maintenance 5−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Battery 5−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Fusing 5−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV Electric Drives
and Controls
Bosch Rexroth AG BT 6.190 1070087068 / 01
5.3 Firmware version 5−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1 Displaying the firmware version 5−3. . . . . . . . . . . . . . . . . . . . . .
5.3.2 Loading the firmware version 5−4. . . . . . . . . . . . . . . . . . . . . . . .
A Annex A−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Abbreviations A−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Index A−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Drives
and Controls
1−1Bosch Rexroth AGBT 6.1901070087068 / 01
Safety Instructions
1 Safety Instructions
The products described were developed, manufactured and tested in
compliance with the fundamental safety requirements of the EU machi-
nery directive. These products normally pose no danger to persons or
property if used in accordance with the handling stipulations and safety
notes prescribed for their configuration, mounting, and proper operation.
Nevertheless, there is some residual risk!
Therefore, you should read this manual before installing, connecting or
commissioning the products or programming the welding system.
Store this manual in a place to which all users have access at any time!
The content of this manual refers to
Dthe mechanical structure
Dthe electrical connection (24 V supply and I/O) and
Dthe functionality
of the diagnostics and operating terminal.
−BT 6.190 (rack−mounted model) and
−BT 6.190 HPG (hand−held programming device).
The weld timers have their own manuals. They complete this ma-
nual!
1.1 Possible Safety Markings on the Product
Warning of dangerous electrical voltage!
Warning of hazards associated with batteries!
Electrostatically sensitive components!
Lug for connecting PE conductor only!
Function ground, ground with low parasitic voltage
Connection of shield conductor only

1−2Electric Drives
and Controls
Bosch Rexroth AG BT 6.190 1070087068 / 01
Safety Instructions
1.2 Safety Instructions in this Manual
DANGEROUS ELECTRICAL VOLTAGE
This symbol is used to warn of dangerous electrical voltage. The fail-
ure to observe the instructions in this manual in whole or in part may re-
sult in personal injury.
DANGER
This symbol is used wherever insufficient or lacking compliance with in-
structions may result in personal injury.
CAUTION
This symbol is used wherever insufficient or lacking compliance with in-
structions may result in damage to equipment or data files.
.This symbol is used to draw the user’s attention to special circumstan-
ces.
LThis symbol is used if user activities are required.
Modifications in this manual as compared to a previous edition are mar-
ked by black vertical bars in the margin.

Electric Drives
and Controls
1−3Bosch Rexroth AGBT 6.1901070087068 / 01
Safety Instructions
1.3 Intended Use
The product described
Dserves in connection with a suitable weld timer
(spot seam variants of series PS 5000 and PS 6000) to
−display and modify parameters
−display and reset errors
and
Dis suitable for operation in industrial environments in accordance with
the following standards:
−EN 50178
−EN 50081-2
−EN 50082-2
−EN 60204-1
In residential environments, in trade and commerce as well as small
enterprises class A equipment may only be used if it does not inad-
missibly interfere with other equipment.
It is not intended for any other use!
DANGER
HF interference is possible!
This is a Class A resistance welding device.
Class A resistance welding devices are not designed für use in pu-
blic low−voltage power supply network that supplies, among
other things, residential buildings becaus it can interfere with
other devices in the area.
DANGER
Any use other than for the purpose indicated may result in perso-
nal injury of the user or third parties or in damage to equipment,
the workpiece to be welded, or environmental damage.
Therefore, our products must never be used for any other than
their respective intended purpose!
.For operation in residential environments, in trade and commercial
applications and small enterprises, an individual permit of the na-
tional authority or test institution is required; in Germany, please
contact the Regulierungsbehörde für Telekommunikation und
Post (RegTP) or its local branch offices.
The faultless, safe functioning of the product requires proper transport,
storage, assembly and installation as well as careful operation.

1−4Electric Drives
and Controls
Bosch Rexroth AG BT 6.190 1070087068 / 01
Safety Instructions
1.4 Qualified Personnel
The requirements as to qualified personnel are based on the require-
ment profiles defined by the ZVEI (Zentralverband Elektrotechnik und
Elektronikindustrie −German Electrical and Electronic Manufacturers’
Association) and the VDMA (Verband deutscher Maschinen- und Anla-
genbau −German Engineering Federation) in:
Weiterbildung in der Automatisierungstechnik
edited by: ZVEI and VDMA
Maschinenbau Verlag
Postfach 71 08 64
D-60498 Frankfurt.
This manual is designed for technicians and engineers with special wel-
ding training and skills. They must have a sound knowledge of the soft-
ware and hardware components of the weld timer, the power supply
used, and the welding transformer.
Project engineering, programming, start and operation as well as the
modification of program parameters is reserved to properly trained per-
sonnel! This personnel must be able to judge potential hazards arising
from programming, program changes and in general from the mechani-
cal, electrical, or electronic equipment.
Interventions in the hardware and software of our products, unless des-
cribed otherwise in this manual, are reserved to specialized personnel.
Tampering with the hardware or software, ignoring warning signs atta-
ched to the components, or non-compliance with the warning notes gi-
ven in this manual can result in serious bodily injury or property damage.
Only skilled persons as defined in IEV 826-09-01 (modified) who are fa-
miliar with the contents of this manual may install and service the pro-
ducts described.
Such personnel are
Dthose who, being well trained and experienced in their field and fami-
liar with the relevant standards, are able to analyze the work to be car-
ried out and recognize any hazards.
Dthose who have acquired the same amount of expert knowledge
through years of experience that would normally be acquired through
formal technical training.

Electric Drives
and Controls
1−5Bosch Rexroth AGBT 6.1901070087068 / 01
Safety Instructions
DANGER!
An exception are persons with cardiac pacemakers!
The strong magnetic fields occurring in resistance welding may
affect the proper functioning of pacemakers. This may be fatal or
cause serious personal injury!
Therefore, persons with pacemakers must stay clear of resistance
welding systems.
We recommend that warning sings as per DIN 40023 are posted at
every entrance to manufacturing shops housing resistance-wel-
ding equipment.
No entry for persons with cardiac
pacemakers!
Danger!
Please note our comprehensive range of training courses. More infor-
mation is available from our training center (Phone: [phone]).

1−6Electric Drives
and Controls
Bosch Rexroth AG BT 6.190 1070087068 / 01
Safety Instructions
1.5 Installation and Assembly
DANGEROUS ELECTRICAL VOLTAGE
Danger of life during installation work while systems are switched
on!
Make sure that all plant sections undergoing operations during
the installation are de-energized and sufficiently protected
against accidental reclosing!
DANGER
Non-workmanlike installation or mounting may lead to personal
injury or damage to property.
Therefore, it is essential that you take the technical data (environ-
mental conditions) into account for installation or mounting.
Installation or mounting must be carried out by skilled personnel
only.
DANGER
Insufficient degree of protection may be life-threatening or cause
damage to property!
Beachten Sie deshalb für Einbau und Montage die Angaben in den
relevanten Kapiteln.
DANGER
Danger of injury and of damage to property through incorrect in-
stallation!
Devices and, in particular, operating means, must be installed so
as to be properly safeguarded against unintentional operation or
contact.
CAUTION
Short circuits!
When cut-outs are drilled or sawed in switchgear cubicles, metal
burr may get into modules already installed there. Or, when coo-
ling water lines are connected, water may leak into the modules in-
stalled.
The possibility of short circuits occurring in the process or even
the destruction of the devices cannot be entirely ruled out.
Therefore, guard any existing modules well before you install a
new module! Any and all warranty excluded in case of non-com-
pliance.

Electric Drives
and Controls
1−7Bosch Rexroth AGBT 6.1901070087068 / 01
Safety Instructions
1.6 Electrical Connection
DANGER
Danger of life through inappropriate EMERGENCY-STOP facili-
ties!
EMERGENCY-STOP facilities must be operative in all modes of the
system. Releasing the EMERGENCY-STOP facility must by no
means result in an uncontrolled restart of the system! First check
the EMERGENCY-STOP circuit, then switch the unit on!
DANGER
Danger to life and limb caused by EMERGENCY STOP devices that
are not located within reach of the operator!
The “BT6.190 HPG” product variant (hand−held terminal) may be
operated only on machines with a permanently installed operating
station and an EMERGENCY STOP device!The EMERGENCY
STOP device of the operating station must be in reach at all times
so that it can be activated immediately in case of a malfunction.
Therefore, cable extensions between the operating station and the
BT6.190 HPG are not permitted!
CAUTION
Connecting lines and signal lines must be laid so as to avoid nega-
tive effects on the function of the units through capacitive or in-
ductive interference!Interference is frequently coupled and de-
coupled in long cables.
Therefore, power and control cables must be routed separately.
The influence of interfering cables on cables susceptible to inter-
ference can be minimized by keeping the following distances:
> 100 mm if cables are run in parallel for < 10 m,
> 250 mm if cables are run in parallel for > 10 m.
The product should be mounted close to the welding systems so
as to avoid cable lengths of more than 25 m.
LIn addition, please comply with all safety regulations regarding electrical
connections and the EMC of the system as a whole in the manuals of the
power supply units.
LMake sure that all contact surfaces are bright, i.e. free of paint, plastic
coating or dirt/oxidation.

1−8Electric Drives
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Bosch Rexroth AG BT 6.190 1070087068 / 01
Safety Instructions
1.7 Operation of the Product
DANGER
In the environment of resistance welding systems, magnetic field
strengths have to be expected which are above the limit values
specified in VDE 0848 Part 4. Especially if manual guns are used,
the limit values for extremities may be exceeded.
In cases of doubt, you should measure the field strength and take
additional measures to ensure safety and health at work. Please
comply with regulation BGV B11 of the German Berufsgenossen-
schaft (professional association) ”Unfallverhütungsvorschrift
elektromagnetische Felder”.
DANGER
The strong magnetic fields occurring in resistance welding may
affect the proper functioning of pacemakers. This may be fatal or
cause serious personal injury!
Therefore, persons with pacemakers must stay clear of resistance
welding systems.
We recommend that warning sings as per DIN 40023 are posted at
every entrance to manufacturing shops housing resistance-wel-
ding equipment:
No entry for persons with cardiac
pacemakers!
Danger!
DANGER
Danger of personal injury and damage to property if devices are
operated before they have been properly installed!
The devices are designed to be installed in housings or switch-
gear cabinets and must not be operated unless properly installed
and switchgear cabinet doors are closed!

Electric Drives
and Controls
1−9Bosch Rexroth AGBT 6.1901070087068 / 01
Safety Instructions
DANGER
Danger of bruises through electrode movement!
All users, line designers, welding machine manufacturers and
welding gun producers are obliged to connect output signals
which initiate the electrode movement so that the applicable sa-
fety regulations are complied with.
For example, by means of ”Two-handed start”, fences, light bar-
riers etc. the risk of bruises can be considerably reduced.
CAUTION
Overheating through inappropriate or insufficient cooling.
The temperature inside the housing must stay within the specified
range.
1.8 Retrofits and Modifications by the User
DANGER
Modifications to the product 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 making any modifications.
This is the only way to determine whether changes can be made
without any problems.

1−10 Electric Drives
and Controls
Bosch Rexroth AG BT 6.190 1070087068 / 01
Safety Instructions
1.9 Maintenance, Repair
DANGEROUS ELECTRICAL VOLTAGE
Prior to any maintenance work −unless described otherwise −the
system must always be switched off and sufficiently secured!
In the event of necessary measurement or test procedures on the
active system, these have to be performed by skilled electrical per-
sonnel.
DANGER
Lithium batteries can cause skin burns or explode in case of im-
proper handling!
Therefore, do not forcefully open batteries, do not attempt to
charge or heat up batteries over 1005C!
CAUTION
Please use only spare parts approved by us!
Use only original replacement batteries! In any case, spent batte-
ries and accumulators should be disposed of as hazardous waste!
CAUTION
Danger to the module!
All ESD protection measures must be observed when using the
module! Prevent electrostatic discharges!
The following protective measures must be observed for modules and
components sensitive to electrostatic discharge (ESD)!
DPersonnel responsible for storage, transport, and handling must have
training in ESD protection.
DESD-sensitive components must be stored and transported in the
prescribed protective packaging.
DESD-sensitive components may only be handled at special ESD-
workplaces.
DPersonnel, working surfaces, as well as all equipment and tools
which may come into contact with ESD-sensitive components must
have the same potential (e.g. by grounding).
DWear an approved grounding bracelet. The grounding bracelet must
be connected with the working surface through a cable with an inte-
grated 1 MWresistor.
DESD-sensitive components may by no means come into contact with
chargeable objects, including most plastic materials.
DBeim Einsetzen von EGB in Geräte und bei ihrer Herausnahme muß
das Gerät spannungsfrei sein.

Electric Drives
and Controls
1−11Bosch Rexroth AGBT 6.1901070087068 / 01
Safety Instructions
1.10 Working Safely
DANGER
If the start signal is present on fault reset (acknowledge), the weld
timer immediately starts the program sequence! Hazardous ma-
chine movements may be the result!
Therefore, before fault reset, you should make sure that there are
no persons in the danger zone of the welding equipment!
DANGER
During operation of the welding equipment welding splashes are
to be expected! They may cause eye injuries or burns. Therefore:
−wear protective goggles
−wear protective gloves
−wear flame-retardant clothes
DANGER
Danger of injury from sheet metal edges and danger of burns from
weld metal!
Therefore: −wear protective gloves
CAUTION
The strong magnetic fields occurring in the resistance welding
process may cause permanent damage 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 wor-
king in the immediate vicinity of the welding equipment.

1−12 Electric Drives
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Bosch Rexroth AG BT 6.190 1070087068 / 01
Safety Instructions
1.11 CE mark
CAUTION
The CE certificate for the described device combination is valid for
use in an industrial environment
For other combinations/applications, the certificate must be deri-
ved from the above, or a new certificate must be issued, if neces-
sary, by the line designer / user.
The described product is an application variant that, due to its
characteristics, cannot satisfy the regulations for terminals,
machines or systems from the start. Therefore, it may be used only
as described.
The electical and mechanical safety and the ambient environment
(foreign bodies, moisture) must be evaluated on the terminal when
it has been installed.
IThe EMC characteristics of this product may change after it has
been installed. As a result, a check of the EMC characteristics of
the end product (terminals, machine, systems) by the
manufacturer of the end product is advisable.

Electric Drives
and Controls
1−13Bosch Rexroth AGBT 6.1901070087068 / 01
Safety Instructions
1.12 Documentation, software release and trademarks
Trademarks
All trademarks of software installed on Rexroth products upon delivery
are the property of the respective manufacturer.
Upon delivery, all installed software is copyright-protected. The software
may only be reproduced with the approval of Rexroth or in accordance
with the license agreement of the respective manufacturer.
MS-DOSrand Windowstare registered trademarks of Microsoft
Corporation.
PROFIBUSris a registered trademark of the PROFIBUS Nutzerorga-
nisation e.V. (user organization).
INTERBUS-Sris a registered trade mark of Phoenix Contact.
DeviceNetris a registered trade mark (TM) of ODVA (Open DeviceNet
Vendor Association, Inc.).

1−14 Electric Drives
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Bosch Rexroth AG BT 6.190 1070087068 / 01
Safety Instructions
Notes:

Electric Drives
and Controls
2−1Bosch Rexroth AGBT 6.1901070087068 / 01
Overview
2 Overview
This manual contains information about
Dthe mechanical system,
Dthe electrical connections and
Dthe functions of diagnostic and control terminals
−BT 6.190 (rack−mounted model) and
−BT 6.190 HPG (hand−held programming device).
CAUTION
There may be malfunctions and damage!
Improper installation, incorrect connection or improper operation
may cause unexpected or incorrect unit reactions and may thus
result in hazardous situations in the welding system.
Therefore, heed the information provided in this manual.
The BT 6.190 is used as a stationary or portable control and diagnostic
terminal for your spot seam weld timer and can be used in conjunction
with the PS 5000 and PS 6000 series of weld timer.
It is designed for
Dstationary (e.g. within the control panel of the welding system; for
hardware, see section 3.1, page 3−1 ff.) or
Dmobile operation (for hardware, see section 3.2, page 3−7 ff.).
The BT 6.190 supports the following functions:
Ddisplay and resetting of all current faults in the timer
Ddisplay and modification of important welding and process data.
.The BT 6.190 has been designed for the display and parameteriza-
tion of production−specific data because access to the entire
range of functions of your weld timer is not required during normal
operation.
If you require access to all the available programming and parame-
terization options of the weld timer, use a PC with ”BOS” welding
software installed.
The operation of the BT 6.190 is described in section 4.

2−2Electric Drives
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Bosch Rexroth AG BT 6.190 1070087068 / 01
Overview
Notes: