Bosch WT PSI 6 Series Manual

PSI 6XXX.190 W1
Technical Information
PSI 6000
101
Edition
Description of Timer and I/O Level

PSI 6000 Description of Timer and I/O Level
PSI 6XXX.190 W1
Technical Information
1070 080 086-101 (01.01) GB
DIN ISO 9001
Reg. no. 16149-01/2
E2001
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
PSI 6XXX.190 W1
I
1070 080 086-101 (01.01) 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 1-4. . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Programming and operating the timer 1-5. . . . . . . . . . . . .
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/Os 3-5. . . . . . . . . . . . . .

Contents PSI 6XXX.190 W1
II 1070 080 086-101 (01.01) 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 Transformer temperature X3 7-6. . . . . . . . . . . . . . . . . . . . .
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 DC link voltage 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Power supply 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1 Internal power supply 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2 External power supply 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 I/O functions 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1 Parallel inputs 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 Parallel outputs 7-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Control diagrams 8-1. . . . . . . . . . . . . . . .
9 BOS-5000 9-1. . . . . . . . . . . . . . . . . . . . . . .
9.1 Programming the Basic-Setup 9-1. . . . . . . . . . . . . . . . . . . .
9.2 Programming the Welding Parameters 9-3. . . . . . . . . . . .
9.3 Input ranges of the Welding Parameters 9-5. . . . . . . . . . .
9.4 Determining the actual values 9-6. . . . . . . . . . . . . . . . . . . .
9.5 Current monitoring in the block programs 9-6. . . . . . . . . .

Contents
PSI 6XXX.190 W1
III
1070 080 086-101 (01.01) GB
Page
10 Commissioning 10-1. . . . . . . . . . . . . . . . . .
10.1 Preparations 10-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Testing the welding program 10-3. . . . . . . . . . . . . . . . . . . . .
10.2.1 Suggestions for a welding test 10-4. . . . . . . . . . . . . . . . . . . .
10.3 Basic-Setup 10-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Welding Parameters 10-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5 Scaling process 10-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6 Adjusting the program to your welding task 10-8. . . . . . . . .
10.7 Activating monitoring 10-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8 Other adjustments and programs 10-9. . . . . . . . . . . . . . . . .
10.9 Saving the Welding Parameters 10-10. . . . . . . . . . . . . . . . . .
11 Messages 11-1. . . . . . . . . . . . . . . . . . . . . . .
11.1 Fault and Status Messages 11-1. . . . . . . . . . . . . . . . . . . . . .
11.2 Ranges of Messages 11-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.1 [A] - Communication Messages 11-2. . . . . . . . . . . . . . . . . . .
11.2.2 [B] - Electrode (Stepper) Messages 11-3. . . . . . . . . . . . . . .
11.2.3 [C] - Messages Concerning the Timer Status 11-3. . . . . . .
11.2.4 [D] - Messages for Current Monitoring 11-4. . . . . . . . . . . . .
12 Maintenance 12-1. . . . . . . . . . . . . . . . . . . . .
12.1 Changing batteries 12-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Ordering 13-1. . . . . . . . . . . . . . . . . . . . . . . .
A Annex A-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Abbreviations, Terms A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Regulation terms A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3 Index A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents PSI 6XXX.190 W1
IV 1070 080 086-101 (01.01) GB
Your notes:

Safety instructions and reader’s information
Automationstechnik
V
1070 080 086-101 (01.01) GB
Safety instructions and reader’s information
Please read this documentation before working with the Weld Timer (WT) PSI 6XXX.190
W1 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 Machinery Directive.
Nevertheless, there is some residual risk!
The present manual describes the following functions:
- timer module PSI 6XXX.190 W1
- 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!

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Safety instructions and reader’s information
VI 1070 080 086-101 (01.01) 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.
!
!

Safety instructions and reader’s information
Automationstechnik
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1070 080 086-101 (01.01) 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 type PSI
6XXX.190 W1.
In connection with the intended power supply and the specified welding equipment, the
weld timer type PSI 6XXX.190 W1
-serves for resistance welding of metals
-is suitable for operation in industrial environments in accordance with
DIN EN 50082-2 and DIN EN 50081-2 concerning electromagnetic compati-
bility (EMC).
The timer is 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!
!

Automationstechnik
Safety instructions and reader’s information
VIII 1070 080 086-101 (01.01) GB
Warning of magnetic fields
In the environment of resistance welding systems magnetic field strengths have to be ex-
pected which usually are below the limits specified in VDE 0848 Part 4; in cases of doubt,
the field strength must be measured.
Dangers, if any, may arise from alternating magnetic fields (critical frequency: 1.6 Hz).
WARNING!
When using manual welding guns, the limit values may be exceeded for the extremities.
In this case, additional work protection measures must be taken.
So far, no problems have been reported. Nevertheless, the possible influences are lower
with medium-frequency welding than with AC welding.
NOTE
The strong magnetic fields arising in connection with resistance welding may cause last-
ing damages to wrist watches, pocket watches, or cards with magnetic stripes (e.g. EC
cards).
Therefore, you should not carry any such items on you when working in the direct vicinity
of the welding equipment.
!

Safety instructions and reader’s information
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1070 080 086-101 (01.01) GB
Not permitted for persons with cardiac pacemakers
WARNING for persons with cardiac pacemakers!
Warning signs should be posted for protecting persons with cardiac pacemakers be-
cause the function of these devices may be disturbed (impulse failure, total failure) and a
negative influence on the pacemaker programming or even a total program destruction
may occur !!!
We recommend posting a warning of the type shown below at all entrances to factory
halls containing resistance welding equipment:
No entry for persons with cardiac
pacemakers!
Danger!
DIN 40023
!

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Safety instructions and reader’s information
X1070 080 086-101 (01.01) GB
Qualified personnel
This manual is designed for welding technicians and engineers with special training and
specific knowledge of the welding technology.
They require profound knowledge of the
- weld timers (WT)
- MF inverters (PSI)
- welding transformers and/or welding rectifier-transformers (PSG)
The term qualified personnel refers to
- engineering personnel familiar with the safety standards of the electrical and au-
tomation technology.
- commissioning personnel entitled to commission, earth and label electrical circuits
and equipment/systems in compliance with the standards of safety technology.
- operating personnel who have been instructed in operating installations in resist-
ance welding technology and who know the contents of the present documenta-
tion as far as operation is concerned.
WARNING!
An exception are persons with cardiac pacemakers!
Due to the strong magnetic fields arising from resistance welding, the function of cardiac
pacemakers may be disturbed. This may cause the death or considerable health dam-
ages to the persons concerned!
Therefore, these persons should avoid the welding system.
Please note our comprehensive range of training courses. More information is available
from our training center (Phone: [phone] / 78258).
!

Safety instructions and reader’s information
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1070 080 086-101 (01.01) GB
Storage and Transport
NOTE
Please note the environmental conditions given in the Technical data section to avoid
damages.
Static discharges may destroy components of the weld timer. Therefore, the original
packaging should be used for storage and transport. The equipment must be protected
against humidity.
NOTE
CDs and floppies must be protected against negative external influences of dust or mois-
ture by suitable packaging. They must never be exposed to the influence of magnetic
fields.

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XII 1070 080 086-101 (01.01) GB
Installation and assembly
CAUTION!
- Please observe all applicable safety and accident prevention regulations! The rec-
ognized rules of electrical engineering must be observed!
- Danger of injury or of damage to property due to inappropriate fastening!
The place of installation and the fastening method for the modules must be in com-
pliance with our specifications!
- Danger of injury on sharp metal edges!
Please wear protective gloves.
- Danger of damage to property through short-circuits!
When drilling or sawing out openings within switch cabinets, metal burr may get
inside modules that have already been installed. It is also possible that water may
emerge during the installation of the cooling water lines and may enter the modu-
les. The possibility of short-circuits and a destruction of the units cannot be entirely
ruled out.
Therefore, the modules should be well partitioned prior to any additional work! No
liability is accepted in the event of non-compliance.
- Danger of life and of damage to property through insufficient protection type!
The protection type of the PSI 6XXX.190 W1 modules is IP 00. The modules shall
be installed together with a power supply as a single unit in a housing with a suffi-
cient degree of protection (at least IP54).
- Danger of injury and of damage to property through incorrect installation!
The weld timer, and especially the operating elements, must be installed so as to
be sufficiently protected against unintentional operation or contact.
- Danger of injury and of damage to property when operating the units outside a
switch cabinet!
The units are designed to be installed in housings or switch cabinets and may only
be operated in such housings or cabinets with the door closed!
- Danger of damages through static discharge!
Elements or components of the weld timer may be damaged by static discharge.
Do not touch any components or printed circuits with your hands. Installing and
configuring the system is reserved to qualified personnel.
NOTE
Connecting lines and signal lines must be laid so as to avoid negative effects on the func
tion of the units through capacitive or inductive interference and in compliance with the
requirements on electromagnetic compatibility (EMC), cf. also section 7 as well as gen-
eral information contained in the Bosch EMC manual for resistance welding components.
!

Safety instructions and reader’s information
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1070 080 086-101 (01.01) GB
Electrical connection
The PSI 6XXX.190 W1 are supplied with 24 V DC. This power supply must provide safety
separation in accordance with the Low-Voltage Directive (72/23/EEC, 93/68/EEC and
93/44/EEC).
WARNING!
- Considerable dangers are associated with the mains connection of the power unit!
- The possible consequences of inappropriate handling include death, severe
bodily injury and damage to property.
- Therefore, the electrical connection may only be made by a skilled electrician who
observes the valid safety regulations, the mains voltage and the maximum current
consumption of the modules.
- The mains voltage must be identical with the nominal voltage indicated on the
nameplate of the product!
- The mains system must be appropriately fused!
- Danger of life through electrical voltage!
- Suitable protective measures in accordance with DIN EN 50063 or DIN VDE 0545,
Part 1 must be installed (e.g. by grounding the welding gun) on the welding hard-
ware!
!

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Safety instructions and reader’s information
XIV 1070 080 086-101 (01.01) GB
Operation
WARNING!
During operation of the welding equipment welding splashes are to be expected! The
consequence may be injuries to the eyes or burns.
Therefore:
- wear protective goggles
- wear protective gloves
- wear flame-retardant clothes
Danger of injury at sheet metal edges and danger of getting burnt at the parts to be wel-
ded!
Therefore:
- wear protective gloves
CAUTION!
- Danger of injury and of damage to property when operating the units outside a
switch cabinet or for purposes other than the intended use!
The units are designed to be installed in housings or switch cabinets and may only
be operated in such housings or cabinets with the door closed. The recognized
rules of electrical engineering must be observed.
- Danger of injury and of damage to property through missing or false interpretation
of fault messages!
- Danger of bruises through electrode movement!
All users, line designers, welding machine manufacturers and welding gun produ-
cers are obliged to connect the output signal of the Bosch weld timer which initiates
the electrode movement so that the applicable safety regulations are complied
with.
The risk of accidents can be considerably reduced by means of, e.g.,
- two-handed start
- fences
- light barriers etc.
- Systems without <Monitor contact> MC
(not available in all weld timers)
If <Monitor contact> MC is connected to +24 VDC, the [squeeze times] must be
selected long enough to permit optimal contact of the part to be welded prior to the
[weld time]. If the [squeeze times] are too short, the electrodes close during [weld
time]. This will cause strong welding splashes, resulting in damages to the elec-
trodes and the part to be welded!
!
!

Safety instructions and reader’s information
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1070 080 086-101 (01.01) GB
- Simulate start
In remote-controlled systems, program execution may begin which may result in
dangerous machine movements. Therefore, before remote starting, it must be en-
sured that nobody is in the dangerous area of the welding machine!
CAUTION!
Damage to property through excessive welding current!
The maximum welding current of the welding hardware used must not be exceeded. No
liability is accepted in the event of non-compliance.
!

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Safety instructions and reader’s information
XVI 1070 080 086-101 (01.01) GB
Retrofits and modifications by the user
The PSI 6XXX.190 W1 has been designed and manufactured by us as a safe unit.
WARNING!
Retrofits or modifications may have negative effects on the safety of the unit!
The possible consequences include death, severe or light bodily injury (personal injury),
damage to property or environmental hazards.
Therefore, please contact us prior to retrofits or modifications to the PSI 6XXX.190 W1
using third-party equipment. This is the only way to determine whether these parts are
suitable for use with our product.
!

Safety instructions and reader’s information
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1070 080 086-101 (01.01) GB
Maintenance and repair
WARNING!
- Danger of life through electrical voltage of power units!
Prior to any maintenance work - unless described otherwise - the system must
always be switched off! In the event of necessary measurement or test procedures
on the active system, the applicable safety and accident prevention regulations
must be strictly observed. In any case, suitable insulated tools must be used!
- Danger of life through inappropriate EMERGENCY-STOP facilities!
EMERGENCY-STOP facilities must be operative in all modes of the system. Re-
leasing the EMERGENCY-STOP facility must by no means result in an uncontrol-
led restart of the system!
- Danger of explosion of batteries!
Do not forcefully open batteries, do not attempt to charge, solder or incinerate the
battery.
Empty batteries should always be replaced by new ones!
CAUTION!
- The right to perform repair/maintenance work on the PSI 6XXX.190 W1 compo-
nents is reserved to the Bosch service department or to repair/maintenance units
authorized by Bosch!
- Only use spare parts/replacement parts approved by Bosch!
- The applicable regulations on the disposal of empty batteries or accumulators
must be observed.
!
!