Bosch PST 6101.321 Manual

PST 6101.321 / PSI 6101.321
Technical Information
PSX 6000
101
Edition
Description of Timer and I/O Level

PSX 6000 Description of Timer and I/O Level
PST 6101.321 / PSI 6101.321
Technical Information
1070 080 056-101 (99.09) GB
DIN ISO 9001
Reg. no. 16149-01/2
E1999
This manual is the exclusive property of ROBERT BOSCH GMBH,
also in the case of Intellectual Property Right applications.
Without their consent it may not be reproduced or given to third parties.
Discretionary charge DM 20.--

Contents
PST 6101.321 / PSI 6101.321
I
1070 080 056-101 (99.09) GB
Contents
Page
Safety instructions and reader’s information V
Explanation of pictographs and symbols V. . . . . . . . . . . . . . . . . . .
Typographic conventions VII. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proper use VII. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning of magnetic fields VIII. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not permitted for persons with cardiac pacemakers IX. . . . . . . . . .
Qualified personnel X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage and Transport XI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and assembly XII. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical connection XIII. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation XIV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retrofits and modifications by the user XVI. . . . . . . . . . . . . . . . . . . . .
Maintenance and repair XVII. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 System 1-1. . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 General 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Block diagram of timer 1-5. . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Programming and operating the timer 1-6. . . . . . . . . . . . .
2 Technical data 2-1. . . . . . . . . . . . . . . . . . .
2.1 Welding timers 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Power unit 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Hardware 3-1. . . . . . . . . . . . . . . . . . . . . . . .
3.1 Structure 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Module front panel without type-specific I/O system 3-2.
3.3 Module front panel type-specific I/O’s 3-5. . . . . . . . . . . . .

Contents PST 6101.321 / PSI 6101.321
II 1070 080 056-101 (99.09) GB
Page
4 Installation 4-1. . . . . . . . . . . . . . . . . . . . . .
5 Cables 5-1. . . . . . . . . . . . . . . . . . . . . . . . . .
6 Suppression of RF noise 6-1. . . . . . . . .
7 Electrical connection 7-1. . . . . . . . . . . . .
7.1 Interfaces 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Programming terminal X1 7-3. . . . . . . . . . . . . . . . . . . . . . . .
7.1.2 Pressure X2 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3 KSR sensor (Toroid) X3 7-5. . . . . . . . . . . . . . . . . . . . . . . . .
7.1.4 Power supply X4 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.5 External device X5 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.6 Stop circuit 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.7 Synchronization voltage (only with PST) 7-6. . . . . . . . . . .
7.2 Power supply 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1 Internal power supply 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2 External power supply 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 I/O functions 7-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1 Serial inputs 7-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 Serial outputs 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3 Parallel outputs 7-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Control diagrams 8-1. . . . . . . . . . . . . . . .

Contents
PST 6101.321 / PSI 6101.321
III
1070 080 056-101 (99.09) GB
Page
9 Commissioning 9-1. . . . . . . . . . . . . . . . . .
9.1 Preparations 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Testing the welding program 9-3. . . . . . . . . . . . . . . . . . . . .
9.2.1 Suggestions for a welding test 9-4. . . . . . . . . . . . . . . . . . . .
9.3 Basic-Setup 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4 Welding Parameters 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 Scaling process 9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6 Adjusting the program to your welding task 9-8. . . . . . . . .
9.7 Activating Stepper (electrode maintenance) 9-8. . . . . . . .
9.8 Activating monitoring 9-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.9 Other adjustments and programs 9-9. . . . . . . . . . . . . . . . .
9.10 Saving the Welding Parameters 9-10. . . . . . . . . . . . . . . . . .
10 Messages 10-1. . . . . . . . . . . . . . . . . . . . . . .
10.1 Fault and Status Messages 10-1. . . . . . . . . . . . . . . . . . . . . .
10.2 Ranges of Messages 10-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.1 [A] - Communication Messages 10-2. . . . . . . . . . . . . . . . . . .
10.2.2 [B] - Electrode (Stepper) Messages 10-3. . . . . . . . . . . . . . .
10.2.3 [C] - Messages Concerning the Timer Status 10-3. . . . . . .
10.2.4 [D] - Messages for Current and Weld Time Monitoring 10-4
11 Maintenance 11-1. . . . . . . . . . . . . . . . . . . . .
11.1 Changing batteries 11-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Ordering 12-1. . . . . . . . . . . . . . . . . . . . . . . .
A Annex A-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Abbreviations, Terms A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Regulation terms A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3 Index A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents PST 6101.321 / PSI 6101.321
IV 1070 080 056-101 (99.09) GB
Your notes:

Automationstechnik
Safety instructions and reader’s information
V
1070 080 056-101 (99.09) GB
Safety instructions and reader’s information
Please read this documentation before working with the Weld Timer (WT) PSI 6101.321 /
PST 6101.321 for the first time.
Store this manual in a place to which all users have access at all times!
The products described have been developed, manufactured, tested and documented in
compliance with the fundamental safety requirements of the EU Machine Directive.
Nevertheless, there is some residual risk!
The contents of this manual refer to the functions of the
- timer modules PSI 6101.321 / PST 6101.321
- I/O level
Explanation of pictographs and symbols
The following warnings and notes may be attached to the individual hardware compo-
nents which are designed to inform the user of certain circumstances.
Warning of dangerous electrical voltage!
Components sensitive to electrostatic discharge!
Disconnect from mains before opening!
Pin for connecting PE conductor only!
Connection of shield conductor only!

Automationstechnik
Safety instructions and reader’s information
VI 1070 080 056-101 (99.09) GB
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. CAUTION
3. NOTE
WARNING!
The term WARNING will be used wherever danger is imminent.
The possible consequences may be death or severe injury (personal injury).
CAUTION!
The term CAUTION will be used wherever a dangerous situation is possible.
The possible consequences include death, severe or light injury (personal injury) dam-
age to property (destruction of modules) or environmental hazards.
In any case, the failure to observe/comply with these instructions will result in the loss of
guaranty.
NOTE
The term NOTE will be used for making recommendations on the use. These sections
contain additional information, recommendations, hints and tips.
Non-compliance with these recommendations may result in damage to property, e.g. to
the machine or the workpiece.
!
!

Automationstechnik
Safety instructions and reader’s information
VII
1070 080 056-101 (99.09) GB
Typographic conventions
General listing - Example: - The message is
displayed on the
screen.
Action DExample: DInsert floppy
DRead value
Screen displays, Italics Example: Battery-Low
messages, displays Tip dress request
(Welding) parameters [in brackets] Example: [Weld time],
[Schedule].
Interface signals, keys, <key> Example: Press <F8>
command fields.
Inputs: Values, texts CAPITAL LETTERS
NOTE
Note concerning this manual: Black bars in the margin of a page indicate modifications
compared to the previous edition.
Proper use
The present manual contains information on the proper use of the weld timer types PSI
6101.321 / PST 6101.321.
In connection with the specified welding equipment, the weld timers type PSI 6101.321 /
PST 6101.321
-serve for resistance welding of metals
-are suitable for operation in industrial environments in accordance with
DIN EN 50082-2 and 50081-2 concerning electromagnetic compatibility
(EMC).
The timers are not intended for any other use!
CAUTION!
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 workpiece to be welded or environ-
mental hazards.
Therefore, our products should only be used for their intended purpose!
!