Bosch Rexroth PS5000 Operating instructions

Rexroth PS5000 / PS6000
Operating and Diagnostic Terminal
BT 6.00
1070080078
Edition 03
Comissioning, Operating Instructions
Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly Technologies
Hydraulics

II Electric Drives
and Controls
Bosch Rexroth AG BT 6.00 1070080078 / 03
Rexroth PS5000 / PS6000
Operating and Diagnostic Terminal BT6.00
Commissioning, Operating Instructions
DOK-PS6000-BT6.00*****-IB03-EN-P
The present manual provides information on
DStructure, installation, connection and
DOperation of the control and diagnostic terminal BT 6.
Description Release
Date
Notes
DOK-PS6000-BT6.00*****-IB02-EN-P 10.2002
DOK-PS6000-BT6.00*****-IB03-EN-P 09.2005
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]
Abt.: 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 6.001070080078 / 03
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 Environmental protection, recovery of materials and re-use 1−4
1.5 Qualified Personnel 1−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Installation and assembly 1−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Electrical Connection 1−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Operating the product 1−9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9 Retrofits and modifications by the operator 1−10. . . . . . . . . . . . .
1.10 Maintenance, repair 1−11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.11 Safe working practices 1−12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.12 CE Marking 1−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.13 Documentation, software release and trademarks 1−14. . . . . . .
2 Overview 2−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Assembly and Connection 3−1. . . . . . . . . . . . . . . .
3.1 BT 6.00 −Built-in unit 3−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Dimensions and assembly 3−1. . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Connection 3−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 BT 6.00 −Hand-held programming terminal (BT 6.00 HPG) 3−7
3.2.1 Connection 3−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Operation 4−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Control elements of BT 6 −Overview 4−2. . . . . . . . . . . . . . . . . .
4.2 Main menu items and their functionality −Overview 4−4. . . . . .
4.3 Selection of main menu items and navigation in sublevels 4−6
4.4 Quick mode 4−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 List of parameter numbers for quick mode 4−8. . . . . . . . . . . .
4.5 Special control functions 4−11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 Display error messages 4−11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2 Select system language 4−11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.3 Set LCD contrast 4−12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.4 Inhibiting the Control Function (change code numbers) 4−12.
4.5.5 Display electrode wear / Reset counter 4−14. . . . . . . . . . . . . . .
4.5.6 Display data of the last weld 4−15. . . . . . . . . . . . . . . . . . . . . . . . .
4.5.7 Display I/O signals 4−16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Maintenance 5−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Battery 5−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Fusing 5−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV Electric Drives
and Controls
Bosch Rexroth AG BT 6.00 1070080078 / 03
Contents
5.3 BT 6 Firmware version 5−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1 Display firmware version 5−3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.2 Load firmware version 5−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Annex A−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Abbreviations A−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Index A−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Safety Instructions
1 Safety Instructions
The products described were developed, manufactured, documented
and tested in compliance with the fundamental safety requirements of
the EU machinery 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 contents of this manual refer to
Dthe mechanical structure
Dthe electrical connection and
Dthe functionality
of the control and diagnostic terminal
−BT 6.00 (built-in unit) and
−BT 6.00 HPG (manual programming terminal).
For the actual weld timers, please refer to the other manuals pub-
lished. They supplement the present manual!
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
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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 circum-
stances.
LThis symbol is used if user activities are required.
Modifications in this manual as compared to a previous edition are
marked by black vertical bars in the margin.

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Safety Instructions
1.3 Intended Use
The product described
Dserves in connection with a suitable weld timer (PS 5000, PS 6000) to
−display and change parameters
−display and reset faults
and
Dis suitable for operation in industrial environments (emission class A,
group 2) in accordance with the following standards:
−EN 50081-2
−EN 50082-2
−EN 60204-1
It is not intended for any other use!
DANGER
Risk of high-frequency interference!
This resistance welding equipment belongs to class A.
Resistance welding equipment class A is not intended for use in
the public low-voltage network supplying, e.g., residential build-
ings, because it may interfere with other equipment in the environ-
ment.
DANGER
Any use other than for the purpose indicated may result in per-
sonal 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
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Safety Instructions
1.4 Environmental protection, recovery of materials and re-use
Environmental protection
Our products do not contain any hazardous materials which may be re-
leased by their intended use. Therefore, no negative effects on the envi-
ronment are to be expected under normal circumstances.
Recovery of materials
The products manufactured by us can be returned to us free of charge
for proper disposal.
However, the following conditions have to be satisfied for this purpose:
Dno deposits such as oil, grease or other contamination
Dno inappropriate extraneous materials or third-party components in-
cluded.
The packaging materials are made of cardboard, wood and polystyrene.
For environmental reasons, please do not return any empty packagings
to us. They can be easily recycled.
The products are to be sent postage prepaid to the following address:
Bosch Rexroth AG
Electric Drives and Controls
Bürgermeister−Dr.−Nebel−Straße 2
D−97816 Lohr am Main
Recycling
Principal components of our electronic equipment:
DSteel, aluminum, copper, plastic materials.
Due to their high metal content, the most of the materials of our products
can be recycled. In order to ensure optimum recovery of metals, the
equipment has to be split into individual components.
The metals that are contained in the electric and electronic modules can
also be recovered using special separating methods. The plastic materi-
als recovered by this process can be disposed of thermally.

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Safety Instructions
1.5 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
welding training and skills. They must have a sound knowledge of the
software 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 de-
scribed otherwise in this manual, are reserved to specialized personnel.
Tampering with the hardware or software, ignoring warning signs at-
tached to the components, or non-compliance with the warning notes
given in this manual can result in serious bodily injury or property dam-
age.
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 prod-
ucts described.
Such personnel are
Dthose who, being well trained and experienced in their field and famil-
iar 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.
DANGER
An exception are persons with cardiac pacemakers!
Due to the strong magnetic fields arising from resistance welding,
the function of cardiac pacemakers may be disturbed. This may
cause the death or considerable health damages!
Therefore, these persons should avoid the welding system.
We recommend posting a warning to DIN 40023 at all entrances to
factory halls containing resistance welding equipment.

1−6Electric Drives
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Bosch Rexroth AG BT 6.00 1070080078 / 03
Safety Instructions
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]).

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Safety Instructions
1.6 Installation and assembly
DANGEROUS ELECTRICAL VOLTAGE
Danger of life when performing assembly works on live systems!
Please ensure that all plant sections worked on in the course of the
assembly have been safely isolated from supply and sufficiently
protected against accidental reclosing!
DANGER
Non-workmanlike installation or mounting may lead to personal
injury or damage to property.
Therefore, you must observe the information provided in the indi-
vidual sections applicable to the installation and assembly.
Installation and assembly are reserved to qualified personnel.
DANGER
Danger of life and damage to property through inadequate degree
of protection!
Therefore, you must observe the information provided in the indi-
vidual sections applicable to the installation and assembly.
DANGER
Danger of injuries and damage to property through inappropriate
installation!
When installing the products and their wiring as well as their con-
trol elements, it must be ensured that they are sufficiently pro-
tected against inadvertent operation or contact.
CAUTION
Short-circuits!
When drilling or cutting holes into switch cabinets, burr may get
inside previously installed modules. Furthermore, when connect-
ing cooling water lines water may leak into modules.
The possibility of short-circuits and destruction of the systems
cannot be entirely ruled out.
Therefore, all affected modules should be well partitioned prior to
all work! Non-compliance will result in the extinction of any war-
ranty claims.

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Safety Instructions
1.7 Electrical Connection
DANGER
Danger of life through inappropriate EMERGENCY-STOP devices!
EMERGENCY-STOP devices must be active and within reach in all
system modes. Releasing an EMERGENCY-STOP device must not
result in an uncontrolled restart of the system! First check the
EMERGENCY-STOP chain before switching on!
DANGER
Danger of life caused by EMERGENCY-STOP devices that are not
located within the operator’s reach!
The ”BT6.00 HPG” ”manual programming terminal” may only be
operated at machinery equipped with a permanently installed con-
trol station and an EMERGENCY-STOP device! The EMERGENCY-
STOP device of the control station must be within reach at all times
so that it can be operated in the event of possible faults.
Therefore, it is not permitted to use extension cables between the
control station and the BT6.00 HPG!
CAUTION
All connection or signal leads must be routed so as to prevent neg-
ative effects on device functions through capacitive or inductive
interference!
In long cables, interference is frequently injected and removed.
Power lines and control cables should be routed separately. The
influence of interfering lines on lines susceptible to interference
can be minimized by observing the following distances:
> 100 mm with parallel installation of cables < 10m,
> 250 mm with parallel installation of cables > 10m.
The product should be mounted close to the welding systems so
as to avoid cable lengths of more than 25 m.
LPlease also note all the safety instructions relevant for electrical connec-
tion and for ensuring EMC of the entire system that have been provided
in the manuals for the individual power unit used.
LIt must be ensured that all contact areas are bare, i.e. free from paint,
plastic coats and dirt/oxidation.

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Safety Instructions
1.8 Operating the product
DANGER
One has to expect that magnetic fields are present in the vicinity
of resistance welding systems, which are above the limits speci-
fied in VDE 0848 Part 4. In particular, the limits for extremities can
be exceeded if manual guns are used.
In cases of doubt, please measure the field strength and provide
additional measures to ensure health and safety at work. Please
note the Instructions BGV B11, “Accident prevention regulation
relating to electromagnetic fields” issued by the Berufsgenos-
senschaft (employers’ third party liability insurance association).
DANGER
Due to the strong magnetic fields arising from resistance welding,
the function of cardiac pacemakers may be disturbed. This may
cause the death or considerable health damages!
Therefore, these persons should avoid the welding system.
We recommend posting a warning to DIN 40023 at all entrances to
factory halls containing resistance welding equipment:
No entry for persons with cardiac
pacemakers!
Danger!
DANGER
Danger of injuries and damage to property through operation of
units outside their intended cabinets!
The units are designed to be installed in housings or switch cabi-
nets and must not be operated unless they have been installed in
such housings and with the cabinet door closed!

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Safety Instructions
DANGER
Danger of bruises and of being caught by electrode and/or work-
piece movements!
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
safety regulations are complied with.
For example, by means of ”Two-handed start”, fences, light barri-
ers etc. the risk of bruises can be considerably reduced.
CAUTION
Danger of overheating in the event of incorrect or insufficient cool
ing.
The temperature inside the housing must be within the specified
limits.
1.9 Retrofits and modifications by the operator
DANGER
Any changes made to the product may endanger the safety of the
unit!
The possible consequences include death, severe or light injury
(personal injury), damage to property or environmental hazards.
Therefore, you should contact us before performing any intended
changes. This is the only way to find out whether or not changes
can be made safely.

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Safety Instructions
1.10 Maintenance, repair
DANGEROUS ELECTRICAL VOLTAGE
Unless described otherwise, maintenance works must be
performed on inactive systems that have been sufficiently
protected against reclosing!
Measuring or test activities that might be necessary on the live
system are reserved to qualified electrical personnel!
DANGER
Lithium batteries may cause causticization or explode if not han-
dled properly!
Therefore, do not open batteries by force, do not recharge or heat
them above 100 degrees Centigrade!
CAUTION
Only spare parts approved by us may be used!
Only use original replacement batteries ! In any case, spent batter-
ies and accumulators should be disposed of as hazardous waste!
CAUTION
Observe all precautions for ESD protection when handling mod-
ules and components! Avoid electrostatic discharge!
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.
DWhen ESD-sensitive components are installed in or removed from
equipment, the equipment must be de-energized.

1−12 Electric Drives
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Safety Instructions
1.11 Safe working practices
DANGER
Program start is immediately possible after fault reset!
If the start signal is present when an error is reset (acknowledged),
the timer will start its program run immediately! This may result in
dangerous machine movements!
Therefore, prior to error-reset, make sure that there is no-one in
the hazard area of the welding equipment!
DANGER
Danger of welding splashes!
Welding splashes have to be expected during operation of the
welding plant! This may result in eye injuries and burns. Therefore
−wear protective goggles
−wear safety gloves
−wear flame-retardant clothes
DANGER
Danger of injuries at sharp metal edges and danger of getting
burnt by hot welded parts!
Therefore, you should wear safety gloves.
CAUTION
Strong magnetic fields!
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 work-
ing in the immediate vicinity of the welding equipment.

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Safety Instructions
1.12 CE Marking
CAUTION
The CE mark for the described combination of devices is applica
ble for use in industrial environments.
For other combinations/applications, the certificate must be de-
rived from the above requirements, or a new certificate must be is-
sued, if necessary. This is the responsibility of the line supplier/
user.
The product described corresponds to an application variant
which is not covered by the provisions concerning end user prod
ucts, machines or systems based on its very nature. Therefore, it
may only be operated as described above.
The evaluation of the electrical and mechanical safety, the envi-
ronmental influences (foreign bodies, moisture) must be carried
out on the final product in encased state.
When installed in an enclosure, the EMC properties of this product
may be subject to change. For this reason, the final product (end-
user device, machine, systems) should be subjected to a verifica-
tion of its EMC characteristics by the end product manufacturer.

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Safety Instructions
1.13 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 trademark of Phoenix Contact.
DeviceNetris a registered trademark (TM) of ODVA (Open DeviceNet
Vendor Association, Inc.).

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Overview
2 Overview
This manual contains information on
Dthe mechanics
Dthe electrical connection and
Dthe functions of the control and diagnostic terminal
−BT 6.00 (built-in terminal) and
−BT 6.00 HPG (manual programming terminal).
CAUTION
Danger of malfunctions and damage!
Wrong installation, faulty connection or improper operation can
lead to unexpected or wrong unit reactions and hence to hazard-
ous situations at the welding station.
So please respect the details in the present manual.
The BT 6.00 is a stationary or portable control and diagnostic terminal for
your weld timer and can be used in connection with the PS 5000 and
PS 6000 series of weld timers.
It is intended for
Dstationary (e.g. in the control panel of the welding station), for hard-
ware, refer to Section 3.1 from page 3−1), or
Dmobile operation (for hardware, refer to Sect. 3.2 from page 3−7).
The BT 6.00 supports the following functions:
DDisplay and reset of all faults currently active in the timer
DDisplay and change of important welding and process data.
.The BT 6.00 has been designed for the display and parameter
setting of production-specific data, because access to the com-
plete range of timer functions is not necessary during normal
operation.
If you need to access all available programming and parameter in-
put features of the weld timer, you should use a PC with the ”BOS”
welding software installed.
The operation of the BT 6.00 is described in section 4.

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Overview
Notes: