Rexroth PSX 6Xxx.630 Timer and I/O Level: Technical Information

Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
Rexroth PSx 6xxx.630 1070087079

Edition 02
Timer And I/O Level
Technical Information
II Bosch Rexroth AG Electric Drives PSx 6xxx.630 1070087079 / 02
and Controls
Title Rexroth PSx 6xxx.630

Timer and I/O Level
Type of Documentation Technical Information
Type of documentation DOK-PS6000-E/A630*****-FK02-EN-P
Purpose of the documentat. This manual provides information about

D the mechanical structure
D the electrical connection (24 V supply and I/O) and
D the functions
of the PSI/PST integrated weld timer.
Follow−up of modifications Previous editions Status Comment

DOK-PS6000-E/A630*****-FK02-EN-P 05.2006
Note on ind. property rights E Bosch Rexroth AG, 2006

Unless expressly authorized, any copying of this document and
utilization and disclosure of its content is not allowed. Damages will
be payable in case of contravention. 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).
Legal validity The data given in this document only intend to describe the product
and must not be understood as guaranteed properties in the legal
sense. We reserve the right to modify the contents of this
Documentation and the availability of the products.
Published by Bosch Rexroth AG

Postfach 11 62
D-64701 Erbach, Germany
Berliner Straße 25
D-64711 Erbach, Germany
Tel.: +49 (0) 60 62/78-0
Fax: +49 (0) 60 62/78-4 28
Dept.: BRC / PAW1
1070087079 / 02 PSx 6xxx.630 Electric Drives Bosch Rexroth AG III
and Controls
Table of Contents
Table of Contents
Page
1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . 1−1

1.1 Possible Safety Markings on the Product . . . . . . . . . . . . . . . 1−1
1.2 Safety Instructions in this Manual . . . . . . . . . . . . . . . . . . . . . . 1−2
1.3 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−3
1.4 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−4
1.5 Installation and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−6
1.6 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−9
1.7 Operation of the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−10
1.8 Retrofits and Modifications by the User . . . . . . . . . . . . . . . . . 1−11
1.9 Maintenance, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−12
1.10 Working Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−13
1.11 CE mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−14
2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1
2.1 Type codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1
2.2 Features of PS 6000 series . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−2
2.3 Programming and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2−5
2.4 Hardware Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−6
2.4.1 Timer front (without I/O module) . . . . . . . . . . . . . . . . . . . . . 2−8
2.4.2 Front of the I/O module ”DEV-NET” . . . . . . . . . . . . . . . . . . 2−10
3 Timer Functions . . . . . . . . . . . . . . . . . . . . . . . . . 3−1

3.1 Main Components of a Welding Station . . . . . . . . . . . . . . . . 3−1
3.2 Types of welding modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2
3.2.1 Single Spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2
3.2.2 Seam mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−3
3.3 Program schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4
3.3.1 Programmable Current Blocks . . . . . . . . . . . . . . . . . . . . . . . 3−4
3.3.2 Impulse Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5
3.3.3 Slope (Current Ramp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7
3.3.4 Programmable Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8
3.4 Regulation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11
3.4.1 Phase Angle (PHA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11
3.4.2 Constant Current Regulation (CC) . . . . . . . . . . . . . . . . . . . 3−12
3.5 Current Prewarning and Limitation . . . . . . . . . . . . . . . . . . . . . 3−14
3.5.1 Current Prewarning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14
3.5.2 Current Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14
3.6 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−15
3.6.1 Current Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−15
3.6.2 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−20
3.6.3 Time monitoring Monitor Stepper . . . . . . . . . . . . . . . . . . . . 3−20
3.7 Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−21
3.8 Measuring Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−21
3.9 Limitation of the 1st Half Cycle (for PST only) . . . . . . . . . . . 3−22
3.10 Automatic Spot Repetition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−23
IV Bosch Rexroth AG Electric Drives PSx 6xxx.630 1070087079 / 02
and Controls
Table of Contents
3.11 Electrode Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−25

3.11.1 Wear Factor and Wear per Welded Part . . . . . . . . . . . . . . 3−25
3.11.2 %I Stepper (Stepper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−27
3.11.3 Tipdressing of Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−27
3.11.4 Prewarning and End of Stepper . . . . . . . . . . . . . . . . . . . . . . 3−28
3.11.5 Prewarning Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−28
3.12 Tip Replacement (Tip Wear Monitoring ) . . . . . . . . . . . . . . . . 3−29
3.13 Electrode Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−29
3.14 Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−31
3.14.1 Force scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−31
3.14.2 Current Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−33
3.15 Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−35
3.16 Weld Transformer Selection (PSI only) . . . . . . . . . . . . . . . . . 3−35
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1

4.1 Integrated weld timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1
4.2 I/O Module ”DEV-NET” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2
5 Electrical Connection . . . . . . . . . . . . . . . . . . . . 5−1

5.1 Interference Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−1
5.2 Integrated weld timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−2
5.2.1 Output of the Internal 24 VDC Voltage Source (X4) . . . . . 5−2
5.2.2 Supply of the Timer Logics (X4) . . . . . . . . . . . . . . . . . . . . . . 5−3
5.2.3 Supply of External Devices (X5) . . . . . . . . . . . . . . . . . . . . . 5−4
5.2.4 24 VDC Voltage Distribution (X4) . . . . . . . . . . . . . . . . . . . . 5−4
5.2.5 Pressure Control and Feedback (X2) . . . . . . . . . . . . . . . . . 5−7
5.2.6 KSR Sensor (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−9
5.2.7 Main switch trigger (X8) (only with PST) . . . . . . . . . . . . . . 5−11
5.2.8 Fan connection (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−13
5.2.9 Programming unit (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−13
5.3 I/O Module ”DEV-NET” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−14
5.3.1 Power Supply (X10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−14
5.3.2 DeviceNet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−16
5.3.3 Signal outputs and inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−16
6 I/O Signal Descriptions . . . . . . . . . . . . . . . . . . . 6−1

6.1 Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1
6.1.1 Alphabetical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1
6.1.2 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−2
6.1.3 Selection of program / spot . . . . . . . . . . . . . . . . . . . . . . . . . . 6−3
6.1.4 Automatic program selection active . . . . . . . . . . . . . . . . . . 6−4
6.1.5 Spot selection ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−4
6.1.6 Ignition on, external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−5
6.1.7 Reset fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−6
6.1.8 Error Reset with WC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−7
6.1.9 Error Reset with Spot Repeat / WC . . . . . . . . . . . . . . . . . . 6−8
6.1.10 Acknowledgement ’Tips Have Been Dressed’ x . . . . . . . . 6−9
6.1.11 Acknowledgement ’Tips have been replaced’ x . . . . . . . . 6−11
6.1.12 Acknowledgement ’Tips have been replaced’ x . . . . . . . . 6−13
1070087079 / 02 PSx 6xxx.630 Electric Drives Bosch Rexroth AG V
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Table of Contents
6.2 Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−15

6.2.1 Alphabetical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−15
6.2.2 Prewarning Tip Replacement x . . . . . . . . . . . . . . . . . . . . . . 6−15
6.2.3 Tip Replacement x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−16
6.2.4 Prop. Valve Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−16
6.2.5 Sheet Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−17
6.2.6 Sheet Thickness Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . 6−17
6.2.7 Weld Complete (WC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−18
6.2.8 Control Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−19
6.2.9 Welding faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−20
6.2.10 Weld/No Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−21
6.2.11 Without Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−21
6.2.12 Without Regulation and Without Monitoring . . . . . . . . . . . 6−22
6.2.13 Automatic Program Selection Active . . . . . . . . . . . . . . . . . . 6−22
6.2.14 Tipdress Prewarning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−22
6.2.15 Tipdressing Request x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−22
6.2.16 Prewarning x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−23
6.2.17 End of Stepper Electrode x . . . . . . . . . . . . . . . . . . . . . . . . . . 6−23
6.2.18 Spot Selection Taken Over . . . . . . . . . . . . . . . . . . . . . . . . . . 6−23
6.2.19 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−24
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−1
7.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−1
7.2 Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−1
8 Status and Error Messages . . . . . . . . . . . . . . . 8−1
9 CE Declaration of Conformity . . . . . . . . . . . . . 9−1
10 Timer Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 10−1
A Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A−1
A.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A−1
A.2 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A−2
VI Bosch Rexroth AG Electric Drives PSx 6xxx.630 1070087079 / 02
and Controls
Table of Contents
Notes:
1070087079 / 02 PSx 6xxx.630 Electric Drives Bosch Rexroth AG 1−1
and Controls
Safety Instructions
1 Safety Instructions
The products described were developed, manufactured and tested in
compliance with the fundamental safety requirements of the EU machi-
nery directive. These products normally pose no danger to persons or
property if used in accordance with the handling stipulations and safety
notes prescribed for their configuration, mounting, and proper operation.
Nevertheless, there is some residual risk!
Therefore, you should read this manual before installing, connecting or

commissioning the products or programming the welding system.
Store this manual in a place to which all users have access at any time!
The content of this manual refers to

D the mechanical structure
D the electrical connection (24 V supply and I/O) and
D the functions
of the PSI/PST integrated weld timer.
The − according to the type of the product − integrated power sup-

ply units have their own manuals. They complete this manual!
L Therefore, please pay attention to the following documentation as well:
D For PST 6xxx:
Thyristor power unit, technical information (1070 080 059)
D For PSI 6xxx:
Medium-frequency inverters, technical information (1070 080 058)
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

1−2 Bosch Rexroth AG Electric Drives PSx 6xxx.630 1070087079 / 02
and Controls
Safety Instructions
1.2 Safety Instructions in this Manual
DANGEROUS ELECTRICAL VOLTAGE

This symbol is used to warn of dangerous electrical voltage. The
failure to observe the instructions in this manual in whole or in part may
result in personal injury.
DANGER
This symbol is used wherever insufficient or lacking compliance with in-
structions may result in personal injury.
CAUTION
This symbol is used wherever insufficient or lacking compliance with in-
structions may result in damage to equipment or data files.
. This symbol is used to draw the user’s attention to special circumstan-

ces.
L This symbol indicates that an activity to be executed by you is described.
Modifications in this manual as compared to a previous edition are mar-

ked by black vertical bars in the margin.
and Controls
Safety Instructions
1.3 Intended Use

The product described
D serves in connection with a welding transformer and the appropriate
power supply unit for
− resistance welding of metals
and
D is suitable for operation in industrial environments in accordance with
the following standards:
− EN 50178
− EN 50081-2
− EN 50082-2
− EN 60204-1
In residential environments, in trade and commerce as well as small

enterprises class A equipment may only be used if it does not inad-
missibly interfere with other equipment.
It is not intended for any other use!
DANGER
Any non−intended use of the devices may cause injury to the user
or third parties, as well as damage to the device, the workpiece to
be machined, or to the environment.
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.
and Controls
Safety Instructions
1.4 Qualified Personnel

The requirements as to qualified personnel are based on the require-
ment profiles defined by the ZVEI (Zentralverband Elektrotechnik und
Elektronikindustrie − German Electrical and Electronic Manufacturers’
Association) and the VDMA (Verband deutscher Maschinen- und Anla-
genbau − German Engineering Federation) in:
Weiterbildung in der Automatisierungstechnik
edited by: ZVEI and VDMA
Maschinenbau Verlag
Postfach 71 08 64
D-60498 Frankfurt.
This manual is designed for technicians and engineers with special wel-
ding training and skills. They must have a sound knowledge of the soft-
ware and hardware components of the weld timer, the power supply
used, and the welding transformer.
Project engineering, programming, start and operation as well as the

modification of program parameters is reserved to properly trained per-
sonnel! This personnel must be able to judge potential hazards arising
from programming, program changes and in general from the mechani-
cal, electrical, or electronic equipment.
Interventions in the hardware and software of our products, unless des-

cribed otherwise in this manual, are reserved to specialized personnel.
Tampering with the hardware or software, ignoring warning signs atta-
ched to the components, or non-compliance with the warning notes gi-
ven in this manual can result in serious bodily injury or property damage.
Only skilled persons as defined in IEV 826-09-01 (modified) who are fa-
miliar with the contents of this manual may install and service the pro-
ducts described.
Such personnel are

D those who, being well trained and experienced in their field and fami-
liar with the relevant standards, are able to analyze the work to be car-
ried out and recognize any hazards.
D those 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!
The strong magnetic fields occurring in resistance welding may
affect the proper functioning of pacemakers. This may be fatal or
cause serious personal injury!
Therefore, persons with pacemakers must stay clear of resistance
welding systems.
We recommend that warning sings as per DIN 40023 are posted at
every entrance to manufacturing shops housing resistance-wel-
ding equipment.
and Controls
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: +49 (60 62) 78258.
and Controls
Safety Instructions
1.5 Installation and Assembly

Danger of life during installation work while systems are switched
on!
Make sure that all plant sections undergoing operations during the
installation are deenergized and sufficiently protected against
accidental reclosing!
DANGER
Non-workmanlike installation or mounting may lead to personal
injury or damage to property.
Therefore, it is essential that you take the technical data (environ-
mental conditions) into account for installation or mounting.
Installation or mounting must be carried out by skilled personnel
only.
DANGER
Insufficient degree of protection may be life-threatening or cause
damage to property!
The degree of protection of the products described is IP 20.
They must be installed in switchgear cubicles providing a degree
of protection of no less than IP 54.
DANGER
Danger of injury and of damage to property through incorrect in-
stallation!
Devices and, in particular, operating means, must be installed so
as to be properly safeguarded against unintentional operation or
contact.
DANGER
Danger of personal injury and damage to property through inade
quate fastening!
The place for installing the modules, and their method of fastening,
must be suitable for their weight!
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Safety Instructions
DANGER
Injuries and bruises may be caused by lifting weights which are too
heavy or by sharp metal edges!
Due to the weight of certain modules, their installation and assem
bly must be carried out properly and with suitable lifting equip
ment.
DANGER
The safety and accident prevention regulations as amended shall
be observed!
Wear a protective helmet, safety shoes and gloves!
CAUTION
Short circuits!
When cut-outs are drilled or sawed in switchgear cubicles, metal
burr may get into modules already installed there. Or, when coo-
ling water lines are connected, water may leak into the modules in-
stalled.
The possibility of short circuits occurring in the process or even
the destruction of the devices cannot be entirely ruled out.
Therefore, guard any existing modules well before you install a
new module! Any and all warranty excluded in case of non-com-
pliance.
CAUTION
Heat accumulation!
Modules must be mounted with a minimum clearance of 100 mm
on top and at the bottom. Without this minimum clearance, heat
may accumulate and cause inverter failure.
CAUTION
Leaks in the cooling water circuit may cause consequential da-
mage!
Cooling water leaks may damage adjacent components. There-
fore, when mounting watercooled modules, always ensure that
other devices in the switchgear cabinet are well protected against
leaking cooling water.
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Safety Instructions
CAUTION
Risk of damage to property by insufficient water quality in the coo
ling water circuit!
Deposits in the cooling system may reduce the water flow, thus im
pairing the performance of the cooling system with time.
Therefore, you should ensure that your cooling water has the follo
wing properties:
D pH value 7 to 8.5
D Degree of hardness Dmax 10 German degrees
(1 German degree = 1.25 British degrees = 1.05 US degrees = 1.8
French degrees)
D Chlorides max. 20 mg/l

D Nitrates : max. 10 mg/l
D Sulfates max. 100 mg/l
D Insoluble substances : max. 250 mg/l
Tap water usually meets these requirements. However, an algicide
should be added.
L For information about dimensions and installation accessories of the

product as a whole as well as information about the cooling system,
please refer to the manuals of the power supply units (see page 1−1).
and Controls
Safety Instructions
1.6 Electrical Connection
DANGER
Danger of personal injury and damage to property through mis-
sing or false interpretation of fault messages!
Therefore, closing of the transformer temperature contact (ther-
mostatic switch, break contact) must inhibit the connected timer!
As regards fault analysis, see also section 8.
DANGER
Danger of life through inappropriate EMERGENCY-STOP facili-
ties!
EMERGENCY-STOP facilities must be operative in all modes of the
system. Releasing the EMERGENCY-STOP facility must by no
means result in an uncontrolled restart of the system! First check
the EMERGENCY-STOP circuit, then switch the unit on!
CAUTION
Connection or signal lines are to be laid out in such a manner that
stray capacitive or inductive pick−ups do not affect any device
functions!
In long lines, interference is often coupled and decoupled. There-

fore, power and control cables must be routed separately. The
effect of interfering cables on interference−sensitive ones can be
minimized by maintaining the following distances:
> 100 mm if cables are run in parallel for < 10 m,
> 250 mm if cables are run in parallel for > 10 m.
Install the product close to the welding units to avoid cable

lengths > 25 m wherever possible.
L In addition, please comply with all safety regulations regarding electrical

connections and the EMC of the system as a whole in the manuals of the
power supply units (see page 1−1).
L Make sure that all contact surfaces are bright, i.e. free of paint, plastic
coating or dirt/oxidation.
and Controls
Safety Instructions
1.7 Operation of the Product
DANGER
Magnetic field strengths that exceed the limit values according to
VDE 0848 Part 4 must be reckoned with in the area of resistance
welding systems. Limit values for extremities can be exceeded,
especially in the case of manual tongs.
In cases of doubt, you should measure the field strength and take
additional measures to ensure safety and health at work. Please
comply with regulation BGV B11 of the German Berufsgenossen-
schaft (professional association) ”Unfallverhütungsvorschrift
elektromagnetische Felder”.
DANGER
The strong magnetic fields occurring in resistance welding may
affect the proper functioning of pacemakers. This may be fatal or
cause serious personal injury!
Therefore, persons with pacemakers must stay clear of resistance
welding systems.
We recommend that warning sings as per DIN 40023 are posted at
every entrance to manufacturing shops housing resistance-wel-
ding equipment:
No entry for persons with cardiac

pacemakers!
Danger!
DANGER
Danger of personal injury and damage to property if devices are
operated before they have been properly installed!
The devices are designed to be installed in housings or switch-
gear cabinets and must not be operated unless properly installed
and switchgear cabinet doors are closed!
and Controls
Safety Instructions
DANGER
Danger of bruises through electrode movement!
All users, line designers, welding machine manufacturers and
welding gun producers are obliged to connect output signals
which initiate the electrode movement so that the applicable sa-
fety regulations are complied with.
For example, by means of ”Two-handed start”, fences, light bar-
riers etc. the risk of bruises can be considerably reduced.
CAUTION
Overheating through inappropriate or insufficient cooling.
The temperature inside the housing must stay within the specified
range.
Aircooled mediumfrequency inverters must always be operated

under forcedair cooling conditions. Convection cooling will not
be sufficient!
Aircooled mediumfrequency inverters must always be operated

under forcedair cooling conditions. Condensation on watercar
rying components must be prevented.
1.8 Retrofits and Modifications by the User
DANGER
Modifications 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, please contact us prior to making any modifications.
This is the only way to determine whether changes can be made
without any problems.
and Controls
Safety Instructions
1.9 Maintenance, Repair

Prior to any maintenance work − unless described otherwise − the
system must always be switched off and sufficiently secured!
If required with the system being active, any measuring or testing
work must be carried out by qualified electricians.
DANGER
Lithium batteries can cause skin burns or explode in case of im-
proper handling!
Therefore, do not forcefully open batteries, do not attempt to
charge or heat up batteries over 100 degrees C!
CAUTION
Please use only spare parts approved by us!
Use only original replacement batteries! In any case, spent batte-
ries and accumulators should be disposed of as hazardous waste!
CAUTION
Observe all precautions for ESD protection when handling modu-
les and components! Avoid electrostatic discharges!
The following protective measures must be observed for modules and

components sensitive to electrostatic discharge (ESD)!
D The following protective measures must be observed for modules
and components sensitive to electrostatic discharge (ESD)!
D Electrostatic discharge Personnel responsible for storage, transport,
and handling must have training in ESD protection.
D ESD-sensitive components must be stored and transported in the
prescribed protective packaging.
D Staff, worktables and all devices and tools coming into contact with
electrostatic sensitive devices must be applied to the same potential
(e.g. grounded).
D grounding Wear an approved grounding bracelet. The grounding bra-
celet must be connected with the working surface through a cable
with an integrated 1 MW resistor.
D ESD−sensitive components must never come into contact with char-
geable objects, including most types of plastics.
D When electrostatic sensitive devices are installed in and removed
from a system, this system must be de−energized.
and Controls
Safety Instructions
1.10 Working Safely
DANGER
If the start signal is present on fault reset (acknowledge), the weld
timer immediately starts the program sequence! Hazardous ma-
chine movements may be the result!
Therefore, before fault reset, you should make sure that there are
no persons in the danger zone of the welding equipment!
DANGER
During operation of the welding equipment welding splashes are
to be expected! They may cause eye injuries or burns.
Therefore:
− wear protective goggles
− wear protective gloves
− wear flame retardant clothes
DANGER
Danger of injury from sheet metal edges and danger of burns from
weld metal!
Therefore:
− wear protective gloves
CAUTION
The strong magnetic fields occurring in the resistance welding
process may cause permanent damage to wrist watches, pocket
watches, or cards with magnetic stripes (e.g. EC cards).
Therefore, you should not carry any such items on you when wor-
king in the immediate vicinity of the welding equipment.
and Controls
Safety Instructions
1.11 CE mark
CAUTION
The CE mark for thyristor unit − welding transformer combinations
(see section 9) refers to industrial applications.
For other combinations/applications, the certificate must be deri
ved from the above or, if necessary, a new certificate must be is
sued. This is the duty of the line constructor / user.
The described product is an application variant that, due to its cha
racteristics, cannot satisfy the regulations for terminals, machines
or systems from the start. Therefore, it may be used only as descri
bed.
The electrical and mechanical safety and the ambient environment
(foreign bodies, moisture) must be evaluated on the terminal when
it has been installed.
The EMC characteristics of this product may change after it has
been installed. As a result, a check of the EMC characteristics of
the end product (terminals, machine, systems) by the manufactu
rer of the end product is advisable.
and Controls
Overview
2 Overview
The PS 6000 series combines the following devices in one housing:
D Welding timer and
D Power supply unit.
The integrated weld timer is used for controlling the integrated power
supply unit and is suitable for
D Spot welding (e.g. in connection with a robot)
D Projection welding
D Repeat mode (e.g. manual welding guns) and
D Seam welding (e.g. roll seams).
In addition to a variation of timers whose main differences lie in their I/O

connection to the higher-level PLC/robot unit and in their functionality,
there are also
different power supply units (MF inverters/thyristor power supply
units) with different cooling systems (air/water) of several different per-
formance classes available for controlling the welding transformers.
2.1 Type codes

The product name contains information about the corresponding pro-
duct variation:
PS_ 6_ _ _ . _ _ _ _ _
Mains voltage
(only for MF inverters):
1: 400−480 VAC
2: 480−690 VAC
Cooling:
L: Air
W: Water
Type of timer
First number: I/O field bus interface
1: 24 V
2: PROFIBUS
3: INTERBUS
6: Device Net
7: Ethernet
2.+3. number: Number of version
Performance class of the power supply unit
Type of power supply unit:
T: Thyristor power supply unit
I: Medium frequency inverter
Example:
PSI 6100.100 L1: Weld timer with 24 V I/O
MF inverter
Air−cooled
Mains supply 400−480 VAC
Type code of PS 6000 series

and Controls
Overview
2.2 Features of PS 6000 series
. For information about dimensions, mains connection, cooling or

welding current, please refer to the manual of the power supply unit
in use (see page 1−1).
D User interface for operation, programming and diagnosis:

− Standard: complete for graphic user interface BOS-5000; runs on
PCs with Windows 95/98, NT4, or W2000 operating system.
− Optional and with limited functions: via operating and diagnostic
terminal BT 220 with PLC function (CL 500) or BT 6. Connection:
via V24.
D Optional access limitation for operation/programming
− By password (interlocking disk)
D Programming connection to PC (BOS-5000):
− Standard: for an individual control via V24
(e.g. for programming on location)
− Optional: contemporary connection of more than on timer via field-
bus interface: PROFIBUS-FMS
INTERBUS-PMS
Ethernet
D I/O connection (communication with e.g. robot/PLC):
Available connections:
− parallel (discrete I/O wiring)
− serial (via bus system):PROFIBUS DP
INTERBUS S
DeviceNet
D Number of programs:
− Maximum of 256 programs; symbolic spot addressing possible.
Because of the great number of programs, in most cases it is pos-
sible to assign a program to each weld spot.
D Programming of times (depends on integrated power supply unit):
− AC technology: in line cycles
− MF technology: in milliseconds
D Universally adaptable welding schedule:
− 3 programmable weld times (1. WLD: preheating weld time; 2.
WLD: weld time; 3. WLD: postheating weld time).
The welding times can be operated either together in one regula-
tion mode (standard operation) or in different regulation modes
(mixed operation).
− The 1.WLD and 3.WLD can be turned off
− Programmable impulse mode for 2. WLD
− Programmable slope mode (current rise/decay time) for 2. WLD
D Types of welding modes:
− Spot welding (e.g. in connection with robots)
− Repeat mode (e.g. in connection with manual guns)
and Controls
Overview
− Roll seams
D Half cycle operation
D Regulation modes:
− PHA (Phase angle)
− CC (Constant Current Regulation)
Mixed operation for individual welding times is possible.
D Current monitoring:
− Reference currents are programmable independently from the re-
gulation command values
− Tolerance band in percent, asymmetrically programmable
− Monitoring in standard and mixed mode possible
D Automatic spot repetition in case of low current
D Timeout
D Electrode Management:
− Stepper function for current (current stepping)
− Tips have been dressed incl. initial dressing
− Stepper function for force (stepping of electrode force)
− Prewarning table with graphic representation of electrode wear
D Proportional valve control:
− Output signal is high after program selection
− Analog and digital pressure control
− Feedback possible
− Electrode force programming in kN for all welding programs
− Force scaling for adaptation to the valve characteristic curve
D Force profile:
− up to 10 different electrode forces can be programmed during the
execution of a program
D External weld time termination on halfwave
D Freely programmable output:
Up to 3 turn-on/-off times can be programmed during the sequence of
a program. Serves e.g. to control a backpressure valve or for weld
spotsynchronous preparation of components that are subject to wel-
ding.
D Scaling programs:
− for current (adjustment of the welding device with regard to an ex-
ternal reference ammeter)
− for force (adjustment of the electrode force with regard to an exter-
nal reference dynamometer)
D Protocol function (ISO 9000):
− Error Protocol
− Weld Fault Protocol
− Data Change Protocol
− Weld Current Protocol
and Controls
Overview
D Integrated diagnostic memory

D Fault allocation:
− Events are programmable either as errors or warnings.
D Status display of I/O signals in online mode
D %I correction:
− for selected programs
− for all programs
− for selected programs
D General overview of system for:
− Start inhibit
− Ignition on, internal
− Timeout
− Current monitoring
− 2. WLD in PHA/CC
− Program-related electrode number
D Upload/Auto-Upload (Data backup)
D Restore (Data restoration)
D Copy of welding programs
D Exchange of timer (data backup and restoration of entire module, inc-
luding counter content and actual values)
D Start simulation:
− Program selection and start of schedule can be initialized via GUI
D Available languages:
− German
− English
− NA English
− Spanish
− French
− Swedish
− Portuguese
− Italian
− Hungarian
D Online and offline programming possible
D Prepared for upgrade with an optional quality module or for extension
with an optional ultrasonic control board (USR).
and Controls
Overview
2.3 Programming and Operation

All necessary parameters will be stored in the timer’s internal battery−
buffered RAM.
Operation, programming, and diagnosis are handled via the connected

PC. The PC can be either connected via
D the timer’s V24 interface (X1) or via
D an optional fieldbus interface (e.g. PROFIBUS).
While the V24 connection allows for access to a single timer only (e.g.
programming on location), the fieldbus interface allows for the contem-
porary connection of more than one timer.
Prerequisites for programming and operation via PC:

D Operating systems Windows95/98, NT4 or W2000
D Software BOS-5000 (”BedienOberfläche Schweißen” = GUI Wel-
ding)
D V24 connecting cable or in case of fieldbus interface corresponding
installation.
. For detailed information about BOS-5000, please refer to the

BOS-5000 manual.
. With regard to time programming, PSI and PST differ from each
other:
PSI: spacing in 1 ms
PST: in line cycles
(at 50 Hz: 1 line cycle corresponds to 20 ms)
(at 60 Hz: 1 line cycle corresponds to 16.6 ms)
. The timer can be programmed ”online” as well as ”offline”.
D offline:
An active connection to the timer is not necessary.
Diagnosis and visualization are not possible.
The programming is handled and saved on the PC and can be trans-
ferred to the timer at a later point in time.
D online:
An active connection to the timer is necessary.
Diagnosis and visualization are not possible.
The programming is handled via PC. Each parameter will be read out
and, after acknowledgement, written back to the timer. This way, mo-
dified and acknowledged parameters will be effective with the sy-
stem’s next program start at the latest.
and Controls
Overview
2.4 Hardware Installation

The timer module is fastened to the right side of the global housing.
In addition to the standard display and operating elements and termi-
nals, it contains
D type-specific I/O module:
for connection of the timer to the higher−level PLC or the robot (these
are preinstalled on delivery and will function only with the appropriate
control firmware).
D one slot for the optional fieldbus module:
for programming/operating/diagnosing the weld timer via fieldbus
D a slot for an optional quality module or for extension with an optional
ultrasonic control board (USR).
PSx 6000
Slot for optional quality module

or ultrasonic control board USR
type-specific I/O module

A
D
R
V24 interface for connecting a PC with

Power supply unit BOS-5000 software
(programming, logging, diagnosis, and error
display for the connected timer)
Slot for fieldbus module for connecting more

than one timer to a central PC with
BOS-5000 software
(programming, logging, diagnosis, and error
display for all timers connected to the
fieldbus)
Battery for buffering the timer’s internal RAM
. The dimensions of the global housing and the functional units for
cooling depend on the size of the integrated power supply unit and
can be slightly different than the above illustrated example.
L For installation and mounting, please refer to the corresponding manu-

als of the power supply unit in use (see page 1−1).
and Controls
Overview
CAUTION
Risk of malfunction and damages!
Incorrect installation, connection, or operation can provoke unex-
pected or erroneous reactions of the device, which may lead to
dangerous situations in the welding station.
Please comply with all instructions in the manuals.
and Controls
Overview
2.4.1 Timer front (without I/O module)
LED LOGIC; green. Is lit when the 24 VDC

(logic supply voltage) is pending.
LED; red. Is lit, when:
with PSI: DC link voltage > 60 V
with PST: Mains voltage ok
LED READY; green. Is lit when there is no error in the

timer. The unit is ready for welding.
LED WELDTIME; yellow. Is lit when the power supply unit
is triggered. A welding current flows.
LED BATTERY ERROR; red. Is lit when the battery must
type-specific I/O module. Refer to page 2−10
Optional quality module or ultrasonic control board USR

be exchanged.
RESET button. Brings the timer back into the

READY status after detection (and
elimination) of an error.
DIP-switch for setting the address at which the central PC can reach
the timer via the fieldbus.
Important only when using fieldbus modules.
A
D
R
Boot LED; red. Is lit when the timer is in ”boot” mode.
”Boot” button for activating the ”boot” mode. Is required for a firmware
exchange in connection with the ”WinBlow” software. Welding processes are
not possible while booting. Exit booting: Turn 24V logic voltage on/off.
V24 connection tot he programming device

(for programming on location).
24 VDC output for the internal power supply unit

24 VDC input to logic voltage supply
Terminals to 24 VDC voltage distribution
24 VDC-Output for fan supply for timers with fan.
X4
24 VDC output for supplying external consumers
X5
Inputs/outputs for controls with
Function ”Current passed without commands”
X8
(see page 5−11)
Output for influencing the electrode force (controlling a proportional X2

control valve)
Fieldbus module
Input for (force) feedback.
Not used X9
Measuring input for constant current regulation (CC) X3

Output/input for monitoring the transformer temperature
Battery for buffering the internal RAM.

and Controls
Overview
. For Technical data of the timer, please refer to chapter 4.1 on page
4−1.
CAUTION
Immediately upon pushing the ”boot” button, welding processes
become impossible! The timer interrupts the program sequence,
switches all signal outputs to 0 V and goes into ”boot” mode (for
firmware exchange). The button shall
− never be pressed during operation and
− may be pressed by authorized personnel
only.
and Controls
Overview
2.4.2 Front of the I/O module ”DEV-NET”
− Diagnostic messages of the module (according to DeviceNet

specification)
− NA: 6 DIP switches for setting the node address (Mac ID)
− DR: 2 DIP switches for setting the baud rate
(each according to DeviceNet specification)
− Bus connection
Connection scheme − please refer to chapter 5.3.2, page 5−16
X13
For information on signal exchange via DeviceNet,
please refer to chapter 5.3.3 on page 5−16
− Signal inputs I0 to I7 (24 VDC), with indicator LED

X12
− Signal outputs O0 to O7 (24 VDC), with indicator LED

X11
− Voltage supply of the I/O modules (24 VDC)

Terminal 1 and 3 connected internally
X10
Terminal 2 and 4 connected internally
. For technical data of the I/O module, please refer to chapter 4.2 on
page 4−2.
and Controls
Timer Functions
3 Timer Functions
3.1 Main Components of a Welding Station

Welding stations that are equipped with PS 6000 generally consist of the
following main components:
D Weld timer with integrated power supply unit (in AC or MF technology;
AC: thyristor power supply unit; MF: medium−frequency inverter)
D suitable weld transformer with current sensor and
D pneumatically or electrically driven gun, electrodes included.
In addition, an upstream control that controls the entire process regar-

ding the work piece and monitors its safety is necessary. This can be pro-
vided by e.g.
D a programmable logic controller (PLC)
D robot control, or
D a combination of the above.
Start PROP
Gun
I A
Weld transformer
PLC or Progr. No. (WLD)
PS 6000 Electrodes
robot or
spot no.
DRM
A I
WC
Current sensor
I: Input
O: Output Actual current value
DRM: Pressure return message
WC: Weld complete
WLD: weld time
Main components of a welding station
The weld timer ensures the controlled flow of the actual welding process.
In order to do so, it must control and regulate a great number of functions
and physical variables. Main tasks are e.g.
D the communication with a higher-level PLC or robot control via I/O si-
gnals
D triggering a proportional control valve or a servomotor in order to in-
fluence the electrode force
D making sure that the different times are scheduled correctly (e.g.
squeeze, current, hold time etc.)
D controlling the power supply unit to produce a correct welding current
and Controls
Timer Functions
D indicating either a correct or erroneous weld at the end of the welding

program.
Current I Time
Weld transformer
Start
Primary Force F Power

circuit
+ + +
− − −
1.SQZ
Secondary circuit + WLD HLD
SQZ
SQZ: Squeeze time (for explanations please refer to chapter 3.3.4, page 3−8 ff)
WLD: weld time
HLD: Hold time (for explanations please refer to chapter 3.3.4)
Physical variables for affecting the weld
3.2 Types of welding modes

In order to execute a welding process, the timer can be operated via PLC
/ robot or controlled manually by an operator.
To this end, the PS 6000 provides for different welding modes:
D Single spot mode
D Seam mode.
3.2.1 Single Spot

Appropriate for utilization in connection with robots, welding machines,
automatic welders and hand tongs; for spot welding, projection welding,
butt welding.
A ”high” level at the START input (see also page 6−2) starts the welding
process (welding program) exactly 1x − starting with the 1.SQZ.
At the end of the program, the timer outputs the WELD COMPLETE
(WC) output signal, as long as no welding error has been detected.
For a new welding process, the start signal has to be toggled off/on.
and Controls
Timer Functions
Start
WC
a welding spot another welding spot

is created is created
Welding operation mode single spot, signal schedule
3.2.2 Seam mode

Suitable for roll seam stations.
With this technique, you pass over the welded parts with rolling electro-
des and the parts are connected by individual spot welds.
As in single spot mode, the weld timer reacts to the start signal and starts
the welding process.
The weld time (2.WLD) and a possibly programmed cool time (2.CT) will
be repeated, as long as the high level at the START input is pending.
If the start signal changes to low level, the timer interrupts the flowing
current impulse and starts the hold time (HLD).
Seam mode is divided in stitch and seal welds:
Stitch weld:Successive weld times are separated from each other by
sufficiently rated cool times, so that successive spot welds
neither touch each other nor overlap.
Seal weld: The cool time is so short that successive spot welds overlap.
Stitch weld Seal weld Seal weld
ÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
2.CT 2.WLD
CT very small or 0
Seam mode
and Controls
Timer Functions
3.3 Program schedule

There are 256 different welding programs (program no. 0 − 255) availa-
ble. First, select the program via the program selection inputs (refer to
page 6−3), then start the welding process via high level at the START
input (see also page 6−2).
Each welding program contains all parameters necessary for the exact
definition of a weld. Basic parameters are e.g.
D Currents that are to be effective in different current blocks (refer to
chapter 3.3.1 ff)
D Times that are supposed to run consecutively (please refer to chapter
3.3.4, page 3−8 ff)
D Electrode force (for further explanations, please refer to page 5−7).
3.3.1 Programmable Current Blocks

The process may require to produce the heat necessary for a single spot
weld in consecutive current blocks.
Therefore, you can execute a spot weld using up to three current blocks
(1. WLD, 2. WLD, 3. WLD). With regard to its time and current, each
block can be programmed separately.
. Programming the currents depends on the active regulation mode

(refer to page 3−11):
PHA (Phase angle): in scale values
CC (Constant Current Regulation): in kA
Between the blocks, cool times can be programmed (1.CT, 3.CT). If you
set a cool time = 0, the two corresponding blocks lie seamlessly next to
each other.
Start of program schedule End of program schedule
+ + +
+ + + + + +
− − − − − −
− − −
1.SQZ 1. 3.
+ 1. WLD 3.C 2. WLD 3.C 3. WLD HLD
SQZ 1. %I: T 2. %I: T 3. %I:
1st current block 2nd current block 3rd current block

(pre−heating time) (post−heating time)
SQZ: Squeeze time (for explanations please refer to chapter 3.3.4, page 3−8 ff)
WLD: weld time
HLD: Hold time (for explanations please refer to chapter 3.3.4)
%I: Current
Available current blocks

and Controls
Timer Functions
1.WLD (1st weld time / pre−heating time):

With this current block, you can preheat the metal with a smaller current
(1.%I) prior to the actual welding process (in the 2nd current block), in
order to reduce the risk of e.g. welding splashes.
If you do not want to use the 1.WLD, simply set 1.WLD = 0.
2.WLD (2nd weld time / 2nd current block):

With this current block, you actually weld a spot with the command cur-
rent (2.%I).
D The 2nd weld time must always be programmed.
D Within the 2.WLD, the functions:
− ”Impulse mode” (refer to page 3−5) and
− ”Slope” (refer to page 3−7) are available.
3.WLD (3rd weld time/ post−heating time):

With this current block, you can heat the metal with a smaller current
(3.%I) after the actual welding process (2nd current block).
This compensates e.g. for too rapid cooling of the spot welds caused by
the electrode’s cooling. It improves the structure of the welded part and
serves to relieve weld stresses.
If you do not want to use the 3.WLD, simply set 3.WLD = 0.
3.3.2 Impulse Mode

In addition to the possibility to distribute the heat necessary for one sin-
gle spot weld on 3 successive current blocks (refer to page 3−4), you
also have the impulse mode at your disposal.
Within the 2nd current block, the heat necessary for welding a spot can
be distributed on up to 9 successive impulses which reduce the risk of
welding splashes as well.
Between the impulses, you can program a 2.CT.
If you set the 2.CT = 0, all impulses lie seamlessly next to each other.
and Controls
Timer Functions
You can set the impulse mode via parameter ”Impulse”.

This parameter determines how often the 2.WLD will be repeated taking
into consideration a programmed 2.CT.
2nd current block

in this example:
2.WLD 20 ms = 1 cycle
Example: Impulse mode OFF
IMP = 1
2.WLD = 60 ms
2.CT (not relevant, because 1 impulse only)
2nd current block
Example: 2 impulses 2.WLD 2.WLD

2.CT
IMP = 2
2.WLD = 60 ms
2.CT = 40 ms
2nd current block

Example: 3 impulses
2.WLD 2.WLD 2.WLD
IMP = 3 2.CT 2.CT
2.WLD = 60 ms
2.CT = 40 ms
Examples of programming the impulse mode

and Controls
Timer Functions
3.3.3 Slope (Current Ramp)

If the Slope function is activated, the timer independently produces a li-
near current increase (upslope) or decrease (downslope) for the 2nd
current block within a programmable time span. The Slope function re-
duces the switch-on current peak and thus the stress on the welding sta-
tion.
For programming, use
D current upslope time (UST) to determine the time span in which the
momentary current shall be increased from ”starting current” to the
command current of the 2.WLD (2.%I), or
D current downslope time (DST) to determine the time span in which
the command current of the 2.WLD (2.%I) shall be reduced to the ”fi-
nal current”. DST (current downslope time)
Please note:
D Current upslope and downslope times are always part of the 2nd cur-
rent block.
The current upslope time starts with the beginning of the 2nd current
block.
The current downslope time ends with the end of the 2nd current
block.
D Current upslope and downslope times are not influenced by an acti-
vated impulse mode or a possibly programmed 2.CT. I.e. they ignore
a possible 2.CT and proceed.
D If the sum of UST and DST is larger than the 2nd current block, the
command current in the 2nd block (2.%I) will never be reached! Fault
messages as e.g. ”current too low” appear.
D Please use, in connection with the slope, the fade-out time (refer to
page 3−18).
Example: 3 impulses including 2nd current block

Slope
2.WLD 2.WLD 2.WLD
UST = 120 ms 2.CT 2.CT
DST = 40 ms
IMP = 3
2.WLD = 60 ms UST DST
2.CT = 40 ms
in this example:
20 ms = 1 cycle
Example: Slope in connection with impulse mode

and Controls
Timer Functions
3.3.4 Programmable Times

The schedule of a welding program depends on the use of different pro-
grammable time spans. Each time span serves a certain purpose within
the program schedule.
. With regard to time programming, PSI and PST differ from each
other:
PSI: spacing in 1 ms
PST: in line cycles
(at 50 Hz: 1 line cycle corresponds to 20 ms)
(at 60 Hz: 1 line cycle corresponds to 16.6 ms)
Welding program execution without impulse mode in the 2nd current block:

Start
1. 2.WLD 3. 3.WLD
1.SQZ SQZ 1.WLD HLD
CT CT
UST DST
Time
Current
Time
Welding program execution with impulse mode in the 2nd current block (example here: impulses = 3):

Start
2. 2.
1. 2.WLD CT 2.WLD CT 2.WLD 3. 3.WLD
1.SQZ SQZ 1.WLD HLD
CT CT
UST DST
Time
Current
Time
Example of a time diagram with all programmable time spans

and Controls
Timer Functions
1.SQZ (1st squeeze time):

During the 1.SQZ the welding gun must be closed completely. No current
flows in this time segment.
In all operating modes (single spot and seam mode), the 1.SQZ always
starts immediately after the start signal.
SQZ (squeeze time):

The squeeze time is used to build up the working force of the electrodes.
No current flows in this time segment.
The welding gun must be closed when the SQZ begins (see 1.SQZ).
The programmed squeeze time (SQZ) starts under the following condi-
tions only:
D High level at input X2/4 (if 0 V at X2/2)
(for required voltage, please refer to chapter 4.1 on page 4−1)
If this condition is missing, the welding program will be selected and star-
ted (and a possibly programmed 1. SQZ will begin), but the further pro-
cesses (schedule) will be delayed until this one condition is met.
. The SQZ must always be higher than 0.

Shortest possible SQZ with PST: 1 cycle
with PSI: 16 ms.
. Within the SQZ, the timer checks, by measuring the ohmic resi-
stance, whether the connected measurement circuit is faultless or
not.
In case of an error (refer to page 5−11), the timer interrupts the wel-
ding program and deletes the output signal ”Control ready”.
1.WLD (1st pre−heating time)

Refer to page 3−5.
1.CT (1st cool time)

If programmed with a value greater than 0, will separate the first from the
second current block. Is used to relieve stress from the welded part.
. The 1.CT can only be programmed if the 1.WLD is larger than 0.

and Controls
Timer Functions
2.WLD (2nd weld time)

2.CT (2nd cool time)

If programmed with a value greater than 0, will separate the individual
impulses with impulse mode. Is used to relieve stress from the welded
part.
. The 2.CT can only be programmed if the impulse mode is activated

(parameter ”impulses” > 1).
UST (Upslope time / Current upslope time)

DST (Downslope time / Current downslope time)

3.WLD (3rd weld time / post−heating time):

3.CT (3rd Cool time)

If programmed with a value greater than 0, will separate the second from
the third current block. Is used to relieve stress from the welded part.
. The 3.CT can only be programmed if the 3.WLD is larger than 0.
HLD (Hold time)

Is used, in order to fix the welded part during cooling. Current has stop-
ped flowing in this time segment.
At the end of the HLD, the welding gun opens up. If there hasn’t been
detected any welding fault, the output signal WELD COMPLETE (WC)
will be output (refer to page 6−18).
and Controls
Timer Functions
3.4 Regulation Modes

The weld timer provides the following regulation modes:
D Phase angle (PHA) and
D Constant Current Regulation (CC).
The allocation between program and regulation mode is very flexible.

Thus, two different regulation possibilities are available:
D Standard operation:
A regulation mode can be assigned to every welding program. The
set regulation mode is valid for all weld times of the program.
D Mixed operation:
Different regulation modes can be assigned to the program’s weld ti-
mes.
. Regulation and monitoring are separate functions! This is why the

current command values are separately parameterizable for regu-
lation and monitoring.
Please refer to chapter 3.6.1, page 3−15 ff.
3.4.1 Phase Angle (PHA)

Special case.
The operation mode PHA doesn’t provide for the regulation of an actual
variable (e.g. current), but triggers exclusively the power supply unit. In
the PST, this causes a triggering of the thyristors during the sinusoidal
half−wave (el. firing angle: 130 degrees to 30 degrees; the larger the fi-
ring angle, the less current flows in the secondary circuit); in the PSI, you
can thus influence the pulse width.
Features PHA:
D Currents are programmed in scale values (%I).
Programmable range: 0.0 to 100.0 scale values.
Programming resolution: 0.01 scale values
D No regulation.
D The resulting current intensity in the secondary circuit depends on the
transition resistance electrode/welded part, and the secondary vol-
tage.
D A current sensor for measuring the actual current is not necessary.
. Current and time monitoring can be enabled in PHA mode.

Current monitoring though requires a current sensor (toroid).
Mains
and Controls
Timer Functions
Mains
Welding
Electrodes
Programming: transformer
value in %I
(scale values)
Power supply
unit
without Actual current Current sensor

only for value (only necessary
current display
monitoring for current
purposes alternatively monitoring)
with current Actual current value

Measured value
monitoring
conditioning
Actual value
Actual kA value
Mean phase angle
in %I (scale values)
Current monitoring
−Status
− Tolerance band −Faults
programmable
reference current
(in kA)
Principle of the unregulated PHA operation
3.4.2 Constant Current Regulation (CC)

Standard case (e.g. with robot guns).
In CC mode, current regulation is activated. The actual current is measu-
red and continuously compared to the programmed command current. A
series-connected controller processes the difference between the com-
mand and the actual value and controls the phase angle/the pulse width
in the power supply unit in order to reach the command current.
and Controls
Timer Functions
Features CC:
D Currents are programmed in kilo Ampere (kA).
Programmable range: 0.5 to 250 kA
(can be limited by parameterization and the power supply unit in use).
Programming resolution: 10 A.
D The current in the secondary circuit is regulated.
D Eliminates the influence of the electric resistance on the weld process
in the secondary circuit (e.g. electrode/welded part contact resi-
stance).
D A current sensor is absolutely necessary for measuring the actual
current (please refer to page 5−9).
Programming: Mains
Command current
value in kA Welding
Electrodes
− transformer
Controller
Power supply
unit
Current sensor
Measured value Actual current value

conditioning
Actual value
Actual kA value
Mean phase angle
in %I (scale values)
Current monitoring
−Status
− Tolerance band −Faults
programmable
reference current
(in kA)
Principle of the CC regulation mode

and Controls
Timer Functions
3.5 Current Prewarning and Limitation
3.5.1 Current Prewarning

Via the ”Current prewarning” parameter it is possible to indicate,
D from which scale value on the message ”Phase Angle Prewarning
has been reached” will be displayed.
This way, in CC regulation mode, the timer can indicate e.g. an imminent
current limitation, caused by e.g. cable losses in the secondary circuit.
. The parameter value must be smaller than the current limitation va-
lue.
3.5.2 Current Limitation
. At first, parameterize the current prewarning.
Via the ”current limitation” parameter, you determine the minimum

phase angle (electric degree)
D in CC mode by the controller’s command value and
D in PHA operation via programming.
To do so, please program the highest permissible scale value.
If the current limitation function reacts, the timer sends the message
”maximum phase angle”.
. The input value for the current limitation is absolute!

Therefore, the ”%I correction” function (see page 3−35) and the
”stepper” function (see page 3−27) might lead to an activation of
the current limitation.
. The parameter value must be greater than the current prewarning.

and Controls
Timer Functions
3.6 Monitoring
The timer can monitor welding processes with regard to the following va-
riables:
D Current (please refer to chapter 3.6.1) and
D Time (please refer to chapter 3.6.2, page 3−20 ff).
Both monitor modes can be switched on and off separately.

Activated monitorings check the relevant actual value in comparison to
the programmed reference values and tolerance bands.
Since the variables current and time affect the heat within the spot, cor-
rectly set reference values and activated monitorings are essential mea-
sures and prerequisites for quality assurance.
. The reference values used for monitoring can be programmed in-

dependently from the regulation parameters.
A modification of the command values for regulation (closed-loop
control) does not affect the monitoring parameters!
Corresponding access rights allow the operator to set new refe-
rence values manually or accept a previously measured actual va-
lue as a new reference value.
3.6.1 Current Monitoring
. A current sensor is absolutely necessary for measuring the actual

Tolerance Range
Current monitoring compares the actual current that has been measured
by means of the r.m.s. value with the ”tolerance band”.
It depends on the programmed tolerance band whether the timer identi-
fies the measured actual current as ”good” or not. The following values
are decisive for the definition of the tolerance band:
D Reference current in kA
D Positive tolerance in % of the reference current
(permissible upper tolerance band).
Actual values above the upper tolerance band lead to the message
”Current too high...”.
D Negative tolerance in % of the reference current
(permissible lower tolerance band).
Actual values below the lower tolerance band lead to the message
”Current too low...” or ”No current...”.
and Controls
Timer Functions
ÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇ
Current too high...
permissible upper
tolerance band
(in %)
Tolerance Reference current in kA
band Current ok
ÇÇÇÇÇÇÇÇÇ permissible lower
ÇÇÇÇÇÇÇÇÇ
Current too low... / no current...
Principle: Tolerance band

tolerance band
(in %)
Conditional permissible tolerance band

In addition to a ”good/bad” statement, it is often desirable to be informed
about the trend of the actual current values in time. In this regard, slow
but continuously increasing actual current values in the lower segment
of the tolerance band are especially interesting: Slowly developing er-
rors in the system (e.g. slowly increasing cable resistance within the
measuring circuit prior to a cable break) can lead to such effects. It is also
possible that not perfectly set reference current values are the cause for
actual current values in the lower segment of the tolerance band.
Therefore, the following additional parameters are at your disposal in

connection with the tolerance band:
D ”Conditional permissible tolerance band” (in % of the reference cur-
rent) and
D ”Repeat factor”.
The parameter ”conditional permissible tolerance band” determines the
upper limit of the conditional permissible tolerance range. The lower limit
is defined via the parameter ”permissible lower tolerance band”.
The ”repeat factor” determines, how many consecutive spot welds may
lie in the conditional permissible tolerance range.
If this value is exceeded, the timer sends the message ”Current too low
for a series of welds”.
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
Current too high...
permissible upper
tolerance band
(in %)
with regard to one Reference current in kA
single measurement:
Current ok
Conditional permissible
Conditional tolerance band (in %)
permissible
tolerance band
permissible lower
tolerance band
Current too low... / no current...
(in %)
Message ”Current too low for a series of welds”
Completed welding spots
Example: Principle of the Conditional Tolerance Band with Repeat Factor = 4

and Controls
Timer Functions
. Messages can be defined either as a ”welding fault” or as a ”war-

ning”. An event that has been defined as a ”warning” does not lead
to a blocking of the timer. A ”welding fault” though always requires
a ”Fault reset” (see page 6−6) in order to start the next welding pro-
cess.
Current monitoring modes

Since there are 3 programmable independent current blocks (refer to
page 3−4), current monitoring should be flexible and easy to handle.
Therefore, the two different monitoring modes ”Standard” and ”Mix” are
available.
D Standard operation:
The entire current profile (1st, 2nd, and 3rd current block, cool times
included) is part of the r.m.s. value measurement.
Here, the complete current profile is represented by only one actual
value and monitored by only one tolerance band.
Because of this simple, but most of the time sufficient monitoring
mode, the quantity of data to be processed remains small, but possi-
ble cool times and different currents within the individual blocks
change the measurement result.
In this case, the reference current should be measured via sample
welds. If you use the 2.WLD only and no impulse mode, you can enter
the command current programmed for the regulation as the reference
current.
Tolerance band
Reference
current
1. * *
block 3. block
1.WLD 1.CT 3.CT 3.WLD

2. block
*: 2.CT
Measuring time
Principle of the monitoring mode ”Standard”
D Mixed operation:
The r.m.s. value will be measured separately for each current block
and monitored by the current blocks’ own tolerance bands (for 1st,
2nd, and 3rd current block). Programmed cool times are not taken
into consideration when calculating the actual value for each current
block.
This leads to a better transparency for the single current blocks, but
the quantity of data to be processed is larger.
In mixed operation, you can always use the command currents pro-
grammed for regulation as the reference currents.
and Controls
Timer Functions
Reference current
Reference Reference
current current
1.
block 3. block
t1 t2 t3
Measuring time 1 2. block Measuring time 3
: Tolerance band Measuring time 2 = t1 + t2 + t3
Principle of the monitoring mode ”Mix”
Fade-out time and trail current

The above descriptions of the current’s temporal schedule are ideal ca-
ses (rectangular form). In reality though, the current recovers and de-
cays at the beginning and the end of a weld time. These effects have an
influence on the r.m.s. value measurement.
With the functions ”Fadeout time” and ”Trail current”, you can affect the
measurement specifically.
D Fade-out time:
Indicates, for how long after the start of a weld time, measured current
values are not to be taken into consideration for the calculation of the
r.m.s. value. This way, if set correctly, you can fade out the entire
transient recovery process.
Use of fadeout time:
− in connection with the ”Slope” function (refer to page 3−7):
please program the same value for the fade-out time as for the cur-
rent upslope time (UST);
− when welding thick sheets and when the use of a deeply immer-
sing welding gun (gun reaches far into the material) is necessary;
− in connection with current scaling:
Measuring instruments for the reference welding current are provi-
ded with a ”fade-out function” as well (e.g. Miyatchi: ”First Cycle”;
indication from which cycle of the weld time on measured values
shall be taken into consideration).
For current scaling, make sure that the measurement instrument
in use is set to the timer’s currently parameterized fade-out time.
D Trail current:
Indicates if the decaying process after the end of the weld time shall
be taken into consideration for the calculation of the r.m.s. value (trail
current ON).
In connection with fade-out times higher than ”0”, this may result in
the determination of too low r.m.s. currents when calculating the mea-
sured value, even though the absolute command current in steady
state has been reached.
and Controls
Timer Functions
Current
Time
Fade- Trail
out current
time
weld time
Fadeout time and trail current
The programmed fadeout time always starts

D at the beginning of a current block
D at the beginning of an impulse.
An activated trail current always starts

D at the end of a current block
D at the end of an impulse.
2. block
1.
block 3. block
Fade-out time:
Trail current
Starting points of the fadeout time and the trail current
. The programmed fadeout time is identical for all weld times and for
all welding programs!
Therefore, please make sure that the fade-out time is always smal-
ler than the smallest programmed weld time.
. An active trail current applies to all weld times and welding pro-
grams.
and Controls
Timer Functions
. If for your application the only quality criteria is the heat introduced
into the spot weld (heat: Q 9 i2 x t x R), please program the fade-out
time with the value ”0” and switch ON the trail current.
3.6.2 Timeout
Time monitoring is separately adaptable to each program and compares
the actual time necessary for the complete current profile to a program-
med reference time.
As actual time we understand the time span from the beginning of the
first current block till the end of the last current block, cool times included.
This way, you can avoid the execution of excessive weld time changes in
the individual welding programs.
The following values are decisive for programming the time monitoring
function:
D Time monitoring ON/OFF
D Reference time
D Permissible time deviation from the programmed reference time.
Actual times above the permissible time deviation lead to the mes-
sage ”Weld time too long...”.
Actual times below the permissible time deviation lead to the mes-
sage ”Weld time too short...”.
permissible time deviation
1. * *
block 3. block
1.WLD 1.CT 3.CT 3.WLD

2. block
*: 2.CT
Reference time
Principle of the timeout function
3.6.3 Time monitoring Monitor Stepper
. A current sensor is absolutely necessary for measuring the actual

It serves when executing the electrode maintenance functions

D ”Stepper” (refer to page 3−27) and
D ”Tip dressing” (see page 3−27)
and Controls
Timer Functions
for monitoring the programmed %I stepper.

This way, you can avoid the execution of excessive changes in the indivi-
dual stepper or tipdressing curves.
With an activated stepper, the timer changes the programmed command
current in dependence of the electrode wear.
The ”Monitor Stepper” gives you the possibility to program, separately
for each singular stepper or tipdressing curve, stepper values in percent
which then will be taken into consideration as reference values for the
monitoring process.
3.7 Interlock
In the welding operation mode ”single spot”, the timer goes into ”Inter-
lock” upon the end of the SQZ. While in ”Interlock”, the 1., 2., and 3.WLD
and the HLD are processed even after the input signal ”Start” has been
reset.
. ”Interlock” can be interrupted only by opening the stop circuit (see

page 5−15).
. In the welding operation mode ”seam mode”, there is no ”Inter-

lock”. If the input signal ”Start” is reset during a weld time, the timer
terminates the cycle that has just begun and continues with the
hold time.
For more information regarding ”Interlock”, please refer to input signal

START on page 6−2.
3.8 Measuring Circuit Test

This function checks the measuring circuit for interruptions and short cir-
cuits during the squeeze time (see page 5−11). This way, errors in the
cables/current sensor can be detected in time.
If an error is detected, the weld timer interrupts the current welding pro-
gram before entering the first programmed weld time and generates a
corresponding message (”measuring circuit open” or ”short circuit in
measuring circuit”).
To activate the function, switch parameter ”Measuring circuit test” to

”On”.
Conditions:
D The parameter ”monitoring stopped” is switched off and
D the function ”current monitoring” (refer to page 3−15) is activated.
and Controls
Timer Functions

cess.
CAUTION
Risk of too high weld current!
Both messages must always be defined as a ”fault”.
Otherwise the controller receives no or erroneous information ab-
out the actual value. This might result in the controller triggering
the power supply unit fully.
After 40 ms at the latest, the welding schedule will be interrupted
with the message ”weld time termination/no current” (”no cur-
rent”: refers to the measured actual value).
3.9 Limitation of the 1st Half Cycle (for PST only)

The activation of the first current half cycle can be limited in order to pro-
tect the weld transformer and the thyristor power supply unit.
Example: A command value of 55 scale units means that

D in welds with smaller command currents (0 to 55 scale units), the 1st
half cycle is not affected
D with higher command currents (> 55 scale units), the 1st half cycle is
limited to 55 scale values.
For programming you have 2 parameters at your disposal:

D ”Limit 1. half cycle”:
Parameter affecting the entire module.
Only the first half cycle of a weld is limited.
D ”1. Halfcycle after cool time”:
Can be set separately for each welding program.
The first half cycle of each weld time or each impulse is limited if pre-
viously a cool time has been programmed > 0.
and Controls
Timer Functions
3.10 Automatic Spot Repetition

This function serves to reduce necessary user intervention in the case of
occasional ”current too low...” or ”no current...” welding faults.
Conditions:
D Current monitoring is active, and
D the function ”monitoring stopped” is switched off.
The function ”Automatic spot repetition” can be switched on and off se-
parately for each welding program via the parameter ”Spot Repeat”.
If the automatic spot repetition is activated, the timer is able to repeat −
starting with the SQZ − an erroneous welding process automatically
once, in case of a ”current too low...” or ”no current...” message. In this
case, the gun remains closed after the erroneous process and program-
med squeeze time, weld times, and hold times are repeated.
If the repetition results in a correct weld, the welding station will then re-
sume its normal operation. If during repetition, another error is detected,
a corresponding message will be displayed (”Current too low...”, ”no cur-
rent...”).
If automatic spot repetition is activated, bad fittings or not perfectly lying

electrodes might lead in extreme cases to a repetition of each single spot
weld. I.e.: the clock time might increase very fast and maybe even unno-
ticed.
Therefore, the timer provides the parameter ”Max. repetition” (highest
permissible amount of spot repetitions in sequence).
An internal counter is always reset to 0 if a weld is successful at first at-
tempt. Otherwise, if the value falls below the ”permissible lower tole-
rance band” and the automatic spot repetition is activated, the counter
will be incremented.
Automatic spot repetition will only take place if the internal counter value
is smaller/equals the ”max. repetition” parameter. If this is not the case,
the timer generates the message ”Current too low for a series of welds”.
Current too high...
permissible upper
tolerance band
(in %)
Current
Reference current in kA
ok
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ permissible lower
: Welds that have

been activated by
automatic spot
Current too low.... / no current...
tolerance band
(in %)
repetition.
Message ”Current too low for a series of welds”
Welds
Example: Principle of the automatic spot repetition with ”max. repetition” = 4

and Controls
Timer Functions

cess.
and Controls
Timer Functions
3.11 Electrode Maintenance

During their life, electrodes are subject to a process-related wear (see
chapter 3.11.1) which can be noticed by e.g. an enlargement of the elec-
trode’s contact point.
Wear
Enlargement of the contact point by electrode wear
To compensate for this effect, the timer provides two different procedu-
res:
D ”Automatic stepper” (refer to page 3−27) and
D ”Tip dressing” (see page 3−27)
Both procedures can be activated either separately or combined.
3.11.1 Wear Factor and Wear per Welded Part

The wear of the electrodes depends on different factors, like e.g. pro-
grammed current, thickness and material of the welded part.
As long as you perform welds of only one type of material with the same
thickness and the same current during the life of an electrode, it can be
easily predicted, after how many welds the electrode is worn and must
be exchanged. The electrode wear can be displayed by means of a ”spot
counter”. The spot counter will be incremented by ”1” after each perfor-
med welding process.
If the parts that are welded during an electrode life consist of different
materials or different gauges, the wear per spot weld is not constant. In
this case, a spot counter is not sufficient anymore.
Therefore, the wear of an electrode in the timer is monitored via a ”wear

counter”.
To this end, the control increases the wear counter after each welding
process by the ”wear factor”. The wear counter cannot only be incremen-
ted by ”1” (as for the spot counter), but by any value.
Since you can enter the right wear factor for the weld in each program, a
correct measurement of the electrode wear is guaranteed.
Wear per part

Via the parameter ”Wear/Part” you can enter the electrode wear that is
caused by the welding process of one single piece. With this variable, the
and Controls
Timer Functions
timer can calculate how many pieces can be welded with the electrode
until the end of stepper (maximum electrode life). The amount of the re-
maining parts will be displayed in the ”Prewarning table” (see page
3−28).
Example:
6 welds must be performed on a part.
Each spot weld (P1 to P6) is produced by a separate welding program
(Prog1 to Prog6).
For the upper spots (P1 to P3), 2 sheets must be welded, for the lower 3
spots (P4 to P6) 3 sheets.
The electrode wear for the spot welds P4 to P6 is higher (thicker mate-
rial). Therefore, the program−specific wear factor in Prog1 to Prog3 must
be programmed with ”1”, while the wear factor in Prog4 to Prog6 is ”1.5”.
The wear per piece is therefore 7.5.
. The wear factors in this example have only exemplary meaning. In

reality the wear factors for the materials and gauges in use will be
calculated in advance.
Wear counter:
0 1 2 3
(New
electrodes)
P1. P2. P3.

WF=1 WF=1 WF=1
P6. P5. P4.

WF=1.5 WF=1.5 WF=1.5
WF: Wear factor 7,5 6 4,5
Example: Calculation of the wear

and Controls
Timer Functions
3.11.2 %I Stepper (Stepper)

The stepper function keeps the current density in the spot weld constant
while during the electrode’s life, the spot weld becomes larger and larger.
To do so, you can define separate stepper curves for up to 10 different
electrode types. A stepper curve determines the percentage with which
the programmed command current should be increased automatically in
dependence of the current electrode wear.
Current increase in %
(in relation to the programmed current)
max.
permissible
100 wear
Stepper curve
Wear
0
Principle: %I stepper
. The resulting current changes can be monitored by means of the

”Monitor Stepper” Function (see page 3−20).
3.11.3 Tipdressing of Electrodes

With electrode tipdressing you can periodically restore the desired con-
tact area during the electrode’s life.
Therefore, after a certain wear, the electrodes must be treated in a tip-
dressing station for electrodes.
The timer requests tipdressing of electrodes via the ”Tipdress prewar-
ning” output signal (see page 6−22) or the ”Tipdressing request”.
The additional possibility to define up to 10 different tipdressing curves

offers a perfect adaptability to different types of electrodes. A stepper
curve determines the percentage with which the programmed command
current should be increased automatically in dependence of the current
electrode wear.
. The resulting current changes can be monitored by means of the

”Monitor Stepper” Function (see page 3−20).
and Controls
Timer Functions
. The initial dressing function can be activated via parameter ”tip-

dressing of new electrodes”.
With Initial tipdressing activated, the timer requests tipdressing
immediately after electrodes have been replaced.
With freshly inserted electrodes this serves e.g.
− to create a defined weld spot diameter
− to create a defined contact angle
− to eliminate a protective sheet.
3.11.4 Prewarning and End of Stepper

When the highest tolerable wear has been reached, new electrodes
must be inserted.
Here, the output signals
D ”Prewarning” (see page 6−23) and
D ”End of stepper” (see page 6−23) and
are provided. They shall only be used if the electrode maintenance func-
tions are activated (parameter ”Stepper”: ON).
3.11.5 Prewarning Table

The prewarning table offers you an overview with fast access to all im-
portant information and operations regarding electrodes with an activa-
ted electrode maintenance function:
D Weld timers to which the individual electrodes have been assigned.
D Current wear (in percent, numerical, and graphical).
The graphic illustration is color coded. This way, upcoming prewar-
nings, tipdress requests, or the end of stepper can be easily recogni-
zed.
D Remaining parts that can still be welded with the relative electrode.
D Reset of one or more wear counters after the cap has been exchan-
ged.
and Controls
Timer Functions
3.12 Tip Replacement (Tip Wear Monitoring )

This function is used to monitor the wear status of the tips. In this way,
damaging of electrodes or bad tip jobs − which may be caused by worn
tip cutters − can be avoided in advance by timely replacement of cutters.
To this end, an additional counter (value ”Tip wear”; value range 0 to

99999) is provided in the timer in addition to the ”normal” tipdressing co-
unter (which is reset after replacement of electrodes). This tip wear co-
unter is not reset after electrode replacement.
The timer increments the respective tip wear counter after each tipdres-
sing of an electrode. It the tip wear counter has reached its programma-
ble prewarning value (value ”Prew. tip wear”), the ”Prewarning tip
replacement” output (see page 6−15) is set, and the message ”Replace
tip” is indicated via the GUI (BOS).
When the tip wear counter has reached its programmable end value (va-
lue ”Max tip wear”), the timer sets the ”Tip replacement” output (see page
6−16).
. A tip’s wear monitoring function can be deactivated by parameteri-
zing the respective ”Max. tip wear” with the value ”0”.
Via the ”Acknowledgement tip replacement” input signal (see page
6−13) or via BOS, a tip counter can be reset to the value ”0” at any time.
3.13 Electrode Force
The indication which force the electrodes shall use to press the welded
parts together (in kilonewton: kN) is part of any welding program.
Therefore, the timer generates − with an internal characteristic curve −
for each programmed force value a corresponding output signal that can
be used as an actuating variable for the electrode’s force.
In order to output the force actuating variable,

D an analog signal to X2 (see page 5−7) and
D 8 serial output signals (”Prop. valve selection”, see page 6−16) are
provided.
The internal characteristic curve can be created either

D automatically by force scaling (please refer to chapter 3.14.1, page
3−31 ff).
or
D manually with the parameters ”conversion factor” and ”zero adjust”.
and Controls
Timer Functions
”Conversion factor” (in kN/Volt):

With this factor, the timer calculates the output value of the actuating va-
riable for the force. See illustration.
”Zero adjust” (in kN):
Moves the zero crossing of the characteristic curve. This way the cha-
racteristic curve can be adapted to the working zero of the actuator sy-
stem in use. See illustration.
Programmed
force in kN
”max. force”
+
Zero adjust
−
0 Actuating variable
for the force
”Max. force”: the parameter limits the max. actuating variable for
highest possible programming of the the force that can be output
electrode force within the welding (Depending on the hardware.
program. at X2 e.g. 10V)
Progr. Progr. force value (in kN) + zero adjust (in kN)
actuating variable
for the force =
Conversion factor (in kN/Volt)
Characteristic curve for output of force value
. In order to make the programmed force work on the electrodes, it is

necessary to set the characteristic curve properly!
. During force scaling, the timer automatically calculates the neces-

sary values for the parameters ”conversion factor” and ”zero ad-
just”. After that, the parameters may not be altered manually!
In addition to the possibility to program an electrode force that is con-

stant for the entire welding process, the timer also offers the following
functions:
D Force profile:
It is possible to program 10 different force values for each welding
program. These force values can then be activated at certain times
within the welding process.
D Force Stepper:
Depending on the selected stepper or tipdress curve, you can deter-
mine the percentage with which the programmed basic force value
should be increased in dependence of the current electrode wear.
and Controls
Timer Functions
3.14 Scaling
. Always scale the force first, then the current!
3.14.1 Force scaling

With the function ”force scaling”, you adjust all components of the wel-
ding station that are part of the force build-up to their reference dynamo-
meter (e.g. force transducer). This bears the following advantages:
D Presetting the gun force in kilonewton (kN)
D Exact reproducibility of logged force values (ISO 9000)
D Force values of all scaled stations can be compared to each other and
transferred to other stations
D Comparable documentation.
. Basically, the timer also works without force scaling. But you can
only benefit from the above mentioned advantages after a force
scaling procedure.
CAUTION
Risk of gun damage!
If you don’t use force scaling, the timer cannot make a correct con-
nection between the programmed force and the actuating variable
for force that is to be output (necessary for controlling the force
of the gun).
Therefore, the force that actually works on the gun can deviate im-
mensely from the programmed force.
The consequences might be erroneous welds and even damages
to the gun.
If you don’t use the force scaling function, it is absolutely neces-
sary to calculate empirically, after each gun exchange, the basic
force value for each required electrode force − starting with the va-
lue ”0”.
Prerequisites for force scaling:

D Proportional control valve, servo gun, or other suitable equipment
that can convert the timer’s actuating variable for force into a mecha-
nical force at the gun.
D External reference dynamometer with appropriate measuring range.
D Coupled programming device with BOS software (for operation and
input of measured values).
and Controls
Timer Functions
For force scaling, preset 2 different force actuating values in % (in rela-
tion to the highest value that can be output), use the reference dynamo-
meter to measure the resulting forces between the electrodes, and enter
the measured forces (in kN) into the timer.
The timer then calculates internally all data necessary for the adjust-
ment.
When executing the force scaling function, please pay special attention
to the following:
L For the two actuating values used for force scaling, the following is appli-
cable:
If possible, the higher value shall generate the maximum force used for
welding (upper end of the force working range).
Both values should differ from each other by at least 20 %. The force re-
quired for electrode tipdressing is not to be assigned to the normal wor-
king range (because most of the times it is lower).
If you do not know which value is to be entered for force scaling, use
small values to execute sample scalings in order to see which forces will
be generated at the gun. This way, you make sure not to overstress or
damage the gun when force scaling. Then, slowly increase the preset
value while executing further force scalings until the higher preset value
generates the maximum force that you can use for welding.
L Please use for all comparable stations the same reference dynamome-
ter.
L Execute for each gun in the welding station and after each gun exchange
a scaling procedure.
L Verify an executed scaling by comparing the basic force values pro-

grammed in test welding programs with the actual values at the gun.
Make sure that the test programs run without current and that people
are safe during the measurements (possible danger caused by robot
movements).
L Execute a new scaling if a component actively participating in force ge-

neration (weld timer, proportional control valve, gun...) has been ex-
changed.
. Force scaling changes the parameter ”Conversion factor” and

”Zero adjust” (in electrode setup, also refer to page 3−29). There-
fore, after a force scaling procedure, the parameters may not be
manually altered!
and Controls
Timer Functions
3.14.2 Current Scaling

The function ”Current scaling” serves to adapt the timer’s entire measu-
ring and control loop to your reference welding current measuring instru-
ment. This bears the following advantages:
D Reproducible, presettable currents with a maximum error below
+/−2%
(in relation to the current value of the reference welding current mea-
suring instrument)
D Exact reproducibility of logged current values (ISO 9000)
D Force values of all scaled stations can be compared to each other and
transferred to other stations
D Comparable documentation.
. The timer also works without current scaling. But you can only be-
nefit from the above mentioned advantages after a force scaling
procedure.
Prerequisites for force scaling:

D A current sensor connected to X3 (see page 5−9).
D An external reference welding current measuring instrument with ap-
propriate current sensor.
D Coupled programming device with BOS software (for operation and
input of measured values).
. Before executing a current scaling always execute a force scaling

procedure (see page 3−31).
For current scaling, preset 2 different currents in scale values, then use
the reference welding current measuring instrument to measure the re-
sulting currents in the secondary circuit, and enter the measured current
values into the timer.
The timer then calculates internally all data necessary for the adjust-
ment.
When executing the current scaling function, please pay special atten-
tion to the following:
L The current sensor of the reference current measuring instrument must

be installed correctly in the secondary circuit. This means:
− always install it in the same place
− install it vertically with regard to the current carrying conductor
− the sensor cable faces away form the current carrying conductor.
and Controls
Timer Functions
L For the two currents (in scale values) used for current scaling, the follo-
wing is applicable:
If possible, the higher value should lie at the upper end of the normal wor-
king range of your weld station.
Both values should differ from each other by at least 20 scale values.
L Please use for all comparable stations the same reference dynamome-
ter.
L Set your reference welding current measuring instrument to the right

type of current (”AC” for PST, ”DC” for PSI) and set the appropriate mea-
suring range.
L Programmed fadeout times and an activated trail current are also effec-
tive during current scaling!
Therefore, prior to the scaling procedure, please check if the correspon-
ding functions are available and correctly set in your measuring instru-
ment.
L Always scale without a welded part and with closed electrodes.
L Execute for each gun in the welding station and after each gun exchange
a scaling procedure.
L Verify an executed scaling by doing a test weld comparing the current

shown in the timer with the current shown in the reference welding cur-
rent measuring instrument.
L Execute a new scaling if a component actively participating in the control

loop (weld timer, transformer, sensor...) has been exchanged.
and Controls
Timer Functions
3.15 Corrections
The timer’s correction functions allow
D changes of current and
D pressure (electrode force).
This way you can quickly execute process-related adjustments and

adaptations of the welding process without changing the originally pro-
grammed data. The corrections function as an addition to the program-
med basic values.
You can activate both types of correction

D for a certain electrode/gun (= Corr. (E) and
D for individual programs or individual program sectors (= Corr. (P).
. When the current correction is changed, the reference current that

is to be monitored will also be internally adjusted.
. The correction values can be limited in the basic settings. This limit
can be set within the range of +/−20%.
3.16 Weld Transformer Selection (PSI only)

In order for the PSI’s power supply unit to function correctly, the timer
must ”know” certain technical data about the weld transformer in use.
This requires the correct setting of a number of parameters in the ”Weld
transformer selection”:
When using PSG weld transformers:

D ”Type”:
Model of the PSG transformer according to name plate (e.g.
”PSG 3100.00”) and
D ”Number”:
Number of parallel transformers.
With this data, the PSI knows the type of the diodes, the diode selection,
and the highest permissible current for the welding station.
When using PSG weld transformers:

D ”Type”:
Please switch to ”Other transform.”.
D ”Number”:
Number of parallel transformers.
and Controls
Timer Functions
D ”Secondary transformer current”:

Maximum secondary current of the transformer. The maximum wel-
ding current is limited to this value.
D ”Transformer’s transformation ratio”:
Transformation ratio primary/secondary. This parameter is neces-
sary for converting primary and secondary current if for current mea-
suring you use the current sensors integrated in the primary circuit
(primary current regulation; used e.g. with transformers without inte-
grated CC sensor).
D ”Number of diodes”:
Number of diodes connected in parallel in the secondary circuit.
D ”Type of diodes”:
Type of diodes used in the weld transformer.
Diode monitoring:
By means of the ”Diode monitoring” parameter, the diode monitoring in
the secondary circuit of the weld transformer can be activated and deac-
tivated.
CAUTION
Risk of destruction of the power supply unit or the weld transfor-
mer!
When diode monitoring is activated, the weld transformer’s di-
odes are no longer monitored by the PSI. Under a high load this
can lead to major damages to the welding station.
Therefore, always turn diode monitoring on!
and Controls
Technical data
4 Technical data
4.1 Integrated weld timer
Degree of protection IP 20
Operating voltage +24 V= ; +20 %, −15 %
with max. +/−5 % ripple
Rated current at 24 V PSI: approx. 1.5 A
(without I/O module and without PST: approx. 1.0 A
additional consumers at X5)
Starting current PSI: approx. 2.0 A for 10 ms
(without I/O module and without PST: approx. 1.5 A for 10 ms
additional consumers at X5)
Operating temperature 0 ... +55 degrees Celsius
Temp. for storage/transportation −25 ... +70 degrees Celsius
Air pressure 0 ... 2000 m above sea level
Humidity Condensation not permissible.
Climatic category 3K3 to EN60721−3−3
Number of programs max. 256;
each program can be called up indi-
vidually via the input signals ”Program
selection” or ”Spot selection”
Programming on location V24/RS232 interface, isolated.
X1 connection: 9-pin D-Sub
Fieldbus for programming PROFIBUS-FMS or
(option) INTERBUS-PMS or
Ethernet 10 MBit
Operating software (firmware) Stored in Flash-Memory;
can be loaded via ”WinBlow” software
package (optional)
Program memory buffered RAM memory
Backup battery Lithium battery Type AA 3.6 V
to buffer RAM data and internal clock
with MAINS OFF.
Battery life approx. 2 years.
Pressure control for analog output (at X2):
proportional valve 0 to +10 V, max. 20 mA or
0 to 20 mA or
4 to 20 mA (at max. 500 ohms).
Input feedback (to X2):
logic 1: +16 V ... +30 V, 20 mA
logic 0: −1 V ... +4 V
and Controls
Technical data
Main switch trigger MST Relay contacts (to X8).

(only with PST) Resilience: 24 VDC, max. 6 A
42 V~, max. 1 A
Electrodes max. 5 (no. 0 to no. 4)
4.2 I/O Module ”DEV-NET”

Function:
Connection of the timer’s I/O to the higher-level PLC or the robot
D via DeviceNet with bus copper cable (serial I/Os) and
D via discrete 24 V signals at X11 and X12 (parallel I/Os).
Operating voltage (at X10) +24 V= +20 %, −15 %

with max. +/−5 % ripple
Current input max. 2 A
depending on the wiring of the sig-
nal in-/outputs
Power loss 0.5 VA per active input
2.4 VA per active output
Signal input field via DeviceNet 9 byte, max. 72 signals (0 to 71)
Signal output field via DeviceNet 9 byte, max. 72 signals (0 to 71)
Signal inputs (X12) logic 1: +16 V ... +30 V, 20 mA
logic 0: −1 V ... +4 V
Signal outputs (X11) +24 V, max. 0.1 A,
short circuit-proof
and Controls
Electrical Connection
5 Electrical Connection
5.1 Interference Suppression

Interferences (RF noise) are caused by transient peaks and can be
spread into the timer either directly or by coupling via connecting lines.
For this reason, measures for interference suppression are necessary.
L Eliminate interferences already at their source. If this is not possible, in-
stall the interference suppression devices as close to the interference
source as possible.
L Make sure that all components that contain inductivities or switch ele-
ments are properly cleared.
L Install interference suppression devices always in such a way that they
cannot break since machines are often subject to strong vibrations.
DIODE RC ELEMENT
+ ∼
GND MP
Diode, suitable for small DC relays RC element for AC relays and AC

motors
DIODE AND ZENER DIODE RC ELEMENT
+
GND
DI-ZD attenuation element for large DC RC element for spark quenching of

contactors and defined drop-out times inductive loads
Examples for interference suppression
. The following table is only an example. The dimensions of the ne-

cessary modules depend on the actual load ratios.
Resistor Capacitor Diode
24 VDC − − 1 N 5060/ZL 12
48 VDC − − 1 N 5060/ZL 22
110 VAC 220 ohms / 1 W 0.5 uF 400/600 V
220 VAC 220 ohms / 5 W 0.1 uF 500 V
440 VAC 220 ohms / 5 W 0.1 uF 1000 V
and Controls
5.2 Integrated weld timer
. For technical data, please refer to chapter 4.1, on page 4−1.
5.2.1 Output of the Internal 24 VDC Voltage Source (X4)

Connection: at X4; plug-in terminal, spacing 3.5 mm, 14-pin,
max. 1.5 mm2.
Mating connector included in shipment.
Cable length: (From the voltage source to the consumer)
max. 10 m with 0.75 mm2
Type of cable: Unshielded, VDE 0281, 0812
(e.g.: Ölflex)
At X4, a 24 VDC supply voltage that the power supply unit derives from
the mains voltage is at your disposal.
. The supply through the internal 24 VDC voltage source and there-
fore the functionality of all devices fed from this source is guaran-
teed only if mains voltage is applied at the mains input of the power
supply unit!
Timer
X4 max. 2.5 A
+24 VDC 5 May be used, e.g., for

power supply of timer
0V 8 logics and of I/O module
Internally generated 24 VDC power supply
L Please consider the following facts when using the internal 24 VDC vol-
tage source:
D max. current load: 2.5 A.

D When supplying the timer logics:
If you switch off the mains voltage at the mains input of the power sup-
ply unit, you automatically switch off the timer as well. In this state,
− neither programming, diagnosis, or visualization via the timer
− communication between timer and PLC/robot is not possible an-
ymore.
D When supplying the I/O module:
If you switch off the mains voltage at the mains input of the power sup-
ply unit, you automatically switch off the I/O module as well. In this
state,
− communication between timer and PLC/robot is not possible an-
ymore.
and Controls
. If the above describe facts are not compatible with your applica-
tion, the 24 VDC supply of timer or I/O module must be provided by
external power supply units.
5.2.2 Supply of the Timer Logics (X4)

max. 1.5 mm.
(e.g.: Ölflex)
The timer logics must be supplied with 24 VDC.
Timer
X4
10 24VDC
Int. logics Supply of the internal timer logics
11 0V
Logics supply input of the timer
The remaining wiring of X4 determines which voltage source supplies

the timer. You can select
D either the internal voltage source (refer to page 5−2) and
D an external power supply unit.
To do so, you only have to set/remove some jumpers at X4.
. For more information about the interconnections of X4, please re-

fer to chapter 5.2.4 on page 5−4 ff.
While a supply through the internal voltage source is preferred in standa-

lone installations (e.g. suspended welding station; additional 24 VDC
power supply units are not necessary), a supply via external power sup-
ply units is mainly used in networked timers (timer can be programmed
even if the welding network has been switched off e.g. via the line PC).
L If you use external voltage sources, please make sure that they are spe-
cified as ”safely separated” according to the Low-Voltage Directive
(72/23/EEC, 93/68/EEC and 93/44/EEC)!
and Controls
5.2.3 Supply of External Devices (X5)

max. 1.5 mm2.
Cable length: Depends on the wiring at X4. See description
below.
(e.g.: Ölflex)
X5 is at your disposal for the 24 VDC supply of an external device (e.g.
force sensor).
The maximum current load/cable length at X5 depends on the voltage
source in use and the entire length of the cable between source and ex-
ternal consumer. The maximum current load at X5 must not exceed
0.5 A.
Timer
X4
10 24VDC Supply of
Int. logics − the internal timer logics and
11 0V − X5
External
max.
X5 consumer
0.5 A. 1 24VDC
2 0V
Connection of external devices to X5
L Make sure not to exceed the limit values specified for current load
(source, connections) and cable lengths!
. The remaining wiring of X4 determines which voltage source sup-

plies X5.
You can use either the internal voltage source (see page 5−2) or an
external power supply unit. To do so, you only have to set/remove
some jumpers at X4. For more information about the interconnec-
tions of X4, please refer to chapter 5.2.4 on page 5−4 ff.
5.2.4 24 VDC Voltage Distribution (X4)

max. 1.5 mm2.
and Controls

(e.g.: Ölflex)
The internal circuit of X4 facilitates the wiring of the 24 VDC supply bran-
ches for the timer and the I/O module substantially. By plugging or remo-
ving certain jumpers, you can realize different supply variations without
altering the remaining wirings in the switch cabinet.
To do so, connect the relevant voltage source to X4/6 (24 VDC) and X4/7
(0 V).
Below you find descriptions of some possibilities. In the following, please
find the illustrations representing the appropriate wiring.
Which kind of wiring is suitable for you, depends on the requirements of
your application.
1. Timer and I/O module are fed by an internal 24 VDC voltage source.
Application: Used preferably in standalone installations.
Advantage: Separate power supply units are not necessary.
Disadvantage: 24 VDC will only be generated if the mains vol-
tage is present at the power supply’s mains input.
2. The I/O module is fed by an internal 24 VDC voltage source, the timer
is fed by an external power supply unit.
Application: Used in networked installations.
Advantage: Programming, diagnosis, and visualization are
still possible even after the mains voltage at the power sup-
ply unit’s mains input has been switched off.
Electrical isolation between timer and I/O module with dis-

crete in-/outputs (parallel I/O) is possible.
Disadvantage: If you switch off the mains voltage at the mains
input of the power supply unit, I/O communication between
timer and PLC/robot is not possible anymore.
3. Timer and I/O module are both supplied by a mutual external 24V
power supply unit.
Application: Used preferably in networked installations.
Advantage: I/O communication between timer and PLC/ro-
bot, programming, diagnosis, and visualization are still
possible even after the mains voltage at the power supply
unit’s mains input has been switched off.
Disadvantage: Electrical isolation between timer and I/O mo-
dule with discrete in-/outputs (parallel I/O) is not possible.
4. Timer and I/O module are both supplied by separate external 24V
power supply units.
Application: Used in networked installations.
Advantage: I/O communication between timer and PLC/ro-
bot, programming, diagnosis, and visualization are still
possible even after the mains voltage at the power supply
unit’s mains input has been switched off.
Electrical isolation between timer and I/O module with dis-
crete in-/outputs (parallel I/O) is possible.
Disadvantage: 2 external power supply units are necessary.
and Controls
Version 1: Version 2:
Timer Timer
X4 X4
1 to I/O module 1 to I/O module
(refer to page (refer to page
2 5−14) 2 5−14)
3 Stop circuit 3 Stop circuit

(see page (see page
4 5−15) 4 5−15)
24VDC 24VDC
5 5
internal internal
voltage 6 voltage 6
source source
7 7
8 8
0V 0V
9 9
24VDC 24VDC 24VDC
10 10
internal internal
logics 11 logics 11 0V
0V 0V
12 12 External
p.s.u.
Version 3: Version 4:
Timer Timer
X4 X4
1 to I/O module 1 to I/O module
(refer to page (refer to page
2 5−14) 2 5−14)
3 Stop circuit 3 Stop circuit

(see page (see page
4 5−15) 4 5−15)
24VDC 24VDC
5 5
internal internal
voltage 6 24VDC voltage 6 24VDC
source source
7 0V 7 0V
8 External 8 External
0V p.s.u. 0V p.s.u.
9 9
24VDC 24VDC
10 10 24VDC
internal internal
logics 11 logics 11 0V
0V 0V
12 12 External
p.s.u.
Examples for wiring

and Controls
5.2.5 Pressure Control and Feedback (X2)

max. 1.5 mm2.
Cable length: max. 50 m at 0.5 mm2
max. 100 m with 0,75 mm2
Type of cable: shielded
(e.g.: NFL 13, Metrofunk; LiYCY)
An analog output signal that can be used for controlling a proportional
control valve is at your disposal at X2 Pin 1. The type of the output signal
can be alternatively programmed as
D a voltage signal (0 to +10 V, max. 20 mA),
D a current signal 0 to 20 mA or
D a current signal 4 to 20 mA.
The proportional control valve converts the pending signal into a pres-
sure which will be applied to the gun cylinder. According to the mecha-
nics of the gun, this will result in the force available at the electrodes (see
also page 3−29).
. For pressure control, 8 serial output signals are available in addi-
tion to the output signal at X2 (”Prop. Valve Selection”, by DEV-
NET; see page 6−16).
. The output signal at X2 will be output immediately after the selec-

tion of a welding program and not only upon its start!
In order to signal to the timer that the gun is closed or that the command
force has been reached, you use
D the input terminal 4 at X2.
The programmed squeeze time (SQZ) starts under the following condi-
tions only:
D High level at input X2/4 (in relation to 0V at X2/2)
(for required voltage, please refer to chapter 4.1, on page 4−1).
If this condition is missing, the welding program will be selected and star-
ted (and a possibly programmed 1.SQZ will begin), but the further pro-
cesses (schedule) will be delayed until this one condition is met.
Which sensors and input signals are used for feedback depends on the
respective application. The entire pressure control and feedback e.g.
can also be handled via PLC program (if proportional control valve and
feedback are not connected to the timer itself but to the PLC or the robot).
In addition, applications without feedback or proportional control valve
are possible as well.
The following illustrations represent several connection possibilities.
and Controls
L Make sure that in installations without feedback signal, the welded part
has been perfectly pressed together before the weld time starts!
In order to do so, you have to program sufficiently long squeeze times.
Insufficient squeeze times lead to a large amount of welding splashes!
This might lead to damage to the electrodes and work pieces.
Proportional control valve

Valve supply
+24VDC D
0V
D
P
X2 Pressure
0 to 10 VDC; 20 mA has
Pressure control signal 1 been
0V reached
GND for terminal 1 and 4 2 D D
3
Feedback 4
Shield 5 D D
Connection of a proportional control valve with feedback
Proportional control valve

Valve supply
+24VDC
X2
0V
Pressure control signal 1 D
GND for terminal 1 and 4 2 D D
3
Feedback 4
Shield
D
5 D D
X4
5
Device-internal +24 VDC
voltage source
0V 8
Connection of a proportional control valve without feedback
. The connection ”without feedback” is applicable if

− the proportional valve does not return a feedback signal, or
− the feedback signal is connected to the PLC/robot.
and Controls
X2
Pressure control signal 1
GND for terminal 1 and 4 2
3
Feedback 4
Shield 5
X4
5
internal voltage +24 VDC
source
0V 8
Wiring without proportional control valve
. The connection ”wiring without proportional control valve” is ap-

plicable if
− you don’t use a proportional control valve or
− the proportional control valve and the feedback signal are con-
nected to the PLC/robot.
L If pressure control and feedback are completely handled by the PLC pro-
gram, the PLC/robot must make sure that the programmed weld time will
be started only if the gun/electrodes are in proper condition.
To do so, two solutions are possible:
1. The PLC informs the weld timer via input X2/4.

With this solution, the welding program will be started, but the SQZ
starts running only when a ”high” level is available at the input mentio-
ned.
2. The PLC starts the welding program only if the proper condition of the
gun/electrodes can be guaranteed.
With this solution, permanently apply high-level to input X2/4 and al-
ways program the lowest SQZ in all welding programs (PST: 1 line cy-
cle; PSI: 16 ms).
5.2.6 KSR Sensor (X3)

max. 1.5 mm2.
Cable length: max. 100 m (with recommended type of cable)
Type of cable: shielded, core cross section min. 0.75 mm2,
(e.g.: 2 x 2 x 0.75 mm2 LiYCY,
Bosch order no.: 1070 913 494)
and Controls
The timers are provided with an integrated Constant Current Regulation

(KSR). The timer controls the current flow in the secondary circuit so that
the programmed command current can actually be reached.
This way, it is possible to compensate process- and handling-related
fluctuations of the contact resistance between electrode - workpiece -
electrode.
A sensor which indicates the current flow in the primary and secondary
circuit of the welding transformer is required for the regulation.
A current sensor installed in the secondary circuit can be connected via
the toroid input (X3; terminal 1 and 2).
. PSI devices additionally have an integrated current sensor for the

primary circuit of the welding transformer. This allows you to
chose between secondary and primary measurement by means of
the software (BOS).
In case of weld times > 1 s or for temporary bridging over in the pre-
sence of failure of the sensor in the secondary circuit, change to
primary measurement.
X3
Toroid input 1
Toroid input 2
Shield 3 D
4
5
Shield connection only at X3 terminal 3! Secondary circuit

to the power supply unit
Connection of the KSR sensor on the secondary side
In order to ensure the proper operation of the sensor, please comply with
the following:
L Install the sensor in such a way that it is safe from damage caused by the
work piece and from welding splashes.
Choose places with the highest possible distance to the busbars or high
current cables. This reduces the influence of externally originating ma-
gnetic induction. Please comply with the above mentioned cable speci-
fications.
Never use magnetizable metal parts for fastening, but preferably copper
or brass.
L Make sure that the currentcarrying conductor is lead straight and centri-
cally through the sensor. The voltage induced in the sensor (and there-
fore the measuring variable) has reached its maximum when the
conductor runs vertically to the spanned sensor plane.
and Controls
L If the sensor is used in movable equipment (e.g. robots), certain parts of

the cables are subject to very strong mechanical stress (e.g. trailing
chain).
In such cases, please use appropriate cables and set the connecting li-
nes in such a way that in case of an error, they can be exchanged quickly
and easily.
L Connect the cable shield only at the side where the timer is located!
L Adjust the timer’s entire control loop regularly in order to avoid measu-
ring faults (current scaling). For this purpose, an external reference wel-
ding current measuring instrument is required.
Measuring circuit test:

During the SQZ, the timer checks, by measuring the ohmic resistance, if
the connected measurement circuit is faultless or not. This way, pro-
blems in the area sensor cable plug can be detected.
The following test criteria apply:
Measured ohmic resistance Result
< 7 ohms short circuit of measuring
circuit
12 to 950 ohms measuring circuit ok
> 1100 ohms measuring circuit open
. Measuring values in between lead to an ambiguously assessable

result.
In case of an error, the timer interrupts the welding process and deletes
the output signal ”Ready”.
5.2.7 Main switch trigger (X8) (only with PST)

max. 1.5 mm2.
(e.g.: Ölflex)
and Controls
The function ”Current passed without command” checks whether a vol-

tage not initiated by the timer has been applied between the primary cir-
cuit terminals of the welding transformer (signal: Current passed without
command). If this is the case, the internal floating contact at X8 (change−
over switch) will short−circuit the terminals 2 and 3.
The use of main switches with a suitable functionality results in automa-
tic triggering of the main switch and thus to deactivation of the power
supply if suitable wiring of X8 (break contact/make contact) has been
provided.
Load:
24 VDC, max. 6 A
42 VAC, max. 1 A X8
1 Facility for
2 triggering the
main switch
3
Timer recognizes fault states: Terminals 2 and 3 short−circuited

No fault status: Terminals 1 and 2 short−circuited
Connection terminals for main switch trigger

and Controls
5.2.8 Fan connection (X4)

max. 1.5 mm2.
(e.g.: Ölflex)
. Not all timers can provide a temperature-controlled 24 VDC connec-
tion of an external forced ventilation (max. 2 A). See wiring diagram
of the corresponding timer.
Forced ventilation modules are used for example in various types
of welding unit housing,
X4 Fan module
1
+24 VDC 13 +24 VDC
PE
0V 14
2
0V
to PE bar
Connection of an external fan module
5.2.9 Programming unit (X1)

Connection: at X1; D-sub, 9-pin, at the cable via socket
Cable length: max. 20 m (with recommended type of cable)
Type of cable: shielded, core cross section min. 0.2 mm2,
Capacity max. 2.5 nF
(e.g.: 3 x 2 x 0.2 mm2 LifYCY, Metrofunk)
For connecting the programming unit (PC, Laptop), please use the
RS232 interface X1.
X1 PC (COM1 or COM2)
1
2 2
RX RX
3
TX 3 TX
4
4
GND 5
5 GND
6
7
8
9
Connector Connector
Shield over a large area of the metallic housing of the plug−in connection
Transmission rate: 19200 bits/s

Parameter: 8E1 (8 data bits, even parity, 1 stop bit)
Transmission: PS5000 block protocol with CRC16
and Controls
5.3 I/O Module ”DEV-NET”

The complete communication between timer and higher-level PLC or ro-
bot is primarily handled via DeviceNet (copper cable).
In addition, there are discrete 24 VDC signals available, which can be
used via PLC, robot or control panel.
Therefor, the I/O module provides
D 8 inputs (24 VDC, at X12)
D 8 outputs (24 VDC, at X11)
D 9 byte input field (DeviceNet connection)
D 9 byte output field (DeviceNet connection).
5.3.1 Power Supply (X10)

max. 1.5 mm2.
(e.g.: Ölflex)
. For further technical data, please refer to chapter 4.2 on page 4−2.
Two types of connection are possible:

1. Connection of the I/O module supply to X4 of the timer or
2. direct connection of the I/O module supply to a separate 24 VDC
power supply unit.
. If you connect the I/O module to the timer’s X4 (1. type of connec-
tion), you can use either the internal voltage supply (see page 5−2)
or an external power supply unit. To do so, you only have to set/re-
move some jumpers at X4. For more information about the inter-
connections of X4, please refer to chapter 5.2.4 on page 5−4 ff.
L Make sure to use only such external voltage sources that are specified
as ”safely separated” according to the Low-Voltage Directive
(72/23/EEC, 93/68/EEC and 93/44/EEC)!
L If an electrical isolation between I/O and timer is necessary, the timer and
the I/O module must be operated via separate 24 VDC voltage supply
units!
L Please make sure that the correct function of the stop circuit (see il-
lustrations below) is guaranteed in every connection type!
In dangerous situations at the welding station or in case of intended
switch-off of the weld timer, the in- and outputs of the I/O module are to
be switched to low level. To do so, an external monitoring device must
open the floating contact which then interrupts the power supply at X10.
and Controls
In case of an open stop circuit, the timer sends the following message:
”Stop circuit open / no 24 V”. This message is automatically reset, i.e. it
disappears automatically when the stop circuit is closed.
I/O module Timer
X10 X4
24VDC 1 1
0V 2 2 0V
24VDC 3 3
0V 4 4 24VDC
Floating contact
bridged internally: Load: 24 VDC, max. 3 A
terminal 1 and 3
terminal 2 and 4
Stop circuit
Connection of the I/O module supply to X4 of the timer
I/O module Stop circuit 24 VDC-power

supply unit
Floating contact
X10 Load: 24 VDC, max. 3 A
24VDC 1 24VDC
0V 2 0V
24VDC 3
0V 4
bridged internally:
terminal 1 and 3
terminal 2 and 4
Direct connection of the I/O module supply to a separated 24 VDC

power supply unit.
L Use terminal 3 at X10 as a 24 V source for triggering the inputs at X12.

Use terminal 4 at X10 as a 0 V reference potential at X11.
L Because of the internal jumper at X10, the incoming supply voltage can
be transferred to further devices.
Make sure, though, not to exceed the limit values specified for current
load (voltage source, connections) and cable lengths!
and Controls
5.3.2 DeviceNet Connection

In order to integrate the timer in a DeviceNet bus system, please use
X13.
Cable length: according to DeviceNet specification

Type of cable: copper, shielded, according to DeviceNet speci-
fication
previous following
DevNet- Weld timer DevNet-
node node
...
1
2
3
4
X13
5
last node with terminator
according to DeviceNet
specification
Example: DeviceNet connection of the last 3 weld timers at the bus
. For more information on which I/O signals are exchanged between

the weld timer and the DevNet host, please refer to chapter 5.3.3.
Setting the DeviceNet address:

via NA switch. Address (MAC ID) according to DeviceNet specification.
Setting the DeviceNet baud rate:

via DR switch, according to DeviceNet specification.
5.3.3 Signal outputs and inputs

Connection X11, X12: Plug-in terminal, spacing 3.5 mm,
max. 1.5 mm2.
Type of cable: unshielded, VDE 0281, 0812 (e.g.: Ölflex)
and Controls
. For further technical data, please refer to chapter 4.2 on page 4−2.
For information regarding the functionality of all signals, please re-
fer to chapter 6.
from PLC/robot/control panel

to PLC/robot/control panel
Input field (control word)

Width: 9 byte.
Input signals are assigned to the individual bits (bit
0 to bit 71).
For assignment, please refer to the following page.
serial with
DeviceNet
through X13
Output field (status word)
Width: 9 byte.
Output signals are assigned to the individual bits (bit
0 to bit 71).
For assignment, please refer to the following page.
Description
X12 refer to page
E0 AUTOMATIC PROGRAM SELECTION ACTIVE 6−4
E1 Not used
E2 Not used
E3 Not used
E4 Not used
E5 Not used
E6 Not used
E7 Not used
X11
A0 Not used
A1 Not used
A2 Not used
A3 Not used
A4 Not used
A5 Not used
A6 Not used
A7 Not used
X10
+24V Supply input 5−14
0V Supply input 5−14
+24V Signal voltage output for passive switch elements 5−14
0V Reference potential for outputs at X11 5−14
Assignment of all signal in− and outputs

and Controls
Input field, byte 0 and 1 Output field, byte 0 and 1

Bit Signal name Description Bit Signal name Description
Refer to page Refer to page
0 TIPS HAVE BEEN DRESSED 6−2 0 WELD COMPLETE (WC) 6−18
1 WELD ON EXTERNAL 6−5 1 WITH IGNITION 6−21
2 RESET FAULT 6−6 2 WITHOUT MONITORING FUNCTION 6−21
3 RESET FAULT WITH SPOT REPEAT 6−7 3 WITHOUT REGUL. AND WITHOUT MON. FUNC. 6−22
4 RESET FAULT WITH SPOT REPEAT 6−8 4 WELDING FAULTS 6−20
5 reserved 5 CONTROL READY 6−19
6 reserved 6 AUTOMATIC PROGRAM SELECTION ACTIVE 6−22
7 reserved 7 reserved
8 ACKNOWLEGEM. ’TIPS HAVE BEEN DRESSED’ 6−9 8 TIPDRESS PREWARNING ELECTRODE 1 6−22
12 ACKNOWLEDGM. ’ELEC. HAVE BEEN REPL.’ 1 6−11 12 TIPDRESSING REQUEST ELECTRODE 1 6−22
Assignment of the input and output field for Device-Net coupling (byte 0 and 1)

Bit Note Bit Note
16 ACKNOWLEDGEMENT ’TIP REPLACEMENT’ 1 6−13 16 PREWARNING ELECTRODE 1 6−23

20 reserved 20 END OF STEPPER ELECTRODE 1 6−23
24 reserved 24 PREWARNING TIP REPLACEMENT 1 6−15
28 reserved 28 TIP REPLACEMENT 1 6−16
and Controls

32 SPOT SELECTION 01 6−3 32 PROP. VALVE SELECTION 01 6−16
40 SPOT SELECTION 256 6−3 40 SHEET THICKNESS 01 6−17

48 SPOT SELECTION 65536 6−3 48 SHEET THICKNESS TOLERANCE 01 6−17
52 reserved 52 SHEET THICKNESS TOLERANCE 16 6−17
56 SPOT SELECTION READY 6−4 56 SPOT SELECTION TAKEN OVER 6−23
57 reserved 57 STATUS 01 6−24
Input field, byte 8 Output field, byte 8

Assignment of the input and output field for Device-Net coupling (byte 8)
and Controls
Notes:
and Controls
I/O Signal Descriptions
6 I/O Signal Descriptions
This chapter contains the descriptions of all I/O signals regarding their
importance for the timer. Signal names are always put in quotation
marks (”Signal name”).
. For information regarding the assignment of all in-/output signals

of the ”DEV-NET” I/O module, please refer to chapter 5.3.3 from
page 5−16.
6.1 Input Signals
6.1.1 Alphabetical Overview
Signal name Page
RESET FAULT 6−6
RESET FAULT WITH SPOT REPEAT 6−8
RESET FAULT WITH WC 6−7
SPOT SELECTION 6−3
AUTOMATIC PROGRAM SELECTION ACTIVE 6−4
SPOT SELECTION READY 6−4
ACKNOWLEDGEMENT ’TIPS HAVE BEEN DRESSED’ 6−11
ACKNOWLEDGEMENT ’ELECTRODES HAVE BEEN RE-

PLACED’ 6−11
ACKNOWLEDGEMENT CUTTER CHANGE 6−13
START 6−2
WELD ON EXTERNAL 6−5

and Controls
6.1.2 Start
A positive edge at the input triggers the acceptance of the currently se-
lected welding program (for more information regarding program selec-
tion, see page 6−3) if the timer is in ”Ready” (see page 6−19).
Schedule:
1. The welding program starts.
If programmed, the 1.SQZ starts running.
2. SQZ starts.
Up to the end of the SQZ, the welding schedule can be aborted by
resetting ”Start”.
. Within the SQZ, the timer checks, by measuring the ohmic resi-
stance, whether the connected measurement circuit is faultless or
not.
In case of an error (refer to page 5−11), the timer interrupts the wel-
ding program and deletes the output signal ”Control ready”.
3. If ”Start” continues to be high after the end of the SQZ, Interlock starts
in single mode. While in Interlock, the 1., 2., and 3.WLD run even after
resetting ”Start”.
After resetting ”Start” in seam mode, only a current cycle that has al-
ready begun will be finished.
. Even with interlock active, welding times can be aborted by ope-
ning the stop circuit (see page 5−15).
. Whether the weld times are executed with or without welding cur-
rent depends on the input signal ”Weld on external” (refer to page
6−5).
4. HLD starts running.

5. The output ”Weld complete” (refer to page 6−18) acknowledges the
weld schedule.
Start
1.SQZ SQZ 1.WLD 1.CT 2.WLD 3. 3.CT 3.WLD HLD

t
Start Interlock
Interlock in single mode

and Controls
Start
1.SQZ SQZ 1.WLD 1.CT n x 2.WLD HLD t
Reset of ”Start” during 2.WLD in seam mode
6.1.3 Selection of program / spot

In dependence on the input signal ”Automatic program selection active”
(see page 6−4), the input signals are used to select the desired
D welding program (0 to 255), or
D welding spot (256 through 1048576).
To do so, the binary coded program/spot number will be applied to the

inputs. Then, use the input signal ”Spot selection ready” (see page 6−4)
to instruct the timer to interpret the program/spot selection input.
: High level of the corresponding signal
Value
Input signal (dec)
Spot selection 01 1
Spot selection 02 2
Spot selection 04 4 ...
Spot selection 08 8
Spot selection 16 16
: :
Spot selection 8388608 8388608
...
00
01
02
03
04
05
06
07
08
09
10
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
11
selected spot number:
Binary coded selection of a spot (of an electrode) via input signals ”Spot selection x”
. When you select a spot then you always select the corresponding
program as well.
and Controls
. Immediately after selection of a welding program, the control out-

puts to X2 an output voltage corresponding to the programmed
setpoint pressure (see page 5−7).
Additionally, the outputs ”Prop. valve selection” (see page 6−16)
signal the setpoint pressure via the DevNet interface.
. The function ”Start simulation” within the user interface (BOS) al-
ways refers to program numbers!
6.1.4 Automatic program selection active

The input signal defines how the timer interprets the bit pattern at the in-
puts ”Spot selection x” (see page 6−3):
D High-level at input: Interpretation as program number.
When the signal ”Spot selection ready” (see Chapter 6.1.5) is set, any
program numbers greater than 255 result in the error message
”Faulty program selection”.
D Low-level at input: Interpretation as program number.
When the signal ”Spot selection ready” (see Chapter 6.1.5) is set, any
program numbers smaller than 256 result in the error message
”Faulty spot number”.
. The status of the input signal is mirrored at the output signal ”Auto-
matic program selection active (see page 6−22).
6.1.5 Spot selection ready

In connection with the output signal ”Spot selection taken over” (see
page 6−23), the input signal is used to perform the handshake with PLC/
robots (e.g. when servotongs are used).
Handshake schedule:
1. The PLC/robot sets the ”Spot selection ready” input as soon as the
desired spot number is pending in the ”Spot selection” inputs (see
page 6−3).
2. The timer reacts with setting the ”Program selection taken over” out-
put signal once it has selected the spot (and the corresponding pro-
gram).
Simultaneously, the timer outputs the programmed command force of
the electrodes, the sheet thickness (see page 6−17) and the sheet
thickness tolerance (see page 6−17).
3. Now, PLC/robot must reset the input signal ”Spot selection ready”.
4. In return, the control resets the output signal ”Spot selection taken
over”.
and Controls
6.1.6 Ignition on, external

Sometimes it is necessary to execute a welding program without weld
current (e.g. within the scope of a clock time optimization at the welding
line or for other settings/tests).
Therefore, an external device (robot, PLC, keylock switch at the control

panel) can determine via this input signal.
1. whether the timer should execute all welding programs without cur-
rent as a rule or
2. whether the timer itself, based on the parameterization, has an in-
fluence on this decision (with or without current).
Regarding point 1.:

If ”Weld on external” is not set, all welding programs in the timer − inde-
pendent from the rest of the timer’s parameterization − will be executed
without current. The power supply unit will not be triggered in this case.
Regarding point 2.:

If ”Weld on external” is set, the reaction depends on the following para-
meters:
D Weld on internal (globally affects all programs in the timer) and
D program−related weld (is part of each welding program and is effec-
tive in the corresponding program only).
The execution of a welding program with current is possible only if

D ”Weld On External” is set and
D Weld on, internal
D the program−related weld (firing) has been switched on.
This corresponds to an AND operation of all 3 mentioned conditions.
. For feedback of this AND operation to an external device, please

use the output signal ”Weld / No weld” (see page 6−21).
and Controls
6.1.7 Reset fault

If an error occurs, the timer goes into ”Block”.
In this state,
D it is not possible to start a welding process (schedule)
D the LED READY at the timer’s front goes off (see page 2−8)
D the output signal ”Control Ready” will be reset (refer to page 6−19).
. Error and status messages are listed in the ”Error list

PS5000/PS6000” (No.: 1070 087 000).
While the timer automatically deletes ”self−resetting” errors after the

cause of the error has been eliminated, ”not self−resetting” errors re-
quire a ”reset fault” after the elimination.
This operation can be executed either via
D Software (BOS),
D the reset button at the timer’s front (see page 2−8) or
D a positive edge of the ”Fault reset” input signal.
L Please note that after ”Reset fault”, the timer only restores the ”Ready”
state. In ”Ready” the following is applicable:
D it is possible to start a new welding process

D the LED READY at the timer’s front is lit
D and the output signal ”Control ready” is set.
. The timer does not execute any other actions!

If the error occurs during a welding process, the gun might still be
closed and the robot e.g. remains on the current welding position.
Via the input signals ”Reset fault with WC” (see page 6−7) and ”Reset
fault with spot repeat” (see page 6−8), other operations can be initiated
in addition to ”Reset fault”. Please refer to the indicated cross referen-
ces.
and Controls
6.1.8 Error Reset with WC
. For basic information, please refer to page 6−6!
A positive signal edge leads to

1. ”Reset fault” and subsequent
2. setting of the signal ”Weld complete” if the input signal ”Start” is still
pending.
DANGER
Hazardous machine movements may be the result!
The signal ”Weld complete” initiates the robot’s positioning to the
next weld spot.
Therefore, make sure to avoid dangerous situations at the welding
station caused by ”Reset fault with WC”!
. ”Reset error with WC” can also be triggered via the GUI (BOS).
”Reset error with WC” is used

D in connection with robots and
D in connection with all errors except ”Current too low” and ”Current too
low for a series of welds”.
. In connection with errors except ”Current too low” and ”Current

too low for a series of welds”, please note the signal ”Reset fault
with spot repeat”. Refer to page 6−8.
If an error occurs while a part is being welded, the robot usually remains
at the welding position with the gun closed. Via ”Reset Fault with WC”, it
is now possible
D to continue the process at the next weld spot.
CAUTION
The current spot weld is erroneous!
Please check the part!
and Controls
6.1.9 Error Reset with Spot Repeat / WC
. For basic information, please refer to page 6−6!
A positive signal edge leads to

1. ”Reset fault” and subsequent
2. repetition of the welding program schedule provided that the input si-
gnal ”Start” is still pending.
If the repetition is completed without another error, the signal ”Weld
complete” will be set.
DANGER
Hazardous machine movements may be the result!
The signal ”Weld complete” initiates the robot’s positioning to the
next weld spot.
Therefore, make sure to avoid dangerous situations at the welding
station caused by ”Reset fault with spot repeat / WC”!
. ”Reset error with WC” can also be triggered via the GUI (BOS).
”Reset error with WC” is used

D in connection with robots and
D in connection with the errors ”Current too low” and ”Current too low for
a series of welds”.
. In connection with other errors, please note the signal ”Reset fault
with WC”. Refer to page 6−7.
If the error ”Current too low” or ”Current too low for a series of welds” oc-
curs while a part is being welded, the robot usually remains at the wel-
ding position with the gun closed. Via ”Reset Fault with WC”, it is now
possible
D to repeat the current, erroneous spot weld.
If, after that, another error occurs, please use ”Reset error with WC”.
and Controls
6.1.10 Acknowledgement ’Tips Have Been Dressed’ x
The timer informs the robot the ”Tipdress prewarning” (see page 6−22)
that ”shortly” a specific tip will need dressing (see page 3−27).
. The time for outputting the signal ”Tipdress prewarning” is para-

meterizable (BOS).
When the robot recognizes the ”Tipdress prewarning”, it must move the
relevant electrode to the tipdress station − at the latest after its maximum
wear has been reached. Dependent on the setting of the parameter
”Stop at end of stepper” (BOS), the timer goes into ”block”, sends the
message ”tipdressing necessary” (see page 6−22), and waits for the
acknowledgment ”Tips have been dressed”.
. The time the robot recognizes ”Tipdress prewarning” depends on

the way it is programmed. The relevant robot inputs are often scan-
ned only before welding of a new part and not after each spot.
This behavior requires the following:
D The time between the output of the signal ”Tipdress Request”
and the maximum wear must be sufficiently set. Only this way it
can be guaranteed that the part can be completely welded before
reaching the maximum wear.
The robot tells the timer that the electrode dressing procedure is finished
by sending the message ”Tips have been dressed”.
As long as a new electrode tipdressing process is still possible at this
point, the timer reacts to a positive signal edge at the ”Tips have been
dressed” acknowledgement as follows:
1. The tipdress counter of the relevant electrode number will be incre-
mented.
2. The wear counter of the relevant electrode number will be reset to va-
lue 0.
3. The ”Tipdress prewarning” output signal (see page 6−22) or ”Tipdres-
sing necessary” (see page 6−22) is reset.
and Controls
Example The following settings are used:

%I Stepper: On
Stepper: active (if Stepper final current > basic current)
Tipdressing: On (if max. tipdressing steps > 0. Here: max. tipdressing steps = 3)
Wear factor: 1.0
Wear start section (offset): 0
Wear stepper section: 100
Max. wear: 100 (= wear stepper section − offset)
Tipdressing inquiry: 10 (= 10 before max. wear)
Prewarning: 30 (= 30 before max. wear)
Current
(%) End of
1. tipdressing 2. tipdressing 3. tipdressing Stepper
Stepper final current
Tipdressing final current
Basic current
90 90 90 70 Current wear
0 0 0 100
”Tipdress prewarning”
Time
Acknowledgement ”Tips have been dressed”
Time
Example: Tipdressing schedule

and Controls
6.1.11 Acknowledgement ’Tips have been replaced’

First, the timer informs the robot via the output signal ”Prewarning” (see
page 6−23) that an electrode must be exchanged ”soon”.
. Prior to the end of stepper (see page 6−23), the time for outputting
the signal ”Prewarning” is parameterizable (BOS) as wear. If tip-
dressing is active, the timer will output ”Prewarning” signal only if
no further tipdressing is permissible.
It depends on the parameterization of the timer whether or not furt-
her welds are still possible after exceeding the end of stepper (pa-
rameter ”stop at end of stepper”).
If the robot recognizes the ”Prewarning”, in ideal circumstances, it mo-

ves the gun to the gun maintenance position in order to exchange the
electrodes.
. The time the robot recognizes ”Prewarning” depends on the way it

is programmed. The relevant robot inputs are usually scanned only
before welding of a new part and not after each spot. This behavior
requires the following:
D The time between the output of the signal ”Tipdressing prewar-
ning” and the end of stepper must be sufficiently set.
D The function ”Stop at end of stepper” is switched off.
Only this way it can be guaranteed that the part can be completely
welded before reaching the maximum wear.
The timer must be informed about the executed electrode exchange ei-
ther via ”Electrodes have been replaced” or via GUI (BOS).
The timer reacts to a positive signal edge at the ”Electrodes have been
replaced” acknowledgement as follows:
1. The tipdress counter of the relevant electrode will be reset.
2. The wear counter of the relevant electrode number will be reset to va-
lue 0.
3. The ”Tipdress prewarning” or ”End of stepper” is reset.
4. When ”Tipdressing of new electrodes” is activated (initial dressing;
please refer to page 3−27), the output ”Initial dressing request” (see
page 6−22) will be activated.
. Electrode ”0” can be reset only via GUI (BOS).

and Controls
Example The following settings are used:

%I Stepper: On
Tipdressing: On (if max. tipdressing steps > 0. Here: max. tipdressing steps = 3)
Wear factor: 1.0
Wear start section (offset): 0
Wear stepper section: 100
Max. wear: 100 (= wear stepper section − offset)
Tipdressing inquiry: 10 (= 10 before max. wear)
Prewarning: 30 (= 30 before max. wear)
Stop at End of Stepper: Off
Current
(%) End of
1. tipdressing 2. tipdressing 3. tipdressing Stepper
Stepper final current
Tipdressing final current
Basic current
70 0 Current wear
100
”Prewarning x”
Time
”End of Stepper x”
Time
Acknowledgement
’Tips have been replaced’ x
Time
Example: Electrode replacement

and Controls
6.1.12 Acknowledgement ’Tips have been replaced’ x

First, the timer informs the robot via the output signal ”Prewarning tip re-
placement” (see page 6−15) that an electrode must be exchanged
”soon”.
When the robot recognizes ”Prewarning tip replacement”, it must re-
place the tip − at the latest after its programmable tipdress counter end
value has been reached. Otherwise, the timer will go into ”block” and wait
for acknowledgement ”Tips have been replaced”.
The robot tells the timer that the tip replacement procedure is finished by
sending the message ”Tips have been replaced”.
The timer reacts to a positive signal edge at the ”Tips have been repla-
ced” acknowledgement as follows:
1. The corresponding tipdressing counter is reset to value 0.
2. The relevant output signal ”Prewarning tip replacement” (see page
6−15) or ”Tip replacement” is reset.
3. Any start inhibit (timer block) is cancelled.
and Controls
Notes:
and Controls
6.2 Output Signals
6.2.1 Alphabetical Overview
Signal name Page
CONTROL READY 6−19
SHEET THICKNESS 6−17
SHEET THICKNESS TOLERANCE 6−17
WELD COMPLETE (WC) 6−18
TIPDRESSING REQUEST x 6−22
TIP REPLACEMENT x 6−16
TIPDRESS PREWARNING x 6−22
END OF STEPPER ELECTRODE x 6−23
WELD/NO WELD 6−21
WITHOUT REGULATION AND WITHOUT MONITORING 6−22

FUNCTION
WITHOUT MONITORING FUNCTION 6−21
AUTOMATIC PROGRAM SELECTION ACTIVE 6−22
PROP. VALVE SELECTION 6−16
SPOT SELECTION TAKEN OVER 6−23
WELDING FAULTS 6−20
STATUS 6−24
TIPDRESS PREWARNING x 6−23
PREWARNING TIP REPLACEMENT x 6−15
6.2.2 Prewarning Tip Replacement x

Informs the PLC/the robot that the tip in question (1, 2, 3, or 4) requires
replacement as soon as possible.
The signal is set when the respective parameterizable tip prewarning va-
lue has been reached.
The ”Tips have been replaced” acknowledgement (see page 6−13) re-
sets ”Prewarning tip replacement”.
. For more information, refer to ”Tip Replacement” on page 3−29.

and Controls
6.2.3 Tip Replacement x

Informs the PLC/the robot that the cutters of the tip in question (1, 2, 3, or
4) require replacement as soon as possible.
The signal is set when the parameterizable value ”Max. tip wear” Has
been reached; it can be reset by means of the programming device
(BOS) or via the ”Tip replacement” acknowledgment (see page 6−13).
. For more information, refer to ”Tip Replacement” on page 3−29.
6.2.4 Prop. Valve Selection

By means of the 8 output signals ”Prop. Valve selection 01” to ”Prop.
Valve selection 128”, the timer transmits the programmed manipulated
power variable via DeviceNet.
To this end, the maximum possible manipulating range at X2 (see page
5−7) is subdivided into 256 discrete steps, and the active output signal of
X2 is output as binary−coded pressure stage.
Value
Output signal (dec)
Prop. valve selection 01 1
Prop. valve selection 08 8 ...
Programmed
254
255
00
01
02
03
04
05
06
07
08
09
10
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
11
analog pressure stage:
Binary−coded output of the active pressure stage
. The signals are used in connection with the ”Sheet thickness” and
”Sheet thickness tolerance” signals to active servotongs.
and Controls
6.2.5 Sheet Thickness

Via the 8 output signals ”Sheet thickness 01” to ”Sheet thickness 128”,
the timer transmits the programmed sheet thickness in binary code via
DeviceNet to the electronic tongs system. In this way, the closing motion
of the tongs in a short distance of the material surface can be influenced
in such a way that the electrodes make contact ”softly”.
Value : High level of the corresponding signal

Output signal (dec)
Sheet thickness 01 1
Sheet thickness 08 8 ...
Programmed
254
255
00
01
02
03
04
05
06
07
08
09
10
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Sheet thickness: 11
Binary−coded output of sheet thickness
6.2.6 Sheet Thickness Tolerance

Via the 8 output signals ”Sheet thickness tolerance 01” to ”Sheet thick-
ness tolerance 128”, the timer transmits the programmed sheet thick-
ness tolerance in binary code via DeviceNet to the electronic tongs
system. In connection with the transmitted sheet thickness (see Chap.
6.2.5), the closing motion of the tongs in a short distance of the material
surface can be influenced in such a way that the electrodes make con-
tact ”softly”.
Value : High level of the corresponding signal

Output signal (dec)
Sheet thickness toler. 01 1
Sheet thickness toler. 08 8 ...
Programmed
254
255
00
01
02
03
04
05
06
07
08
09
10
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
11
Sheet thickness tolerance:
Binary−coded output of sheet thickness tolerance

and Controls
6.2.7 Weld Complete (WC)

The output signal ”Weld complete” informs the connected peripherals
(PLC/robot) about the termination of the welding process.
This way, the next step of the working process can be initiated. The lo-
gics for generating a WC is activated in the following cases:
1. in case of single spot welding (e.g. in connection with robots) after
each spot
2. in case of seam mode (e.g. roll seam welds) at the end of the seam
3. upon ”set WC” (possible only via BOS)
4. upon ”Reset Fault with WC” (see page 6−7).
. How long the WC remains set, depends on the input signal ”Start”.
See ”WC period”.
The 1. and 2. case give you the possibility to adjust the WC to your appli-
cation via parameterization (BOS).
D Automatic output of the WC only after a proper weld, or even after an
erroneous weld.
D Time at which the WC should be set (see ”WC starting time”).
WC period
Normally, the timer resets the signal ”Weld complete” automatically if it
recognizes a negative edge at the input ”Start”.
Nevertheless, there are situations possible in which the ”Start” signal is
reset prior to setting the WC. Here, a triggering on the negative edge of
”Start” is not possible. Therefore, when setting the WC, the timer checks
whether ”Start” is still pending and reacts as follows:
”Start” is set: WC will be reset only after a negative edge of
”Start”
Start” is not set: WC will be reset after the parameterized WC pe-
riod (GUI (BOS); default: 20 ms).
”Start” is not pending anymore:

Start Progr. WC period runs.
t
WC
t
WLD HLD Progr. Period
”Start” is still pending:

Neg. edge resets WC.
Start
t
WC
t
WLD HLD
WC period depends on signal ”Start”

and Controls
. The programmed WC period also runs during start simulation

(BOS)!
WC starting period
The time, at which ”Weld complete” shall be output, is − in relation to the
end of the HLD − parameterizable within the following limits:
D with PSI: +/−1000 ms
D with PST: +/−50 cycles.
Restriction: The earliest possible output of the WC is possible after 20
ms or 1 cycle after the start of the HLD.
Default setting: End of HLD minus 20 ms or 1 cycle (see ”example”).
This way, the starting time of the WC can be anticipated and moved into
the HLD time as well as delayed.
Neg. value Pos. value
WC
t
WLD HLD
Moving of WC starting time
Example: ”Fast robot communication”

If ”Weld complete” is used as a command for positioning the robot to the
next spot, you can compensate constant response times (caused by si-
gnal processing in the robot, drive, or PLC area) by anticipating the star-
ting time of the WC. This will lead to shorter clock times.
CAUTION
Damage to the installation caused by positioning movements with
a closed gun are possible!
Therefore, make sure that the electrodes are already open when
the robots’ drives start!
6.2.8 Control Ready

The output signal indicates that the timer is ready to weld.
In this state,
D you can start a new welding schedule (see page 6−2)
D the LED READY at the timer’s front is lit (see page 2−8).
and Controls
If an error occurs, the timer goes into ”Block”.

In this state,
D the LED READY at the timer’s front goes off
D the output signal ”Control Ready” will be reset.

PS5000/PS6000” (No.: 1070 087 000).
In order to restore the ”Ready”-state of the timer after an error, you have
the following possibilities at your disposal:
1. Push the reset button at the timer’s front (see page 2−8) or
2. a positive edge of the ”Fault reset” input signal
(refer to page 6−6) or
3. a positive edge at the ”Reset fault with WC” input signal
(refer to page 6−7) or
4. a positive edge at the ”Reset fault with spot repeat” input signal (refer
to page 6−8) or
5. operation via software (”Reset fault”, ”Reset fault with WC”, and ”Re-
set fault with spot repeat” are also possible via BOS).
6.2.9 Welding faults

If an error occurs during welding,
D the timer sets the output ”Welding Fault” and
D deletes the output signal ”Control Ready” (refer to page 6.2.8).
Further welding processes can only be started, when all pending errors
are eliminated and acknowledged (reset). Please refer to ”Reset fault”
on page 6−6.

PS5000/PS6000” (No.: 1070 087 000).
. It depends on the parameterization of the timer (BOS; fault alloca-

tion) whether an event is interpreted as a fault or a warning.
and Controls
6.2.10 Weld/No Weld

Via the output signal ”Weld/No weld” you can check whether the cur-
rently selected welding program is executed
D with current (output is set) or
D without current (output is not set).
During a welding program you can work with current only if

D ”Weld on External” (see page 6−5) is set and
D Weld internal (parameterizable via BOS) and
D program−related weld (parameterizable via BOS) have been swit-
ched on.
I.e. that ”Weld/No weld” is the result of an AND operation of all 3 mentio-
ned conditions.
6.2.11 Without Monitoring

Via this output signal you can check whether the currently selected wel-
ding program is executed
D without current monitoring (output is set) or
D with current monitoring (output is not set).
CAUTION
Incorrect welding may occur!
If current monitoring is switched off, actual current values that lie
outside the permissible tolerance bands do not lead to a welding
fault!
Therefore, make sure that all weldings that might be executed ”wi-
thout monitoring” are checked sufficiently!
During the process of a welding program, current monitoring is active

only in the following cases (”Without monitoring” is not set):
D the timer−related Monitoring stopped (effective for all programs) is
switched off
D the program-related current monitoring is active for all weld times.
and Controls
6.2.12 Without Regulation and Without Monitoring

Via the ”Without regulation and without monitoring” output signal, you
can check − while monitoring and regulation inhibit are deactivated for
the entire module − whether all welding programs are executed with
deactivated start inhibit and activated weld (firing)
D with current monitoring, and
D in CCR mode.
The output signal is not set only if exactly this is the case.
In all other situations, the output signal will be set.
CAUTION
Incorrect welding may occur!
If current monitoring is switched off, actual current values that lie
outside the permissible tolerance bands do not lead to a welding
fault!
Therefore, make sure that all weldings that might be executed ”wi-
thout monitoring” are checked sufficiently!
6.2.13 Automatic Program Selection Active

Mirrors the state of the input signal of the same name (see page 6−4).
6.2.14 Tipdress Prewarning x

Informs the PLC/robot that the active electrode must be tipdressed as
soon as possible.
If further electrode tipdressing is still allowed at this point, the signal will
be set when a parameterizable wear value is reached.
The acknowledgement ”Tips have been dressed” resets ”Tipdress pre-
warning”.
. For more information, refer to ”Electrodes have been replaced x”

on page 6−9 ff.
6.2.15 Tipdressing Request x

Informs the PLC/robot that the relevant electrode must be tipdressed.
If further electrode tipdressing is still allowed at this point, the signal will
be set when a parameterizable wear value is reached.
The acknowledgement ”Tips have been dressed” resets ”Tipdressing re-
quest x”.
and Controls
. For more information, refer to ”Electrodes have been replaced” on

page 6−9 ff.
6.2.16 Prewarning x
Will be set when a parameterizable wear value is reached. The output
signal informs the PLC/robot that the active electrode will reach the end
of stepper soon and that the electrode must therefore be replaced.
A positive edge of ”End of stepper” resets ”Prewarning x”.

on page 6−11 ff.
6.2.17 End of Stepper Electrode x

Informs the PLC/robot that the active electrode has reached the end of
stepper.
The acknowledgement ”Tips have been replaced x” resets ”End of step-

per electrode x”.
. It depends on the parameterization of the timer whether or not furt-

her welds are still possible after exceeding the end of stepper (pa-
rameter ”stop at end of stepper”).

on page 6−11.
6.2.18 Spot Selection Taken Over

Reaction to the ”Spot selection ready” input signal.
See page 6−4 for information on the functions.
and Controls
6.2.19 Status
Via the ”Status 1” through ”Status 128” outputs, the control transmits its
current status in binary code via INTERBUS-S.
Value
Output signal (dec)
Status 01 1
Status 02 2
Status 04 4
Status 08 8 ...
Status 16 16
Status 32 32
Status 64 64
Status 128 128
254
255
00
01
02
03
04
05
06
07
08
09
10
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
11
Current timer status:
Binary coded output of current timer status
Currently, the following messages are defined:
Code
Description
(dec)
00 OK
01 Weld off, internal
02 Weld off, external
03 Faulty program selection
04 Faulty spot selection
05 Sequence inhibited
06 No weld program
07
08
09
0A Battery error
0B Memory cleared
0C Hardware error
0D External temperature too high
0E Stop circuit open / no +24V
0F Main switch triggered / Current passed without command
10 measuring circuit open
11 short circuit of measuring circuit
12 No primary voltage in the 1. half cycle
13
and Controls
Code
(dec) Description
14
15 No current (standard mode)
16 No current 1. weld time (mix mode)
19 Current too low (standard mode)
1A Current too low 1. weld time (mix mode)
1B Current too low 2. weld time (mix mode)
1C Current too low 3. weld time (mix mode)
1D Current too high (standard mode)
1E Current too high 1. weld time (mix mode)
1F Current too high 2. weld time (mix mode)
20 Current too high 3. weld time (mix mode)
21 Current too low for a series of welds (standard mode)
22 Current too low for a series of welds 1. weld time (mix mode)
25 Time too short (standard mode)
26 Time too short 1. weld time (mix mode)
29 Time too long (standard mode)
2A Time too long 1. weld time (mix mode)
2B Time too long 2. weld time (mix mode)
2C Time too long 3. weld time (mix mode)
2D Minimum phase angle 1. weld time
2E Minimum phase angle 2. weld time
2F Minimum phase angle 3. weld time
30 Maximum phase angle 1. weld time
33 Full sine 1. weld time
and Controls
Notes:
and Controls
Maintenance
7 Maintenance
7.1 Battery
In order to buffer the RAM (contains the entire parameterization with all
welding programs) and the internal clock, an integrated battery is provi-
ded.
Type of battery: Lithium
Size: AA
Voltage: 3.6 V
Order No.: 1070 914446
When the remaining battery capacity becomes critical, the timer genera-
tes an error message or warning (parameterizable). The LED BATTERY
FAULT at the timer’s front is lit (see page 2−8).
If the event has been defined as an error message, a welding process is
not possible in this state.
L Include battery replacement in the regular maintenance schedule of the

installation! Replacement: at least every 2 years.
CAUTION
Damage caused by improper handling of electronic components!
Therefore, batteries must be replaced by authorized technical per-
sonnel only!
CAUTION
Data loss!
Without a pending supply voltage and after removal of the battery,
data back-up is guaranteed for up to 24 hours only.
Therefore, always have at your disposal a new battery and insert
it immediately upon removal of the old one.
Battery replacement The battery may be exchanged while the timer is running.
1. Turn the battery cover on the timer’s front (see page 2−8) to the left
and remove the old battery.
2. Insert the new battery correctly. For correct polarity, please refer to
the illustration on the front of the timer.
3. Now, close the battery compartment with the battery cover.
7.2 Firmware
The timer will be shipped with the latest firmware installed. Via the pro-
gramming device (BOS), the version of the firmware can be displayed.
and Controls
Maintenance
In rare cases, it may be necessary to update the firmware.
CAUTION
Risk of damage by improper handling.
Firmware updates may therefore be carried out upon our instruc-
tion and by authorized technical personnel only!
For a firmware update, you need

D a pointed object for operating the ”boot” button (for position, refer to
page 2−8),
D a PC with ”WinBlow” software,
D a suitable connecting cable (timer <−> PC, for wiring, refer to page
5−13) and
D a data carrier (floppy disk, CD) with the corresponding firmware.
L Proceed as follows:
1. Connect one of the PC’s V24 interfaces (COM1 or COM2) to the ti-
mer’s X1.
2. Start the ”WinBlow” software. Select the desired language and the
V24 interface.
3. Insert a data carrier with the firmware into the PC. Select the path and
file name of the firmware. Firmware files carry the extension ”.hex”.
4. Click on ”Backup − Load Firmware − Restore”.
You are prompted to set the bootstrap mode on the unit.
. Further welding processes are not possible anymore!

If you want to exit the bootstrap mode at this point, you have to in-
terrupt the timer’s 24 VDC power supply (see page 5−3).
5. Push the recessed ”boot” button on the front of the timer. This way, the
unit is switched from operating to bootstrap mode. This condition is
indicated by the ”Boot” LED above the button.
. After having initiated the next step, do not interrupt the power sup-
ply until the complete firmware has been loaded!
6. Confirm at the PC that the bootstrap mode has been activated. The
firmware is now being loaded. A bar indicates the current status of the
process.
7. Wait until the PC indicates that the transfer is complete.
8. Interrupt the timer’s 24 VDC power supply for at least 5 seconds (re-
move X4). Then reinstall X4.
The timer is booted with the new firmware.
9. Check the firmware version via the programming device (BOS).
and Controls
Maintenance
Notes:
and Controls
Status and Error Messages
8 Status and Error Messages
If timer−relevant events occur during operation, you will be informed by

the timer.
Primarily you can differ between

D faults and
D warnings.
In case of faults
D the LED READY at the timer’s front goes off (see page 2−8)
D the serial output signals ”Status” (refer to page 6−24) show important
higher level causes for errors
D the output signal ”Control Ready” will be reset (refer to page 6−19).
In case of warnings
D other welding processes can still be executed.
. It depends on the parameterization of the timer (BOS; fault alloca-

tion) whether an event is interpreted as a fault or a warning.
Errors as well as warnings can be ”self−acknowledging”.

”Self-resetting” means that the timer automatically deletes such events
after elimination of the error’s or warning’s cause. They do not require a
manual ”Reset fault”.
Examples for self-resetting faults:
− Stop circuit open / no 24 V
− Power voltage off / too low
The timer uses code numbers to signal faults and warnings. Only in the
programming device or in the line PC, the code numbers are substituted
by text. This saves memory resources in the timer and reduces the time
necessary for communication.

PS5000/PS6000” (No.: 1070 087 000).
and Controls
Status and Error Messages
Notes:
and Controls
CE Declaration of Conformity
9 CE Declaration of Conformity
and Controls
CE Declaration of Conformity
and Controls
Timer Diagrams
10 Timer Diagrams
The following pages contain some examples of timer diagrams.

Timer Diagrams
Timer Diagrams
10−2
Bosch Rexroth AG Electric Drives
Start
Selection of program / spot
ÉÉ ÉÉ
ÉÉ ÉÉ
Pressure return message
Ignition on, external
and Controls
Analog pressure output
ÉÉ É
Weld Complete WC
(Start/Period programmable before end of HLD)
ÉÉ
1. Squeeze time
Squeeze time
1. weld time
PSx 6xxx.630
1. break time
2. weld time
3. break time
3. weld time
1070087079 / 02
Hold time
Example for normal schedule, single spot

Timer Diagrams
1070087079 / 02
Start
Selection of program / spot
Pressure return message ÉÉ

ÉÉ ÉÉ
ÉÉ
PSx 6xxx.630
Ignition on, external
Analog pressure output ÉÉ É

Weld Complete WC
(Start/Period programmable before end of HLD)
ÉÉ
1. Squeeze time
and Controls
Electric Drives Bosch Rexroth AG
Squeeze time
1. weld time
1. break time
2. weld time
3. break time
3. weld time
Hold time
Example for normal schedule, seam mode
10−3
and Controls
Timer Diagrams
Notes:
1070087079 / 02 PSx 6xxx.630 Electric Drives Bosch Rexroth AG A−1
and Controls
Appendix
A Appendix
A.1 Abbreviations
AC Alternating current HOT Hold−open time. Time between two welding

points in which the solenoid valve is not ac-
DC Direct current tivated. Only relevant for the Serial spot op-
erating mode.
CSE Electrostatic sensitive assemblies and
components PE Protective Earth.
EMC Electromagnetic compatibility PU Programming unit / welding processor
IS Individual-spot operating mode: for auto- PHA Phase angle.

matic and manual systems
PSG Transformer-rectifier unit for PSI types.
ESD Electrostatic discharge. Abbreviation 3.CT Cooling time. Time between the current
for all designations that are concerned pulses/blocks (1st, 2nd, 3rd CT).
with electrostatic discharge, e.g. ESD
protection, ESD-sensitive. RO Relay output.
DST End slope time. Time in which the LST Scale values. Measure for the electrical
SCV
drops to the end of the 2nd WLD. phase angle.
ext. External, e.g. related to +24 V current for Slope Current ramp. Current rises/falls from an
signal elements (switches) and controlling initial to a final value.
elements (valves) outside of the control. SS Serial spot. Operating mode for manually
WC Stepping contact. The signal is issued after operated systems.
the spot is completed.
PLC Programmable logic control.
MST Main switch trigger WT Weld timer. Also referred to as timer or re-
IMP Impulse number. Number of impulses that sistance weld control.
form the 2nd WLD.
UST Initial slope time. Time in which the LST in-
kA Kiloamperes creases from the start of the 2nd WLD.
Constant current control. Keeps the current Stepper Current stepping for compensation of elec-
KSR trode wear
in the welding circuit constant.
Constant voltage control. Controls power WLD Current time. There are three types: 1st
CVC WLD (preheating current time), 2nd WLD
supply voltage variations.
(main welding current time) and 3rd WLD
POW General abbreviation for Power; can refer (postheating current time).
to SV (scale values) or kA. The times and power of all 3 current times
can be programmed differently.
PSU Power section unit (thyristor or inverter) Impulses and slopes can be programmed
only in the 2nd WLD.
SV Solenoid valve. Activation of cylinders to
close the electrodes. Temp. Temperature.
SLC Supply load control. Monitors and changes Monit. cont. Monitoring contact.
the load in the power supply E.g. for monitoring of the pressure cylinder
(which closes the electrodes) or of the elec-
HLD Holding time. Time after the last under−cur- trode position (e.g. ”Tongs closed”).
rent time, during which the parts to be
welded can cool off. SQZ Derivative−action time. Time that runs be-
fore the welding time. The electrodes
PHT Post−heating time. Also called the 3rd WLD squeeze together the parts to be welded.
PHT (pre−heating time) Also called the 1st UCT
Weld/no Weld/No weld The firing pulses for trigger-
weld ing the power section are switched on and
off.
A−2 Bosch Rexroth AG Electric Drives PSx 6xxx.630 1070087079 / 02
and Controls
Appendix
A.2 Index
Symbols D
(pre−heating time), 3−5 Degree of protection, 4−1
%I Stepper, 3−27 DeviceNet Connection, 5−16
Diagrams, 10−1
Numbers Dimensions, 2−2
1. Half cycle, 3−22 Diode monitoring, 3−36
A E
Acknowledgement ’Tips have been dressed’, 6−9 Electrical Connection, 1−9
Acknowledgement ’Tips have been replaced’, 6−13 Electrode force, 3−29
Acknowledgment ”Tips have been replaced”, 6−11 Electrode life (Stepper), 3−28, 6−23
Air pressure, 4−1 Electrode maintenance, 3−25
Assembly, 1−6 Electrostatic sensitive assemblies and components,
Automatic program selection active, 6−4, 6−22 1−12
Automatic spot repetition, 3−23 EMC, 5−1
EMERGENCY−STOP facilities, 1−9
B End of stepper electrode x, 6−23
Backup battery, 4−1 Error reset with spot repeat / WC, 6−8
Battery, 4−1 Error reset with WC, 6−7
Battery replacement, 7−1 errors, 8−1
ESD, A−1
C workplace, 1−12
Cables, 1−9 protection, 1−12
CC, 3−12 Ethernet, 4−1
CE mark, 1−14, 9−1
Code numbers, 8−1 F
Communication, 5−14 Fade-out time, 3−18
Condensation, 4−1 Failure of the sensor, 5−10
Conditional permissible tolerance band, 3−16 Fan connection, 5−13
Connection, 5−1 Features, 2−2
Constant current regulation, 3−12, 5−10 Fieldbus module, 2−6
Control ready, 6−19 Firmware, 7−1
Cooling, 2−2 Firmware update, 7−2
Cooling water, 1−8 Force, 3−29
Chlorides, 1−8 Force profile, 3−30
Degree of hardness, 1−8 Force scaling, 3−31
Insoluble substances, 1−8 Force Stepper, 3−30
Nitrates, 1−8
pH value, 1−8 G
Sulfates, 1−8 Grounding bracelet, 1−12
Corrections, 3−35
CSE, 1−12, A−1 H
CT (cool time), 3−9, 3−10 Hardware, 2−6
Current blocks, 3−4 HLD (hold time), 3−10
Current downslope time (DST), 3−7 Humidity, 4−1
Current input, 4−2
Current monitoring:, 3−15 I
Current passed without command, 5−12 I/O interface, 2−6
Current prewarning and limitation, 3−14 I/O Module ”DEV−NET”, 2−10, 4−2, 5−14
Current scaling, 3−33 I/O module supply, 5−14
Ignition on, external, 6−5
and Controls
Appendix
Impulse mode, 3−5 Q

Input signals, 6−1 Qualified personnel, 1−4
Installation, 1−6 Quality module, 2−6
Intended Use, 1−3
INTERBUS−PMS, 4−1 R
Interference suppression, 5−1 Rated current, 4−1
Interlock, 3−21, 6−2 RC element, 5−1
Regulation modes, 3−11
K Repair, 1−12
KSR sensor, 5−9 Repeat factor, 3−16
Reset fault, 6−6
M Retrofits, 1−11
Main components of a welding station, 3−1 Robots, 3−2
Main switch trigger, 4−2, 5−11 Roll seam, 3−3
Mains connection, 2−2 RS232, 5−13
Maintenance, 1−12, 7−1
Measuring circuit test, 3−21, 5−11 S
Mixed operation Safety instructions, 1−2
Monitoring, 3−17 Scaling, 3−31
Regulation, 3−11 Schedule diagrams, 10−1
Modifications, 1−2 Seal weld, 3−3
Modifications by the user, 1−11 Seam mode, 3−3
Monitoring, 3−15, 6−21 Secondary circuit, 5−10
Monitoring modes, 3−17 Self−resetting, 8−1
Sheet thickness, 6−17
O Sheet thickness tolerance, 6−17
offline, 2−5 Signal descriptions, 6−1
online, 2−5 Signal outputs and inputs, 5−16
Operating temperature, 4−1 Single spot, 3−2
Operating voltage, 4−1, 4−2 Slope, 3−7
Operation, 2−5 Spare parts, 1−12
Output signals, 6−15 Spot repetition, 3−23
Overview, 2−1 Spot selection, 6−3
Spot selection taken over, 6−23
P SQZ (squeeze time), 3−9
PE, A−1 Standard operation
PHA, 3−11 Monitoring, 3−17
Phase angle, 3−11 Regulation, 3−11
Post−heating time, 3−5 Start, 6−2
Power loss, 4−2 Starting current, 4−1
Power supply, 5−14 Status, 6−24
Pressure control, 4−1, 5−7 Stepper, 3−27
Prewarning, 3−28, 6−23 Stepper monitoring, 3−20
Prewarning table, 3−28 Stitch weld, 3−3
Prewarning tip replacement, 6−15 Storage, 4−1
Primary circuit, 5−10 Supply of external devices, 5−4
PROFIBUS−FMS, 4−1 Supply of timer logics, 5−3
Program selection, 6−3
Programming, 2−5 T
Programming unit, 5−13 Testing work, 1−12
Programs, 4−1 Time monitoring Monitor Stepper, 3−20
Prop. valve selection, 6−16 Timeout, 3−20
Proportional control valve, 5−7 Timer Diagrams, 10−1
Timer front, 2−8
A−4 Bosch Rexroth AG Electric Drives PSx 6xxx.630 1070087079 / 02
and Controls
Appendix
Tip replacement, 3−29, 6−13, 6−15, 6−16

Tip stepper, 6−16
Tip wear monitoring, 3−29
Tipdress prewarning, 6−22
Tipdressing, 3−27
Tipdressing of electrodes, 3−27
Tipdressing request, 6−22
Tips have been dressed, 6−9
Tips replacement, 6−11
Tolerance range, 3−15
Toroid input, 5−10
Trail current , 3−18
Type codes, 2−1
Types of welding modes:, 3−2
U
Ultrasonic control board, 2−4, 2−6
UST (current upslope time), 3−7
V
Voltage distribution, 5−4
Voltage source, 5−2
W
Warnings, 8−1
Wear factor, 3−25
Wear monitoring for tips, 3−29
Wear per part, 3−25
Weld (firing), 6−21
Weld complete, 6−18
Weld transformer selection (PSI only), 3−35
Weld/No Weld, 6−21
Welding current, 2−2
Welding faults, 6−20
Welding splashes, 1−13
Without Monitoring, 6−21
Without regulation and without monitoring, 6−22
WLD (weld time), 3−5
Working safely, 1−13
X
X1, 5−13
X10, 5−14
X11, 5−16
X12, 5−16
X13, 5−16
X2, 5−7
X3, 5−9
X4, 5−2, 5−3, 5−4, 5−13
X5, 5−4
X8, 5−11
and Controls
Appendix
Notes:
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 (0)93 52-40-50 60
Fax +49 (0)93 52-40-49 41
[email protected]
www.boschrexroth.com
Printed in Germany
1070087079 DOK-PS6000-E/A630*****-FK02-EN-P

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Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

Rexroth PSx 6xxx.630 1070087079

Title Rexroth PSx 6xxx.630

Type of documentation DOK-PS6000-E/A630*****-FK02-EN-P

Purpose of the documentat. This manual provides information about

Follow−up of modifications Previous editions Status Comment

Note on ind. property rights E Bosch Rexroth AG, 2006

Published by Bosch Rexroth AG

1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . 1−1

3 Timer Functions . . . . . . . . . . . . . . . . . . . . . . . . . 3−1

3.11 Electrode Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−25

4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1

5 Electrical Connection . . . . . . . . . . . . . . . . . . . . 5−1

6 I/O Signal Descriptions . . . . . . . . . . . . . . . . . . . 6−1

6.2 Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−15

8 Status and Error Messages . . . . . . . . . . . . . . . 8−1

9 CE Declaration of Conformity . . . . . . . . . . . . . 9−1

10 Timer Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 10−1

Nevertheless, there is some residual risk!

Therefore, you should read this manual before installing, connecting or

The content of this manual refers to

The − according to the type of the product − integrated power sup-

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

1.2 Safety Instructions in this Manual

DANGEROUS ELECTRICAL VOLTAGE

. This symbol is used to draw the user’s attention to special circumstan-

L This symbol indicates that an activity to be executed by you is described.

Modifications in this manual as compared to a previous edition are mar-

1.3 Intended Use

In residential environments, in trade and commerce as well as small

It is not intended for any other use!

. For operation in residential environments, in trade and commercial

The faultless, safe functioning of the product requires proper transport,

1.4 Qualified Personnel

Project engineering, programming, start and operation as well as the

Interventions in the hardware and software of our products, unless des-

Such personnel are

No entry for persons with cardiac

Please note our comprehensive range of training courses. More infor-

1.5 Installation and Assembly

DANGEROUS ELECTRICAL VOLTAGE

D Chlorides max. 20 mg/l

L For information about dimensions and installation accessories of the

1.6 Electrical Connection

In long lines, interference is often coupled and decoupled. There-

Install the product close to the welding units to avoid cable

L In addition, please comply with all safety regulations regarding electrical

1.7 Operation of the Product