Bosch Rexroth BOS 6000 User manual

Rexroth BOS 6000 4
dition 01
Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly TechnologiesHydraulics

| 1070087074 / 01BOS 6000
Electric Drives
and Controls
Bosch Rexroth GmbH | Rexroth BOS 6000
User Manual
DOK-PS6000-BOS6000****-AW01-EN-P
The content of this manual refers to
• the structure and the functionality
of the BOS 6000 user interface.
Previous editions Release
Date Notes
DOK-PS6000-BOS6000****-AW01-EN-P 06.2006
© Bosch Rexroth Electric Drives and Controls GmbH, 2006
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 data specified above only serve to describe the product. No
statements concerning a certain condition or suitability for a certain
application can be derived from our information. The given
information does not release the user from the obligation of own
judgement and verification. It must be remembered that our
products are subject to a natural process of wear and aging.
Bosch Rexroth Electric Drives and Controls GmbH
Postfach 11 62
D-64701 Erbach
Berliner Straße 25
D-64711 Erbach
Tel.: [phone]
Fax: [phone]
Abt.: BRC/PAW1
Title
Type of Documentation
Document Typecode
Purpose of Documentation
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Contents
1070087074 / 01 | BOS 6000 Electric Drives
and Controls| Bosch Rexroth GmbH iii
ContentsThe BOS 6000 Help System................................................9
Software version.........................................................................9
Activating Help.........................................................................10
Description of the symbols in the menu lines...........................11
Show (Unhide)/Hide.............................................................11
Previous (Back)...................................................................11
Next.....................................................................................11
Start page (Home)...............................................................11
Print.....................................................................................11
Show Contents (structure) view...............................................12
Keyword search........................................................................12
Text search...............................................................................13
Use favorites............................................................................14
Including topics in the Favorites list.....................................14
Displaying the topics in the Favorites list.............................14
Deleting topics from the Favorites list..................................15
Renaming the topics in the Favorites list.............................15
Safety Instructions ............................................................17
Why” and “What for”?...............................................................17
Symbols used...........................................................................18
Proper use................................................................................19
Qualified personnel..................................................................20
Safe working practices.............................................................21
Trademarks, copyright..............................................................22
Getting to know the BOS 6000 user interface.................23
Basics.......................................................................................23
Overview of the interface structure...........................................24
Meaning of important icons......................................................26
Functions in the menu line .......................................................28
File | Para. data import/export | Export …............................28
File | Para. data import/export | Import …............................28
File | Exit..............................................................................28
Edit | Programming..............................................................28
Edit | Diagnosis....................................................................28
Edit | Setup..........................................................................29
Edit | Correction...................................................................29
Edit | Oscilloscope function..................................................29
Edit | Export record set........................................................29
Edit | Autobackup.................................................................29

Contents | 1070087074 / 01BOS 6000
Electric Drives
and Controls
Bosch Rexroth GmbH |iv Edit | Timer change..............................................................29
Edit | Copy...........................................................................29
Edit | Firmware changing.....................................................29
Edit | Login...........................................................................29
Language.............................................................................29
Functions | Timer reference.................................................30
Functions | Spot reference...................................................30
Functions | Prewarning........................................................30
Functions | Error table.........................................................30
Functions | Network overview..............................................30
Functions | Protocol.............................................................30
Functions | Compare...........................................................30
Functions | Parameter overview..........................................30
Functions | Rights administration.........................................30
Help | Help...........................................................................30
Help | About.........................................................................30
The available windows.............................................................31
Login....................................................................................31
Timer Reference..................................................................32
Add/ChangeTimer................................................................35
Connection set-up................................................................38
Programming.......................................................................41
Programming: Schedule......................................................42
Programming: Seq. Pg.2 .....................................................55
Programming: Stepper.........................................................61
Programming: General........................................................72
Programming: Electrode......................................................80
Programming: Thyristor-Unit-Parameter..............................93
Diagnosis.............................................................................96
Diagnosis: Diagnostics I/O...................................................97
Diagnosis: Users Diagnostics I/O......................................100
Diagnosis: Start Simulation................................................101
Diagnosis: Timer-Information.............................................104
Diagnosis: Last Weld.........................................................106
Setup.................................................................................107
Setup: Stepper curves.......................................................108
Setup: Tipdress curves......................................................110
Setup: Fault-Setup.............................................................111
Setup: Communication ......................................................112
Correction..........................................................................116
Correction: Correction........................................................117
Spot Reference..................................................................119
Prewarning.........................................................................121
Error table..........................................................................123
Network overview..............................................................125
Protocol..............................................................................127
Compare............................................................................131
Parameter Overview..........................................................133
Set Access Level...............................................................134
FTP-Upload.......................................................................134
Backup...............................................................................136
Restore..............................................................................136
Autobackup........................................................................137

Contents
1070087074 / 01 | BOS 6000 Electric Drives
and Controls| Bosch Rexroth GmbH v
Timer change.....................................................................139
Copy..................................................................................140
Firmware change...............................................................141
Para.-Data Import/Export (Parameter-Backup).................143
Para.-Data Import/Export (Parameter-Restore).................144
Set Counter........................................................................145
Current calibration.............................................................146
Force calibration................................................................147
Corresponding Programs...................................................148
Spot Comment...................................................................149
Detail Info...........................................................................150
How to …..........................................................................153
Exit BOS 6000........................................................................153
Log in timers to BOS 6000.....................................................153
Delete timers from BOS 6000 ................................................154
Change the communication data of logged-in timers.............155
Export Timer Reference.........................................................156
Import Timer Reference.........................................................156
Print Timer Reference............................................................156
Copy Timer Data....................................................................157
Export timer data (backup).....................................................158
Restore Timer data (download)..............................................159
Compare Timer Data..............................................................160
Influence data comparison at program start...........................162
Define access levels for individual objects.............................163
Copy the contents of a numerical input field..........................165
Sort tables..............................................................................166
Filter tables.............................................................................166
Show / Print / Export logs.......................................................167
Change parameters and transfer to timer ..............................169
Export spot reference.............................................................171
Export spot reference to an Excel file.....................................171
Import spot reference.............................................................171
Print spot reference................................................................172
Compare spot reference.........................................................172
Enter/change spot references................................................172
Display spot comments..........................................................172
Delete spot references...........................................................173
Show electrode status............................................................173
Confirm electrode change......................................................174
Set electrode counter.............................................................175
Export parameter data to ASCII file........................................175
Import parameter data from ASCII file....................................176
Replace a defective timer.......................................................177
Upgrade the timer firmware....................................................179
Reset faults ............................................................................181
Add fault information ..............................................................183
Perform current calibration.....................................................184
Perform force calibration........................................................187

Contents | 1070087074 / 01BOS 6000
Electric Drives
and Controls
Bosch Rexroth GmbH |vi Fault messages...............................................................191
Stop / No 24V.........................................................................191
Stop circuit closed..................................................................191
Weld without Command.........................................................192
Control stop............................................................................192
Power-Unit not ready..............................................................192
External Over-Temperature....................................................193
Cooling temperature too high.................................................193
Transformer temp too high.....................................................193
Battery-Low............................................................................194
Memory deleted......................................................................194
Data download started ...........................................................194
No schedule programmed......................................................194
Hardware Fault.......................................................................195
I/O-Bus Fault..........................................................................196
Half-Cycle Monitoring.............................................................196
Circuit Breaker Off..................................................................196
Sync / Power Fault.................................................................196
Synchronization OK................................................................197
Start Inhibited.........................................................................197
Sequence externally cancelled...............................................197
Program Parity Fault..............................................................197
24V off/to low..........................................................................198
Supply Voltage Fault..............................................................198
Timer switched on..................................................................198
Power voltage to high.............................................................198
Power voltage off/to low.........................................................199
Power voltage off/to low receipt.............................................199
No Weld external....................................................................199
Weld external.........................................................................200
No Weld internal.....................................................................200
Weld internal..........................................................................200
With stroke, with weld.............................................................200
No stroke, no weld..................................................................200
%I too large/Force/Pressure too high/PHA is too high...........200
Extend stepping request.........................................................201
Extended electrode life Near End of Stepper.........................201
End of stepper........................................................................201
End of stepper........................................................................202
Electrode changed.................................................................202
Stepper exceed......................................................................202
Prewarning reached...............................................................202
Dress-Request reached.........................................................202
Dressing necessary................................................................203
Max. number of spots welded before dressing.......................203
Electrode dressed..................................................................203
Tipdress prewarning...............................................................203
Electrode life tipdress.............................................................203
Cutter blade changed.............................................................204
Cutter1: Cutter not running.....................................................204
Cutter1: Dressing process aborted.........................................204
Cutter1: Max. mill duration exceeded.....................................204

Contents
1070087074 / 01 | BOS 6000 Electric Drives
and Controls| Bosch Rexroth GmbH vii
Cutter1: Temperature fault.....................................................204
Cutter1: Motor protection trip..................................................205
Cutter1: Emergency-Stop.......................................................205
Cutter2: Cutter not running.....................................................205
Cutter2: Dressing process aborted.........................................205
Cutter2: Max. mill duration exceeded.....................................205
Cutter2: Temperature fault.....................................................206
Cutter2: Motor protection trip..................................................206
Cutter2: Emergency-Stop.......................................................206
Phase Angle prewarning reached..........................................206
Maximum Phase Angle Reached...........................................206
Secondary monitoring circuit is open .....................................207
Secondary monitoring circuit is shorted.................................207
Termination of Weld / no current............................................207
No voltage 1.HW....................................................................208
Primary Voltage Measuring Fault - KUR Mode......................208
Reweld By Timer Active.........................................................208
Inhibit Monitoring Mode Active...............................................208
No Weld..................................................................................208
Without regulation, without monitoring...................................209
No current …..........................................................................209
Low Current ….......................................................................209
Over Current …......................................................................209
Low Current-series of welds-…..............................................210
Current measurement range exceeded ….............................210
Weld time too short …............................................................210
Weld time too long ….............................................................211
Diode Over Current................................................................211
Diode defect...........................................................................211
Overcurrent or Earth-fault.......................................................212
Max. primary current reached................................................212
Driver-Fault.............................................................................213
No weld contactor enable.......................................................213
Isolation contactor feedback fault...........................................213
No Weld Enable or Weld Pressure Input Gun 1.....................213
No Weld Enable or Weld Pressure Input Gun 2.....................213
No Water Flow Gun 1.............................................................214
No Water Flow Gun 2.............................................................214
Weld Contactor Gun 1 Open..................................................214
Weld Contactor Gun 2 Open..................................................214
Weld Contactor Gun 1 Did Not Open.....................................214
Weld Contactor Gun 2 Did Not Open.....................................214
Monitor contact open..............................................................215
Mains Power Balance Monitoring Activated...........................215
Mains Power Balance Monitoring Ok.....................................215
Auxiliary contactor monitor.....................................................215
Fault-Reset.............................................................................216
Welding-Fault Reset...............................................................216
Slave error..............................................................................216
Current Measurement Range Exceeded................................216
Scaling: Communication error................................................216
Scaling: no valid measuring value received...........................217
Scaling: no measuring value received....................................217

Contents | 1070087074 / 01BOS 6000
Electric Drives
and Controls
Bosch Rexroth GmbH |viii Scaling: protocol fault.............................................................217
Scaling: wrong mode..............................................................217
Scaling: Sequence aborted....................................................218
Scaling: current out of range..................................................218
Scaling: Diff. primary / secondary current too large ...............218
Scaling: result invalid..............................................................219
Force monitoring: time too long..............................................219
Force monitoring: time too short.............................................219
Force monitoring: Force/Pressure too high............................219
Force monitoring: Force/Pressure too low.............................220
Error US measurement..........................................................220
Error US control loop..............................................................220
PSQ Sequence Cancelled......................................................221
USP not calculated.................................................................221
USP too high..........................................................................221
USP too low............................................................................221
spot repetition with US...........................................................221
PSQ hardware fault................................................................222
PSQ internal communication error.........................................222
PSQ temperature too high......................................................222
USP temperature too high......................................................222
USP hardware fault................................................................223
PSQ watchdog fault................................................................223
PSQ not available...................................................................223
PSQ sequence error...............................................................223
USP communication error......................................................223
US measuring loop fault.........................................................224
PSQ memory deleted.............................................................224
PSQ ok...................................................................................224
Glossary...........................................................................225
Index.................................................................................235

The BOS 6000 Help System
1070087074 / 01 | BOS 6000 Electric Drives
and Controls| Bosch Rexroth GmbH 9
The BOS 6000 Help System
In this chapter, you will find basic information concerning the BOS
6000 Help system.
Software versio n Help version: 2.0 (10.05.2005)
Valid as of BOS software version: 1.14.5 (20.12.2004)
Note: For more information on BOS:
FileReadme.chm
(Directory "Bosch Rexroth AG"):
System requirements, installation, update or removal of
the software.
FileHistory.htm (English) or
fileHistory_GER.htm (German)
(Directory "Bosch Rexroth AG"):
Modification history of the individual BOS versions.
via menu itemHelp | About…:
Part numbers, version data
Copyright 2002-2006.
All rights reserved, including applications for protective rights.

The BOS 6000 Help System | 1070087074 / 01BOS 6000
Electric Drives
and Controls
Bosch Rexroth GmbH |10 Reproduction or distribution by any means subject to our prior
written permission.
All information is provided for reference only and is subject to
change at any time. No liability is accepted.
Activating Help The Help system can be activated in different ways:
• via Help menu item in a BOS 6000 window
• via Help command button (if available and not dimmed)
• via F1 butto n if any window of the BOS 6000 interface is active.
Note: In many areas, the Help is “context-sensitive“. That
means that the current system status (active window,
input field below mouse pointer) is detected and a
suitable help topic is called up when Help is invoked by
pressingF1.
The Help window displayed is divided into 3 major areas:
• top: Menu line.
Here, you may choose various Help functions.
• left: Display area for the following functions:
Show Contents (structure), Keyword search, Text search and
Use favorites.
• right: Field for displaying the contents of the subjects.

The BOS 6000 Help System
1070087074 / 01 | BOS 6000 Electric Drives
and Controls| Bosch Rexroth GmbH 11
Descrip tion of the symbols in th e menu lines
The following functions/icons are offered in the menu line of the
Help window:
Show (Unhide)/Hide • Shows or hides the left window area containing the “Content”,
“Index”, “Find” and “Favorites” tabs.
Previous (Back) • While you navigate through the Help topics, the system
remembers all topics viewed in the order they have been called.
Previous (Back) jumps back one position towards the
beginning of the navigation path.
Next • If Previous (Back) has been pressed at least once,Next jumps
forward one position towards the end of the navigation path.
Start page (Home) • Jumps directly to the first Help topic.
Print • Opens the ”Print help topics” window.
You can choose whether you only want to print the current Help
topic or its sub-topics as well (if existent). Then you confirm
your choice by pressingOK and follow your computer’s print
dialog.

The BOS 6000 Help System | 1070087074 / 01BOS 6000
Electric Drives
and Controls
Bosch Rexroth GmbH |12Show Contents (structure) view
In the left window area, you can view the structure of all available
Help topics.
1. If the left window area does not appear, you can show it using
theShow (Unhide)menu line symbol.
2. Click on the “Content” tab in the left window area.
The available Help topics are shown in a tree structure. By
clicking on a Help topic, the system displays the description
relating to the contents.
Note: Book symbols represent a topic with sub-topics. To
show/hide sub-topics, you simply have to double-click on
the book symbol.
Note: To fully extend the structure tree or to close the
branches except the main topics, move the mouse
pointer to the left window area, press the right mouse
button and then select “Open all” or “Close all” in the
pop-up menu appearing.
Keyword search1. If the left window area does not appear, you can show it using
theShow (Unhide) menu line symbol.
2. Click on the “Index” tab in the left window area.
All keywords are listed in alpha-numerical order in the
keywords list. The description relating to the topic can be
displayed by double-clicking on an index entry.
3. For searching, enter the desired term in the “Find keyword“
field.
After each character input, the system will select a
corresponding keyword from the index list. For this purpose, it
compares the string entered to the available index entries. If no
exact entry match is found, the system will choose the lower
next keyword from the list according to the sort sequence.
4. Click on theShow (View) command button to view the
relevant description.

The BOS 6000 Help System
1070087074 / 01 | BOS 6000 Electric Drives
and Controls| Bosch Rexroth GmbH 13
Text search 1. If the left window area does not appear, you can show it using
theShow (Unhide) menu line symbol.
2. Click on the “Find” tab in the left window area.
3. For searching, enter the desired term(s) in the “Find term“ field.
If necessary, you may use the wildcard character “*” for any
possible string. The individual search terms can be logically
combined by the AND, OR, NEAR, NOT operators and the
bracket symbols “(“ and “)”. The search itself is not case-
sensitive, however, the operators have to be written in capital
letters.
Example: The query “help AND (version NOT 2003)” will find
all topics containing both the terms “help” and “version”, but not
“2003”.
4. Use the check boxes in the lower left part of the window to
define the desired search scope.
5. Click on theList topics command button to list all topics that
match the query. Now, the relevant topics can be displayed by
double-clicking on a list entry or by clicking on theShow
(View) command button after having selected a topic.

The BOS 6000 Help System | 1070087074 / 01BOS 6000
Electric Drives
and Controls
Bosch Rexroth GmbH |14Use favori tes Topics that are frequently needed or especially important can be
included in the permanent Favorites list that is listed in alpha-
numerical order (and can even be given a different name there!).
Thus, after closing and re-opening the Help function, the topics of
interest are immediately displayed again.
Including topics in the Favorite s list
1. If the left window area does not appear, you can show it using
theShow (Unhide) menu line symbol.
2. Use the functions "Contents (structure)", "Keyword search",
"Text search" or "Use favorites" in order to display the relevant
contents.
3. Click on the “Favorites” tab in the left window area.
In the lower left display area, the system will enter the name of
the topic in the “Current topic” field.
4. If desired, you can change the topic name according to your
requirements. The topics displayed can be included in the
Favorites list under the name displayed by clicking on the Add
command button.
Note: Alternative to Add command button:
• Right mouse click in Favorites list
• Select menu item ”Add”.
Displaying t he topics in the Favorites list
1. If the left window area does not appear, you can show it using
theShow (Unhide) menu line symbol.
2. Click on the “Favorites” tab in the left window area.
3. If there are any entries in the list, you can display the relevant
topics by double-clicking on a list entry or by clicking on the
Show (View) command button after having selected a topic.
Note: Alternative toShow (View)command button:
• Right-click on the desired topic in the Favorites list
• Select menu item ”Show (View)”.

The BOS 6000 Help System
1070087074 / 01 | BOS 6000 Electric Drives
and Controls| Bosch Rexroth GmbH 15
Deleting topics fr om the Favorites list
1. If the left window area does not appear, you can show it using
theShow (Unhide) menu line symbol.
2. Click on the “Favorites” tab in the left window area.
3. Select the relevant list entry and click on theRemove
command button to delete the entry.
Note: Alternative toRemovecommand button:
• Right-click on the desired topic in the Favorites list
• Select menu item ”Remove”.
Renaming the topics in the Favorites list
1. If the left window area does not appear, you can show it using
theShow (Unhide) menu line symbol.
2. Click on the “Favorites” tab in the left window area.
3. Right-click to select the relevant topic and select the “Rename”
menu item
4. Enter the new name for the topic.
5. Acknowledge the new topic name with the Enter key.
Note: Renaming can be canceled by hitting theEsc key.

The BOS 6000 Help System | 1070087074 / 01BOS 6000
Electric Drives
and Controls
Bosch Rexroth GmbH |16

Safety Instructions
1070087074 / 01 | BOS 6000 Electric Drives
and Controls| Bosch Rexroth GmbH 17
Safety Instructions
This section contains important safety-related information.
Why” and “ What for”?
The products described were developed, manufactured and tested
in compliance with the fundamental safety requirements of the EU
machinery directive. These products pose no danger to persons or
property if they are used in accordance with the handling
stipulations and safety notes prescribed for their configuration,
mounting, and proper operation.
Nevertheless, there still is som e residual risk!
 Please note the information provided in the previous section in
this context!
The present information refers to the
• Functionality of the BOS 6000, the “Welding User Interface”.
Information concerning
• the mechanical construction
• the electrical connection (24V supply and I/O) and
• the functionality
of the hardware addressable via BOS is described more in detail in
the relevant manuals. There, you will also find safety information
that is important for product handling. Store this documentation in
a place to which all users have access at any time!
 You should know and understand the issues at stake before
installing, connecting or commissioning the products or
programming the system.
 In case of uncertainty, you should always contact your
supervisor!

Safety Instructions | 1070087074 / 01BOS 6000
Electric Drives
and Controls
Bosch Rexroth GmbH |18Symbol s used DANGER This symbol is used wherever insufficient or lacking
compliance with instructions may result inpersonal
injury.
CAUTION This symbol is used wherever insufficient or
lacking compliance with instructions may result in
damage to pro perty .
Note: This symbol is used to draw the user’sattentionto
special circumstances.
 This symbol indicates that youhave to do something orhave
to create certain conditions. If a special order has to be
observed, the relevant paragraph will start with a serial number
instead of an arrow.

Safety Instructions
1070087074 / 01 | BOS 6000 Electric Drives
and Controls| Bosch Rexroth GmbH 19
Proper use Ourweld timers
• serve for resistance welding of metals in connection with a
welding transformer and the appropriate power unit, and
• are suitable for operation in industrial environments in
accordance with the following standards: EN 50178, EN 60204-
1, EN 50081-2, EN 50082-2.
In residential environments, in trade and commerce as well as
small enterprises, class A equipment may only be used if it
does not inadmissibly interfere with other equipment.
TheBOS 6000 user interface described here serves for
• Operation and
• Parameter input
of weld timers of the PSS 5000 and PSx 6000 series.
Any other application is deemed improper use!
DANGER The consequences of an improper use include
personal damages of the user or of third parties as
well as damages to property – the technical
equipment, the workpiece to be processed, or
environmental hazards.
Therefore, our products should only be used for
their intended purpose!
Note: For operating the hardware in residential environments,
in trade and commercial applications and small
enterprises, an individual permit of the national 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, erection and installation as well as careful
operation.

Safety Instructions | 1070087074 / 01BOS 6000
Electric Drives
and Controls
Bosch Rexroth GmbH |20Qualified personnel The present documentation is designed for specifically trained
engineers with special knowledge of the welding technology. They
must have sound knowledge of the software and hardware
components of the weld timers, the power units used, and the
welding transformers.
Project engineering, programming, start and operation as well as
the modification of program parameters is reserved to properly
trained personnel! This personnel must be able to judge potential
hazards arising from programming, program changes and in
general from the mechanical, electrical, or electronic equipment.
Such personnel are
• those who, being well trained and experienced in their field and
familiar with the relevant norms, are able to analyze the jobs
being carried out and recognize any hazards which may have
arisen
• those who have acquired the same amount of expert knowledge
through years of experience that would normally be acquired
through formal technical training.
DANGER Risks for persons with c ardiac 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.
Please note our comprehensive range of training courses. Please
refer tohttp://www.boschrexroth.com for the latest information on
training courses, teachware and training systems.
Our Erbach Didactic Center will be pleased to provide you with
further information,
telephone: (+49) (0) 60 62 78 600.