Bosch Manual REROTH PSI 6xxx.637.737 Control and IO

1070087130 / 01 | PSI 6xxx.637/.
737 Electric Drives | Bosch Rexroth AG 1

and Controls
Electric Drives Linear Motion and
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Rexroth PSI 6xxx.637/.737 1070087130

Edition 01
Control and I/O Level
Technical Information
2 Bosch Rexroth AG | Electric Drives PSI 6xxx.637/.737 | 1070087130 / 01
and Controls
.
1070087130 / 01 | PSI 6xxx.637/.737 Electric Drives | Bosch Rexroth AG 3
and Controls
Rexroth PSI 6xxx.637/.737 1070087130

Edition 01
Technical Information
and Controls
Title Rexroth PSI 6xxx.637/.737

Type of documentation Technical Information
Documentation type DOK‐PS6000‐E/A637_737*‐FK01‐EN‐P
Purpose of the docu The present manual contains information on

mentation • the mechanical construction
• the electrical connection (24V supply and I/O) and
• the functionality
of the weld timer integrated into the PSI.
Development of modifica Previous editions Status Note

tions
DOK‐PS6000‐E/A637_737*‐FK01‐EN‐P 03.2010
Copyright note EBosch Rexroth Electric Drives and Controls GmbH, 2010.
It is not permitted to release or copy the present document, or to exploit
or disclose its contents, unless expressly permitted. Any infringement
of this copyright will create liability for damages.
All rights reserved in the event of granting of patents or utility models
(DIN 34-1).
Binding force The data indicated below is intended to describe the product only. No
binding information concerning a special property or suitability for a cer
tain purpose can be derived from this manual. This information does not
release the user from performing his own assessments and verifica
tions. Please note that our products are subject to natural wear and
aging.
Edited by Bosch Rexroth Electric Drives and Controls GmbH

Postfach 11 62
D‐64701 Erbach
Berliner Straße 25
D‐64711 Erbach
Tel.: +49 (0) 60 62/78‐0
Fax: +49 (0) 60 62/78‐728
Abt.: DCC/PAW1
and Controls
Table of Contents
Table of Contents
Page
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Possible icons on the product . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Safety instructions in this manual . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 Environmental protection, recovery of materials and re-use 13
1.5 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.6 Installation and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.8 Start-up and operation of the product . . . . . . . . . . . . . . . . . . 20
1.9 Retrofits and modifications by the operator . . . . . . . . . . . . . 22
1.10 Maintenance, repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.11 Safe working practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.12 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1 Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Features of the PS 6000 series . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Programming and operation . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4 Hardware structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4.1 Front side of the timer (without I/O module) . . . . . . . . . . . 32
2.4.2 Front of the I/O module ”DEV-NET” (PSI 6xxx.637) . . . . 34
2.4.3 Front side of the I/O module “I/O DISK” (PSI 6xxx.737) . 35
3 Timer functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1 Main components of a welding plant . . . . . . . . . . . . . . . . . . . 37
3.2 Welding modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2.1 Single spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3 Repeat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3.1 Seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4 Program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4.1 Programmable current blocks . . . . . . . . . . . . . . . . . . . . . . . 41
3.4.2 Impulse mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4.3 Slope (current increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4.4 Programmable times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5 Regulation modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.5.1 Phase angle (PHA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.5.2 Constant-current regulation (KSR) . . . . . . . . . . . . . . . . . . . 49
3.5.3 UIR regulation (UIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.6 %I prewarning and limitation . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.6.1 %I prewarning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.6.2 %I limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.7 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.7.1 Current monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.7.2 Time monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.7.3 Monitor stepper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.8 Latching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.9 Measuring loop test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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3.10 Automatic spot repetition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.11 Electrode maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.11.1 Count factor and Wear per component . . . . . . . . . . . . . . . 61
3.11.2 %I stepping (Stepper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.11.3 Tip dressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.11.4 Warning and end of stepper . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.11.5 Warning table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.12 Cutter motor control / Tip dress management . . . . . . . . . . . 64
3.12.1 Mode "Off" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.12.2 Mode "Electric drive" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.12.3 Mode "Pneumatic drive" . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.13 Electrode force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.14 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.14.1 Force calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.14.2 Current calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.15 Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.16 Welding transformer data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.17 Q Stop (Quality Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.18 Isolate weld contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.19 Weld Circuit Degradation (WCD) . . . . . . . . . . . . . . . . . . . . . . 80
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.1 Integrated weld timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2 I/O Module ”DEV-NET” (PSI 6xxx.637) . . . . . . . . . . . . . . . . . 82
4.3 I/O module “I/O DISK” (PSI 6xxx.737) . . . . . . . . . . . . . . . . . . 83
5 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . 85
5.1 Interference suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.2 Integrated weld timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.2.1 Output of the internal 24 VDC voltage generator (X4) . . . 86
5.2.2 Logic supply of the weld timer (X4) . . . . . . . . . . . . . . . . . . . 87
5.2.3 Power supply to external units (X5) . . . . . . . . . . . . . . . . . . 88
5.2.4 24 VDC voltage distribution (X4) . . . . . . . . . . . . . . . . . . . . . 89
5.2.5 Pressure control and feedback (X2, X9) . . . . . . . . . . . . . . 92
5.2.6 CCR sensor (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.2.7 Transformer temperature monitoring (X3) . . . . . . . . . . . . . 99
5.2.8 Fan connection (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.2.9 Programming device connection (X1) . . . . . . . . . . . . . . . . . 101
5.3 I/O communication to Robot/PLC . . . . . . . . . . . . . . . . . . . . . . 102
5.3.1 Power supply (X10) of the used I/O modules . . . . . . . . . . 102
5.3.2 DeviceNet Connection (PSI 6xxx.637 only) . . . . . . . . . . . . 104
5.3.3 Discrete signal outputs / inputs (PSI 6xxx.637) . . . . . . . . 104
5.3.4 Discrete signal outputs / inputs (PSI 6xxx.737) . . . . . . . . 105
5.3.5 Serial signal outputs / inputs (PSI 6xxx.637 and .737) . . 107
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6 I/O signal descriptions . . . . . . . . . . . . . . . . . . . . . . 109

6.1 Input signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.1.1 Alphabetic overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.1.2 Weld contactor enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.1.3 Weld contactor closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.1.4 Calibrate gun resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.1.5 Tip dress - motor overload tripped . . . . . . . . . . . . . . . . . . . 111
6.1.6 Tip dress - motor current tripped . . . . . . . . . . . . . . . . . . . . . 111
6.1.7 Tip dress - RPM sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.1.8 Tip dress motor on (air/elec) . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.1.9 End of component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.1.10 Start 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.1.11 Spot number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1.12 Weld on external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.1.13 Fault reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.1.14 Fault reset with reweld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.1.15 Fault reset with weld complete (WC) . . . . . . . . . . . . . . . . . 117
6.1.16 Tips have been dressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.1.17 Electrodes have been replaced . . . . . . . . . . . . . . . . . . . . . . 119
6.1.18 Feedback transformer x . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.1.19 Operate force sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.2 Output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.2.1 Alphabetic overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.2.2 Weld complete (WC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.2.3 Weld on (with welding current) . . . . . . . . . . . . . . . . . . . . . . . 123
6.2.4 Tip dress required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.2.5 Prewarning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.2.6 End of stepper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.2.7 New electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.2.8 Magnet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.2.9 Close weld contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.2.10 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.2.11 Tip dress enable circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.2.12 Tip dress sequence running . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.2.13 Tip dress OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.2.14 Tip dressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.2.15 UI regulation active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.2.16 UI monitoring active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.2.17 Q Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.2.18 Acknowledge end of component . . . . . . . . . . . . . . . . . . . . . 127
6.2.19 Transformer x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.2.20 Operate force sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.2.21 Timer ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6.2.22 Weld fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6.2.23 Without weld process monitoring . . . . . . . . . . . . . . . . . . . . . 130
6.2.24 Pressure output bit x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.2.25 Start tip dress request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.2.26 Pressure inside tolerance area . . . . . . . . . . . . . . . . . . . . . . 130
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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7.2 Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

7.2.1 Firmware update via ”WinBlow” . . . . . . . . . . . . . . . . . . . . . . 132
7.2.2 Firmware update via "FWUpdate" . . . . . . . . . . . . . . . . . . . . 133
8 Status and fault messages . . . . . . . . . . . . . . . . . . 137
9 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
10 Timer diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
A Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
A.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
A.2 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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Safety instructions
1 Safety instructions
The products described were developed, manufactured, tested and
documented in compliance with the requirements of the EU.
This product poses no danger to persons or property if it is used in ac
cordance with the handling stipulations and safety notes prescribed for
its configuration, mounting, and proper operation.
Nevertheless, there still is some residual risk!
L Therefore, you should read this manual before installing, connecting or
commissioning the products or programming the welding system.
L Store this manual in a place to which all users have access at any time.
The contents of this manual refer to
• the mechanical construction
• the electrical connection (24V supply and I/O) and
• the functionality
of the weld timer integrated into the PSI.
The - according to the type of the product - integrated AC power units/in
verters have their own manuals. They are applicable in addition to the
present manual!
L Therefore, please also note the following documentation manuals:
• For PSI 6xxx: Medium-frequency inverter (1070 080 059)
The faultless, safe functioning of the product requires proper transport,

storage, erection and installation as well as careful operation.
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Safety instructions
1.1 Possible icons on the product
Icon Meaning
Dangerous Electrical Voltage
Hazards associated with batteries!
Electrostatically sensitive components
PE conductor connection
Function ground, ground with low parasitic voltage
Shield connection
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Safety instructions
1.2 Safety instructions in this manual
DANGER The DANGER class of symbols is used wherever insufficient or lacking

compliance with instructions results in personal injury.
This symbol class always contains the "DANGER" signal word.
WARNING The WARNING class of symbols is used wherever insufficient or lack

ing compliance with instructions may result in personal injury.
This symbol class always contains the "WARNING" signal word.
CAUTION The CAUTION class of symbols is used wherever insufficient or lack

ing compliance with instructions may result in damage to equipment
or data files.
This symbol class always contains the "CAUTION" signal word.
L This symbol indicates the need to observe/perform certain things.
1. Any numbers, if present, mean

2. that a defined order
3. has to be observed.
☞ This symbol is used to draw the user’s attention to special circum

stances.
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Safety instructions
1.3 Proper use
WARNING Danger due to inappropriate use!

The use for purposes other than the intended use may result in per
sonal damage to the user or third persons or damage to the equipment,
the workpiece to be welded or environmental hazards.
Therefore, you should only use our products for their intended pur
pose!
The product described

• serves in connection with an integrated AC power unit/inverter and
the appropriate welding transformer for
- resistance welding of metals
and
• is suitable for operation in industrial environments (emission class A,
group 2) in accordance with the following standards:
- EN 50178
- EN 50240
- EN 60204‐1
Any other application is deemed improper use!
CAUTION Risk of high-frequency interference!

This resistance welding equipment belongs to class A.
Class A resistance welding equipment is not intended for use in the
public low-voltage network supplying, e.g., residential buildings, be
cause it may interfere with other equipment in the environment.
Therefore, make sure that no other devices or their functioning can be
affected if the present product is operated.
☞ For operation in residential environments, in trade and commercial ap

plications and small enterprises, an individual permit of the national au
thority or test institution is required; in Germany, please contact the
Bundesnetzagentur (BNetzA) or its local branch offices.
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Safety instructions
1.4 Environmental protection, recovery of materials and re-use
Environmental protection
Our products do not contain any hazardous materials which may be re
leased by their intended use. Therefore, no negative effects on the en
vironment are to be expected under normal circumstances.
Recovery of materials
The products manufactured by us can be returned to us free of charge

for proper disposal.
However, the following conditions have to be satisfied for this purpose:
• no deposits such as oil, grease or other contamination
• no inappropriate extraneous materials or third-party components in
cluded.
The packaging materials are made of cardboard, wood and poly

styrene.
For environmental reasons, please do not return any empty packagings
to us. They can be easily recycled.
The products are to be sent postage prepaid to the following address:
Bosch Rexroth Electric Drives and Controls GmbH
Bürgermeister-Dr.-Nebel-Straße 2
D-97816 Lohr am Main
Germany
Recycling
Principal components of our electronic equipment:

• Steel, aluminum, copper, plastic materials.
Due to their high metal content, most of the materials of our products
can be recycled. In order to ensure optimum recovery of metals, the
equipment has to be split into individual components.
The metals that are contained in the electric and electronic modules can
also be recovered using special separating methods. The plastic mater
ials recovered by this process can be disposed of thermally.
L Simple or rechargeable batteries, if any, must be removed from the
products prior to recycling them! Please also note the information
provided in the "Battery disposal" section!
Battery disposal
In accordance with the EU provisions relating to batteries, the end user
has to return any simple or rechargeable batteries to a dealer or the
public collection facilities for disposal.
L In order to avoid short-circuit in the battery collection boxes, please fix
adhesive tape to the battery poles or put each battery in a separate
plastic bag.
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Safety instructions
1.5 Qualified Personnel
WARNING Employing unqualified personnel or non-compliance with warning

notes can result in bodily injury and/or property damage.
Therefore, make sure that the work is carried out by properly qualified
personnel only.
Any warning notes/instructions on the product or the related docu
mentation must be observed!
WARNING Possible functional disturbance of cardiac pacemakers!

Due to the strong magnetic fields arising from resistance welding, the
function of cardiac pacemakers may be disturbed. This may cause the
death or considerable health damages!
Persons with cardiac pacemakers must avoid resistance welding
equipment for this reason.
☞ We recommend posting a warning sign in sufficient proximity to the

welding equipment:
Possible functional disturbance of cardiac pacemakers

due to strong magnetic fields!
No entry for persons with cardiac pacemakers!
The present documentation is designed for specifically trained engin

eers with special knowledge of the welding technology. These persons
must have profound knowledge of the software and hardware compon
ents of the weld timer, the power unit/power supply, and the welding
transformer.
L 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 mechan
ical, electrical, or electronic equipment.
L Interventions in the hardware and software of our products, unless de
scribed otherwise in the related documentation, are reserved to our
specialized personnel. Our written approval is required with respect to
other persons!
and Controls
Safety instructions
L For this reason, only electrotechnicians who are familiar with the con
tents of this manual may install and service the products described.
Such personnel are
• those who, being well trained and experienced in their field and fa
miliar with the relevant norms, are able to analyze the jobs being car
ried out and recognize any hazards which may have arisen.
• those who have acquired the same amount of expert knowledge
through years of experience that would normally be acquired
through formal technical training.
Training
Please note our comprehensive range of training courses.

Please refer to http://www.boschrexroth.com/training for the latest in
formation on training courses, teachware and training systems.
For more information, you may also contact our

Erbach Training Center
SAL 2
Berliner Straße 25
D-64711 Erbach
Germany
Tel.: +49 (0) 60 62 78‐600
Fax: +49 (0) 60 62 78‐833
training.brc@boschrexroth.de
and Controls
Safety instructions
1.6 Installation and assembly
WARNING Dangerous Electrical Voltage!

Possibility of cardiac arrhythmia, burns, shock!
Please ensure that all plant sections worked on in the course of the as
sembly, repair and maintenance procedures have been safely isolated
from supply and sufficiently protected against unauthorized/accidental
reclosing!
The performance of testing activities on live plant components shall be
reserved to skilled personnel using suitable tools!
WARNING Danger of life and damage to property through inadequate degree of

protection!
The degree of protection of the products described is IP 20.
They must be installed in a switch cabinet satisfying at least degree of
protection IP 54!
WARNING Possibility of personal injuries and damage to property in the event of

inappropriate/careless planning/performance of installation or as
sembly works!
• Installation and assembly are reserved to qualified personnel who
also has expert knowledge in the field of electromagnetic compatib
ility!
• You must observe the information provided in the "Technical Data"
(environmental conditions) applicable to the installation and as
sembly!
• When installing the devices and the control elements it must be en
sured that they are sufficiently protected against inadvertent opera
tion or contact!
• Select the place of installation and the method of fastening the mod
ules according to their weight!
• Always use suitable hoisting equipment!
• Wear a protective helmet, safety shoes and gloves!
• Please note the safety and accident prevention regulations!
CAUTION Danger of short-circuit through metal burr or cooling water leaks!

When drilling or cutting holes into switch cabinets, burr may get inside
previously installed modules.
Furthermore, when connecting cooling water lines water may leak into
modules.
Therefore, all affected modules should be well partitioned prior to all
work! Non-compliance will result in the extinction of any warranty
claims!
and Controls
Safety instructions
CAUTION Overheating due to heat accumulation!

Heat accumulation may cause the unit to fail.
A sufficient installation clearance must remain above and below the
modules (refer to "Technical Data" section)!.
CAUTION Consequential damages due to leaks in the cooling fluid circuit!

In the event of a leak in the cooling fluid circuit, there is a risk of dam
aging the surrounding components by leaking cooling water.
Therefore, water-cooled modules must be installed so that the units in
side the switch cabinet are sufficiently protected against leaking cool
ing water.
CAUTION Deposits may cause the cooling system to fail!

Deposits/contamination in the cooling system may restrict the perform
ance of the cooling system with time and consequentially cause the
unit to fail.
Make sure that an air cooling system does not get contaminated too
quickly and can be easily cleaned.
When water cooling is used, you must ensure that the cooling water
used has the following properties:
• pH : 7 to 8.5
• Degree of hardness Dmax : 10 German degrees = 12.5 British
degrees = 10.5 U.S. degrees =
= 18 French degrees
• Chlorides : max. 20 mg/l
• Nitrates : max. 10 mg/l
• Sulfates : max. 100 mg/l
• Insoluble components : max. 250 mg/l
Tap water usually meets these conditions. However, an algaecide
must be added to the water.
L It must be ensured that operating panels are reachable ergonomically

and displays can be easily read out.
L The product should be installed in close proximity to the welding equip
ment in order to keep the lengths of the necessary connection cords to a
minimum.
For length data, refer to "Electrical connection" section.
L For dimensional data of the entire product, accessory kits for installa
tion, information concerning the cooling system, and the mains and
transformer connection data, please refer to the manuals provided for
the AC power supply unit/inverter used.
and Controls
Safety instructions
1.7 Electrical connection

reclosing!
WARNING Danger of life through inadequate PE conductor system!

All components must be connected to the PE system of the plant.
The electrical continuity of the PE conductor system must be verified
in accordance with EN 60204 Part 1.
WARNING Danger of life through inappropriate Emergency-Stop/Emergency-

Halt facilities!
Emergency-Stop/Emergency-Halt facilities must be active and within
reach in all system modes. Ensure compliance with EN 60204-1!
Releasing an Emergency-Stop/Emergency-Halt facility must not result
in an uncontrolled restart of the system!
Check the proper functioning of the Emergency-Stop/Emergency-Halt
circuit prior to start-up!
WARNING The incorrect or incomplete connection of I/O signals may result in haz
ardous situations at the installation or a damage of the plant!
Upon commissioning, make sure that the I/O signals have been prop
erly wired and are correctly transmitted!
Any user, line supplier, welding machine manufacturer and welding
gun provider is obligated to connect all output signals that cause move
ments (such as solenoid and prelift) in compliance with the applicable
safety regulations (e.g. ISO 13849) and to ensure that risks to the per
sonnel are safely avoided!
Please note that electronic outputs are considered "unsafe" in accord
ance with the safety regulations!
For example, "two-handed start", guards, light barriers, etc. can
considerably reduce the risk of bruises.
Also note the information concerning the effects of the I/O signals
available and concerning the status and error messages.
and Controls
Safety instructions
L All connection cords and signal leads must be routed so as to prevent

negative effects on device functions through capacitive or inductive in
terference!
In long, parallel cables, interference is frequently injected and removed.
Power lines and control cables should be routed separately for this
reason.
The influence of interfering lines on lines susceptible to interference can
be minimized by observing the following distances:
> 100 mm: with parallel installation of cables < 10m,
> 250 mm: with parallel installation of cables > 10m.
L Please also note all the safety instructions relevant for electrical con
nection and for ensuring EMC of the entire system that have been
provided in the manuals for the AC power supply unit / inverter used
(refer to page 9).
L It must be ensured that the contact areas are bare, i.e. free from paint,
plastic coats and dirt/oxidation.
and Controls
Safety instructions
1.8 Start-up and operation of the product
WARNING Danger through start-up in systems that do not comply with the provi
sions of the Machinery Directive!
The products described are components to be installed in machines
for the purpose of the Machinery Directive (2006/42/EEC).
Therefore, the products must not be started up unless the machine in
which the products have been integrated complies with the provisions
of the Machinery Directive!
Ensure compliance with EN 60204-1!
WARNING Possible functional disturbance of cardiac pacemakers!

Due to the strong magnetic fields arising from resistance welding, the
function of cardiac pacemakers may be disturbed. This may cause the
death or considerable health damages!
Persons with cardiac pacemakers must avoid resistance welding
equipment for this reason.
☞ We recommend posting a warning sign in sufficient proximity to the

welding equipment:
Possible functional disturbance of cardiac pacemakers

due to strong magnetic fields!
No entry for persons with cardiac pacemakers!
WARNING Danger of injuries and damage to property through operation of units

outside their intended cabinets!
The units are designed to be installed in housings or switch cabinets
and must not be operated unless they have been installed in such
housings and with the cabinet door closed!
WARNING The max. permitted limit values of the magnetic field strength may be
exceeded!
One has to expect that magnetic fields are present in the vicinity of res
istance welding systems, which are above the limits specified in the EC
Directive "Electromagnetic Fields” (2004/40/EC). In particular, the lim
its for extremities can be exceeded if manual guns are used.
In cases of doubt, please measure the field strength and provide addi
tional measures to ensure health and safety at work.
Please note the Instructions BGV B11, “Accident prevention regula
tion relating to electromagnetic fields” issued by the Berufsgenos
senschaft (employers’ third party liability insurance association).
and Controls
Safety instructions
WARNING Program start is immediately possible after fault reset!

If the start signal is present when a fault is reset (acknowledged), the
timer will start its program execution immediately!
Therefore, prior to fault reset, make sure that there is no-one in the
hazard area of the welding equipment!
WARNING Danger of impacts, bruises, entanglement and burns!

Robots, welding guns and fixing elements may generate very high dy
namic forces and extremely fast movements. In addition, expulsion
may occur during a welding schedule.
You should always be aware of the possibility that motions can be
triggered by faults of the system!
Always stay outside the danger area of the welding system when it is
running!
Do not ever deactivate any safety-relevant functions!
CAUTION Possibility of overheating/condensation through inappropriate or in

correct cooling!
The temperature in the installation area must be within the specified
limits!
Air-cooled medium-frequency inverters may only be operated with
"forced cooling". Cooling by means of convection is not sufficient!
Water-cooled medium-frequency inverters may only be operated if the
cooling fluid circuit has been activated!
Condensation on the water-conducting components is not permitted!
CAUTION Strong magnetic fields!

Due to the strong magnetic fields arising from resistance welding,
wristwatches, pocket watches, or magnetic stripe cards (e.g., EC
cards) may be damaged/destroyed for ever.
Therefore, you should not carry such items on you while working in the
immediate vicinity of the welding system.
CAUTION Plugging or unplugging modules or connectors/terminals into/from live

systems may damage the system and produce unexpected plant reac
tions!
The timer's power supply should always be disconnected before in
serting/removing any timer modules.
Unless described otherwise, never unplug or plug any connectors/ter
minals on live systems!
and Controls
Safety instructions
L Make sure that all guards and covers are sufficiently rigid to offer protec
tion against the maximum possible kinetic energy of the plant!
L Make sure that all Emergency-Stop/Emergency-Halt switches are loc
ated within the reach of operators and can be quickly activated in the
event of hazards!
L Check the proper functioning of the Emergency-Stop/Emergency-Halt
circuit prior to start-up!
L Make sure that an unintentional (re-)start of the machine is not possible
(e.g. by safely disconnecting the power supply of the drives through an
Emergency-Stop/Emergency-Halt circuit or using a safe start interlock)!
L You should always be aware of the possibility that motions can be
L The plant functionality installed must be carefully tested for any faults!
We do not accept any liability for damage resulting from the execution of
a program, an individual program block or the manual movement of the
handling units.
Furthermore, we accept no liability for consequential damages which
could have been avoided by programming the PLC appropriately!
1.9 Retrofits and modifications by the operator
WARNING Any changes made to the product may endanger the safety of the unit
or even render it entirely unsafe!
Therefore, you should contact us before performing any intended
changes. This is the only way to find out whether or not changes can
be made safely.
and Controls
Safety instructions
1.10 Maintenance, repair

reclosing!

namic forces and extremely fast movements.
You should always be aware of the possibility that motions can be
WARNING Lithium batteries may cause causticization or explode if not handled

properly!
Therefore, do not open batteries by force, do not recharge or heat
them above 100 degrees Centigrade!
L Only use spare parts/replacement parts approved by us!

L In any case, spent batteries and accumulators should be disposed of in
accordance with the applicable provisions of the law!
Also refer to page 13, "Battery disposal" section.
L The following protective measures must be observed for modules and
components sensitive to electrostatic discharge (ESD):
• Personnel responsible for storage, transport, and handling must
have training in ESD protection.
• ESD-sensitive components must be stored and transported in the
prescribed protective packaging.
• ESD-sensitive components may only be handled at special ESD
workplaces.
• Personnel, working surfaces, as well as all equipment and tools
which may come into contact with ESD-sensitive components must
have the same potential (e.g. by grounding).
• Wear an approved grounding bracelet. The grounding bracelet must
be connected with the working surface through a cable with an integ
rated 1 MOhm resistor.
• ESD-sensitive components may by no means come into contact with
chargeable objects, including most plastic materials.
• When inserting or removing ESD-sensitive components in/from
other devices, the device must be safely disconnected from the
supply.
and Controls
Safety instructions
1.11 Safe working practices

namic forces and extremely fast movements. In addition, expulsion
may occur during a welding schedule.
Always stay outside the danger area of the welding system when it is
running!
L You should always be aware of the possibility that motions can be

L Wear protective goggles in order to protect your eyes against expulsion
or hot metal burr!
L Wear protective gloves in order to protect yourself against injuries on
sharp metal edges and burns on the parts to be welded!
L Only wear flame-retardant working clothes!
L Before starting to work, subject the plant to a reasonable, practical
check for possible damages (e.g. visual inspection).
L Report any damages and malfunctions of the unit to your servicing and
repairs department immediately!
L Safely halt any servo guns before intervening in or accessing the
danger area!
L Prior to cleaning or prolonged service interruptions, the plant must be
completely de-energized by opening its main switch and protected
against unauthorized or accidental reclosing!
1.12 CE marking
The CE mark for the product (refer to Section 9) is applicable for use in
industrial environments.
☞ For other combinations/applications, the certificate must be derived
from the above requirements, or a new certificate must be issued, if ne
cessary. This is the responsibility of the line supplier/user.
The product described corresponds to an application variant which is
not covered by the provisions concerning end user products, machines
or systems based on its very nature. Therefore, it may only be operated
as described above.
☞ When installed in an enclosure, the EMC properties of this product may
be subject to change. For this reason, the final product (end user
device, machine, systems) should be subjected to a verification of its
EMC characteristics by the end product manufacturer.
L The evaluation of the electrical and mechanical safety, the environ
mental influences (foreign bodies, moisture) must be carried out on the
final product in encased state.
and Controls
Overview
2 Overview
The PS 6000 series integrates the following in a single enclosure
• weld timer, and
• power unit.
The integrated weld timer serves to drive the integrated power unit and
is suitable for
• spot welding (e.g. in combination with a robot)
• projection welding,
• repeat welding (e.g. manual guns), and
• seam welding tasks (e.g. roll seam).
In addition to various timer types that can be mainly distinguished by

their I/O connection to the host PLC/robot unit and the timer functionali
tiy,
different types of power units (MF inverter power units) with different
cooling methods (air/water) and graduated power ratings are also avail
able for controlling the welding transformer.
2.1 Type designation
The name of the product assembly indicates the product variety con
cerned:
PS_ 6___.___ __

Line voltage range
(only for MF inverters):
1: 400-480 VAC
2: 480-690 VAC
Cooling:
L: Air
W: Water
Timer type
first digit: I/O connection:
1: 24 V
2: PROFIBUS
3: INTERBUS
4: RS232
6: Device Net
7: Ethernet
2nd and 3rd digit: version number
Power class of the power unit and
TriCore CPU varieties (6xCx.xxx)
Type of power unit:
T: Thyristor power unit
I: Medium-frequency inverter
Example:
PSI 6100.100 L1: Weld timer with 24 V I/O, MF inverter, air-cooled,
line voltage 400-480 VAC
Type designation of the PS 6000 series

and Controls
Overview
2.2 Features of the PS 6000 series
☞ For further information about the dimensions, line connection, cooling

or welding output, please refer to the manual of the inverter used (refer
to page 9).
• User interface for operation, programming and diagnosis:

- standard: complete graphical user interface BOS, executable on
PCs with operating systems Windows 2000 or higher.
- optionally with limited functional scope: using BT 6 control and
diagnosis terminal.
Links: via V24.
• optional access protection for operation/programming
- via password
• Programming link to PC (BOS).
- standard: for one individual timer via V24 (e.g. for local program
ming)
- optional: simultaneous connection of several timers via Ethernet
field bus interface
• 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
Ethernet IP
• Number of programs:
- max. 256 programs, symbolic spot addressing is possible.
Due to the high number of programs, a separate program can be
assigned to each spot to be welded in most cases.
• Time programming:
- in milliseconds.
• universal adaptability of the welding schedule
- 3 programmable weld times (PreWLD: pre-heating time,
MainWLD: welding current time, PstWLD post-heating time).
The weld times can be jointly operated in a single control mode
(standard mode) and in different control modes (mixed mode).
- PreWLD and PstWLD can be deactivated
- programmable pulse operation for MainWLD
- programmable slope (current upslope/downslope time) for
MainWLD
• Welding modes:
- spot welding (e.g. in combination with a robot)
- repeat welding (e.g. in combination with a manual guns)
- Roll seam
• Half-wave mode
and Controls
Overview
• Closed-loop control modes:

- PHA (phase angle)
- KSR (Constant-current-regulation)
- UIR (adaptive controller)
Mixed operation is possible (mixed mode: control mode can be sepa
rately configured for PreWLD, MainWLD and PstWLD).
• Current monitoring:
- Reference currents can be programmed independent of the regu
lation command values
- tolerance band in percent, with asymmetric programming capab
ility
- Monitoring in standard or mixed mode possible (mixed mode:
control mode can be separately configured for PreWLD,
MainWLD and PstWLD).
• automatic spot repetition if current was too low
• Time monitoring
• Electrode management
- Stepper function for %I (%I stepping)
- Electrode tip dressing including initial dressing
- Stepper function for pressure (electrode force stepping)
- Warning table with graphic representation of electrode wear
• Generating the gun force:
- Programming the force in kN for each welding program
- Output as analog actuating variable (voltage, current) that is
already present when the program has been selected.
Digital control available, depending on timer type.
- Feedback is possible
- Force calibration for adjustment to the valve characteristic
• Pressure profile:
- up to 10 different electrode forces can be programmed during a
program schedule
• external termination of weld with half-cycle accuracy
• freely programmable output:
up to 3 different on/off times during a program schedule can be pro
grammed Used, e.g., to drive a back-pressure control valve or for
preparing parts to be welded synchronous to the spot weld.
• Calibration programs:
- for current (to adjust the welding equipment to an external refer
ence ammeter)
- for force (to adjust the electrode force to an external reference
force meter)
• Logging functions (ISO 9000):
- Fault/event log
- Weld fault protocol
- Data change protocol
- Welding current log
• integrated diagnosis memory
and Controls
Overview
• Fault allocation:
- Events can be programmed as faults or warnings
• Status display of I/O signals in online mode
• %I correction:
- program-specific input
- electrode-specific input
• General overview of the welding equipment in the plant image
• Global timer display of
- Start inhibit (P)
- Weld internal on (P)
- Time monitoring
- Current monitoring
- Current mode in MainWLD (PHA / KSR)
- Electrodes used
- Programs using a certain electrode.
• Backup/Auto-Backup (data backup)
• Restore (data retrieval)
• Copying welding parameters
• Comparison between timers and/or backup files
• Start simulation:
- Program selection and schedule start can be initiated by BOS
• languages currently available (for BOS):
- German
- English
- NA English
- Spanish
- French
- Swedish
- Portuguese
- Italian
- Hungarian
• Online and offline programming is possible
• PSI-types only: Prepared for upgrading with an optional quality mo
dule or extension using the optional ultrasonic or U/I controller sys
tem (PSQ 6000 XQR).
and Controls
Overview
2.3 Programming and operation

All necessary parameters are always kept in a battery-buffered RAM in
side the timer.
Operation, programming and diagnosis are performed via the connec
ted PC. The following optionsare available for connecting the PC:
• V24 interface of the weld timer (X1) or
• optionally available field bus interface (Ethernet)
While the V24 connection is intended for accessing a single timer only
(e.g. local programming), the field bus interface provides for the simul
taneous connection of several timers.
Conditions for programming and operation at the PC:
• PC with operating system Windows 2000 or higher
• BOS software ( Bedienoberfläche Schweißen = welding user inter
face)
• V24 interface cable or corresponding installation for field bus inter
face.
☞ For detailed information on the BOS software, please refer to the BOS
manual and the Online Help function.
The weld timer can be programmed both "online" and "offline".
• offline:
no active connection to timer possible.
Diagnosis or visualization are not possible.
Programming is carried out on the PC, where the program is stored
and can be transferred to the timer later.
• online:
requires active connection to timer.
Diagnosis and visualization are possible.
Programming is carried out on the PC. Each parameter is retrieved
from the timer and written back to the timer after confirmation. As a
result, any parameters that have been modified will take effect upon
the next program start of the system.
and Controls
Overview
2.4 Hardware structure

The timer module is permanently installed at the right-hand side of the
unit's enclosure.
In addition to the standard display and control elements as well as
connection terminals, it contains
• the type-specific I/O module for connecting the timer to the higher-le
vel PLC or the robot (is installed upon delivery and operative with the
suitable timer firmware only)
• a slot for the optional field bus module for programming/operation/
diagnosis of all weld timers connected to the field bus.
• a slot for an optional quality module, or for extension using the optio
nal ultrasonic or U/I controller system (PSQ 6000 XQR; PSI-types
only).
PSx 6000
Slot for an optional quality module or ultra

sonic or U/I controller system (PSQ 6000
XQR)
type-specific I/O module

A
D
R
V24 interface for connecting a PC with BOS

Power unit software
(Programming, logging, diagnosis and fault
display for the connected weld timer)
Slot for field bus module for connecting several

timers to a host PC with BOS software
(Programming, logging, diagnosis and fault
display for all the weld timers connected to the
field bus)
Battery for buffering the timer's internal RAM
☞ The dimensions of the unit's housing and the functional units for cooling
depend on the size of the integrated power unit, therefore, they may dif
fer from the example shown above.
and Controls
Overview
L For installation and assembly, therefore, you must observe the informa
tion provided concerning the power unit used (for manual no., refer to
page 9).
CAUTION Possibility of malfunctions and damages!

The incorrect installation, improper connection or operation faults may
lead to an unexpected or undesired unit response and thus to dange
rous situations at the welding system.
Therefore, all information contained in the individual manuals must be
observed.
and Controls
Overview
2.4.1 Front side of the timer (without I/O module)
LOGIC LED, green. Is on if 24 V DC (logic

supply voltage) is available).
LED, red (only operative if LOGIC LED is illuminated in green)
Is on if DC link voltage > 60 V
READY LED, green. Is on if no error is present in the

timer. The unit is ready for welding.
WELD TIME LED; yellow. Is on while the power unit is activated.
optional ultrasonic or U/I controller system (PSQ 6000 XQR)

BATTERY FAULT LED; red. Is on if a new battery is
type-specific I/O module. Refer to page 35.

to be inserted.
RESET button. Returns the timer to READY state when a fault

has occurred (and has been corrected).
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
Boot LED; red. Is on while the timer is in ”Boot” mode. D
R
”Boot” key for calling up the ”Boot” mode. Required for a firmware upgrade in
connection with the ”WinBlow” software. Welding is not possible in ”Boot”
mode. Exiting Boot mode: Toggle 24 V logic voltage off / on.
V24 connection to programming terminal (for programming on location).

Refer to Sect. 5.2.9 on page 101
24 VDC output of the internal voltage source

24 VDC input for logic power supply
Terminals for 24 VDC voltage distribution (refer to Sect. 5.2.4 on page 89
24 VDC supply output for power supply to fan if timer is equipped with a fan
(refer to Section 5.2.8 on page 100). X4
24 VDC output for power supply to force sensor, e.g.

Refer to Section 5.2.3 on page 88.
X5
not used
X8
Output for influencing the electrode force
(analog activation of a proportionate control valve or a servo gun).
Digital (24 VDC) and analog (0..10 VDC) inputs for (force) feedback. X2
Refer to Section 5.2.5 from page 92.
Field bus module
Analog input for (force) feedback.

X9
Refer to Section 5.2.5 from page 92.
Measuring input for constant-current regulation (KSR).

Refer to Section 5.2.6 on page 96 X3
Output/input for monitoring the transformer temperature
(refer to Section 5.2.7 on page 99)
Battery for buffering the unit's internal RAM

and Controls
Overview
☞ For technical data of the timer module, refer to Sect. 4.1 page 81.
☞ The red LED can only signal the timer status if the logic supply voltage is
present (green LED LOGIC is lit)!
WARNING Dangerous voltages may be present at the unit even if the red LED is
not lit!
Therefore, use suitable measuring equipment and an appropriate
measuring method to ensure that the unit is de-energized before carry
ing out any work on the unit.
CAUTION The welding schedule is aborted!

Immediately upon pushing the ”boot” button, welding processes be
come impossible! The timer interrupts the program sequence, swit
ches all signal outputs to 0 V and goes into ”boot” mode (for firmware
exchange). For this reason, the button shall
- never be pressed during operation and
- only be pressed by authorized personnel.
and Controls
Overview
2.4.2 Front of the I/O module ”DEV-NET” (PSI 6xxx.637)
- 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).
Settings of the switches: please refer to chapter 5.3.2 on page 104.
- Bus connection
Connection scheme - please refer to chapter 5.3.2, page 104
X13
For information on signal exchange via DeviceNet,
please refer to chapter 5.3.5 on page 107
- Signal inputs I0 to I7 (24VDC), with indicator LED

please refer to chapter 5.3.3 on page 104 X12
- Signal outputs O0 to O7 (24VDC), with indicator LED

please refer to chapter 5.3.3 on page 104 X11
- Voltage supply of the I/O modules (24VDC)

Terminal 1 and 3 connected internally
X10
Terminal 2 and 4 connected internally
☞ For technical data, refer to Sect. 4.2 Page 82.

and Controls
Overview
2.4.3 Front side of the I/O module “I/O DISK” (PSI 6xxx.737)
- Fuse (M 1.6 A) to protect the signal output O0
- Fuse (M 1.6 A) to protect the signal outputs O1 to O12
- Signal inputs I0 to I13 (24VDC), with control LED

- 2x voltage output for power supply to the ext. input circuits
(internally tapped from X10)
please refer to chapter 5.3.4 starting on page 105
- Signal inputs I14 to I20 (24VDC), with control LED

- 1x voltage output for power supply to the ext. input circuits
- Signal outputs O00 to O12 (24VDC), with control LED

- 0 V reference potential of the 24 VDC signal outputs
- Power supply to the I/O module (24 VDC)

Terminals 1 and 3 linked internally
Terminals 2 and 4 linked internally
☞ For technical data, refer to Sect. 4.3 Page 83.

and Controls
Overview
Notes:
and Controls
Timer functions
3 Timer functions
3.1 Main components of a welding plant

Welding systems equipped with PS 6000 normally consist of the fol
lowing main components:
• Weld timer with integrated MF inverter
• suitable welding transformer (including current sensor for secondary
measurement)
• pneumatically or electrically operated electrode gun.
Furthermore, a higher-level controller is required that controls the entire
manufacturing process of the part and also monitors its safety aspects.
Suitable controllers include
• a programmable logic controller (PLC)
• a robot controller
• manual control (e.g. of manual guns), or even
• a combination of these possibilities.
PS 6000
Start PROP
Welding gun
I O
Spot no.
PLC or (WLD) Trans-

Electrodes
robot former
Internal
current sensor DRM
O I
WC
optional external
I: Input current sensor
O: Output Actual current value
PROP: Proportionate control valve
DRM: Digital pressure feedback (gun closed)
WC: Weld complete contact
WLD: Weld time
Main components of a welding plant
The weld timer ensures the controlled performance of the actual wel
ding process. For this purpose, it must provide open- and closed-loop
control of many functions and physical quantities. Its main tasks in
clude, e.g.:
• Communication with a higher-level PLC or robot controller via I/O si
gnals.
• Controlling a proportionate control valve or a servo gun for influ
encing the electrode force.
• Ensuring the proper schedule of various time intervals (e.g. pre-
weld, main weld, post-weld time etc.).
• Driving the power unit to generate the proper welding heat.
• Signalling a correct or incorrect weld at the end of the welding pro
gram schedule.
and Controls
Timer functions
Current I Time
Transformer
Start
Primary Force F %I
circuit
1.SQZ
Secondary circuit + WLD HLD
SQZ
SQZ: Squeeze time (for explanations, refer to Sect. 3.4.4 starting on page 45)
WLD: Weld time
HLD: Hold time (for a description, refer to Sect. 3.4.4 )
Physical quantities for influencing the weld

and Controls
Timer functions
3.2 Welding modes

In order to perform a welding process, the weld timer can be controlled
automatically by a PLC/robot or manually by the operator.
There are various welding modes available in PS 6000 for this purpose.
• Single spot
• Repeat
• Seam
3.2.1 Single spot

Suitable for use in connection with robots, welding machines, automatic
welding equipment and manual welding guns, for spot welding, projec
tion welding, butt welding.
A high level at the Start input (refer to page 112) initiates the welding
schedule (or welding program) exactly once, starting with the pre-
squeeze time (1.SQZ).
At the end of the program, the timer outputs the WELD COMPLETE
(WC) output signal, if no welding fault has occurred.
For the next program start, the Start signal has to be switched off and
back on.
Start
WC
one spot weld another spot weld

is produced is produced
Single spot welding mode, signal sequence
3.3 Repeat
The Repeat mode is suitable for manual electrode guns and manually
operated welding machines.
The weld timer initially responds to the start signal as in single spot
mode and starts the welding schedule.
If the start signal is still present after the end of the hold time (HLD), the
solenoid valve signal will be switched off. The welding gun is opened.
The Off time (OFF) runs. During this time, the operator can pull on the
welding gun towards the next spot.
After the end of the OFF time, the solenoid valve will be energized
again, and the welding schedule will be restarted - this time beginning
with the SQZ.
This sequence will be repeated for as long as the relevant start input is
high.
and Controls
Timer functions
Start
Solenoid
one spot weld OFF another spot weld

is produced is produced
Repeat welding mode, signal sequence
3.3.1 Seam
Suitable for roll seam applications.
The parts to be welded are joined by individual spot welds while rolling
electrodes are moved along.
The weld timer initially responds to the start signal as in single spot
mode and starts the welding schedule.
The weld time (MainWLD) and a cool time (2.CT), if programmed, will be
repeated for as long as the START input remains high.
When the start signal becomes low, the timer will cancel the actual cur
rent pulse and start the hold time (HLD).
In seam operation, a distinction is made between a stitch weld and a
seal weld.
Stitch seam: a series of weld times is separated in time by sufficiently
long cool times so that subsequent spot welds neither
touch nor overlap.
Seal weld: the cool time is configured very short so that subsequent
spot welds overlap.
Stitch seam Seal weld Seal weld
ÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
ÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ
2.CT MainWLD
CT very short or 0
Seam operation principle

and Controls
Timer functions
3.4 Program execution

A total of 256 separate welding programs (prog.no. 0 to 255) are availa
ble. The inputs for spot selection (refer to page 113) are used to initially
select the desired spot number. With a next step, the timer automati
cally searches the pattern of the selected spot number within the spot
reference table and if found, the appropriate welding program is started
by a high level at the Start input (refer to page 112).
Each welding program contains all of the parameters that are required
for the precise definition of a weld. Basic parameters include, e.g.
• %I values that are to be effective in different current blocks (refer to
Section 3.4.1 and following)
• For times that are to be subsequently processed, refer to Sect. 3.4.4
starting on page 45)
• Electrode force (for a description, refer to page 92).
3.4.1 Programmable current blocks

For reasons of process technology, it may be necessary to supply the
amount of heat required for a single spot weld in the form of consecutive
current blocks.
Therefore, a spot weld can be generated from a maximum of three cur
rent blocks (PreWLD, MainWLD, PstWLD), with each block being sepa
rately programmable in terms of duration and %I.
☞ Programming of the %I values is subject to the active regulation mode
(refer to page 48):
PHA (phase angle): in scale values
KSR (Constant-current-regulation): in kA
Cool times (1.CT, 3.CT) can be programmed in between the blocks. If a
cool time is set = 0, the relevant 2 blocks are seamlessly performed.
Start program execution End program execution
1.SQZ PreWLD 1.CT MainWLD 3.CT PstWLD HLD

+ 1. %I 2. %I 3. %I
SQZ
1st current block 2nd current block 3rd current block
(Pre-heating time) (Post-heating time)
SQZ: Squeeze time (for explanations, refer to Sect. 3.4.4 starting on page 45).
WLD: Weld time
HLD: Hold time (for a description, refer to Sect. 3.4.4 )
%I: Heat/%I
Available current blocks
PreWLD (1.WLD / Pre-heating time):

Using this current block, the metal can be pre-heated before the actual
weld is performed (in the 2nd current block) using a lower heat (1.%I),
e.g., in order to reduce expulsion.
If you do not want to use the PreWLD, simply program PreWLD=0.
and Controls
Timer functions
MainWLD (2.WLD / 2nd current block):

Welds the actual spot using the command heat (2.%I).
• The MainWLD time has to be programmed in all instances.
• Within the MainWLD, the functions
- "impulse mode" (refer to page 43) and
- "Slope" (refer to page 44) can be used.
PstWLD (3.WLD / post-heating time):

Using this current block, the metal can be post-heated after the actual
weld has been performed (in the 2nd current block) using a lower heat
(3.%I).
The purpose is to prevent the spot from cooling too fast, e.g., as a result
of electrode cooling. This post-heating will improve the joint between
the parts to be welded and serves to balance stress.
If you do not want to use the PstWLD, simply program PstWLD=0.
and Controls
Timer functions
3.4.2 Impulse mode

In addition to the possibility of providing the amount of heat required for
a single spot through 3 subsequent current blocks (refer to page 41),
impulse mode may be used.
It serves to apply the required amount of heat in the 2nd current block to
the spot weld through up to 9 consecutive impulses, which in turn redu
ces expulsion.
A 2nd cool time can be programmed in between the impulses.
If the 2nd cool time is set = 0, all impulses are seamlessly performed.
You can influence the impulse mode via the "Impulse" parameter.
It determines how often the MainWLD is to be repeated with due regard
to a prgrammed 2.CT.
2nd current block

Example: Impulse mode OFF MainWLD
IMP = 1
MainWLD = 60 ms
2.CT (not relevant because 1 impulse only)
2nd current block

Example: 2 impulses
IMP = 2 MainWLD MainWLD
2.CT
MainWLD = 60 ms
2.CT = 40 ms
2nd current block

Example: 3 impulses
IMP = 3 MainWLD MainWLD MainWLD
MainWLD = 60 ms 2.CT 2.CT
2.CT = 40 ms
Programming example for impulse mode

and Controls
Timer functions
3.4.3 Slope (current increase)

If slope has been activated, the weld timer automatically generates a
linear current increase/decrease for the 2nd current block within a pro
grammable period of time. In this way, switch-on peaks and thus stress
on the welding plant can be reduced.
For programming, you use
• the Upslope time (UST) to define the period of time during which the
current is to increase from its start value to the commanded current
during the MainWLD (2.%I), and/or
• the Downslope time (DST) to define the period of time during which
the current is to decrease from the MainWLD (2.%I) to the final %I.
Please note:
• The upslope/downslope times are always part of the 2nd current
block.
The upslope time starts at the beginning of the 2nd current block.
The downslope time ends at the end of the 2nd current block.
• The upslope and downslope times are not influenced by active
impulse mode and a programmed 2.CT, if any. They are also per
formed throughout a possible 2.CT.
• If the total time of the UST and DST is longer than the 2nd current
block, the command %I is never reached in the 2nd current block
(2.%I)! Fault messages such as "Low current" will be output.
• In connection with the slope, you should use the fade-out time (refer
to page 55).
2nd current block

Example: 3 impulses with slope MainWLD MainWLD MainWLD
UST = 120 ms 2.CT 2.CT
DST = 40 ms
IMP = 3
MainWLD = 60 ms
2.CT = 40 ms UST DST
Example: Slope in connection with impulse mode

and Controls
Timer functions
3.4.4 Programmable times

The way in which a welding program is executed depends on the use of
various programmable periods of time. Within the program execution,
each period of time serves a specific purpose.
☞ The times are programmed in 1 ms intervals.
Welding program execution without impulse operation in 2nd current block:

Start
MainWLD
1.SQZ SQZ PreWLD PstWLD HLD
1.CT
3.CT
UST DST
Time
Current
Time
Welding program execution with impulse operation in 2nd current block (example: impulse=3):
Start
2.CT 2.CT
MainWLD MainWLD MainWLD

1.SQZ SQZ PreWLD PstWLD HLD
3.CT
1.CT
UST DST
Time
Current
Time
Model time diagrams with all programmable periods of time
1. SQZ (pre-squeeze time):

The electrode gun should entirely close during the 1.SQZ. No current
flows during this period of time.
The 1.SQZ is processed immediately following the Start signal in all
welding modes (single spot, repeat, and seam).
and Controls
Timer functions
SQZ (squeeze time):

During this time, the working pressure of the electrodes is built up.
No current flows during this period of time.
The electrode gun must be entirely closed at the beginning of SQZ
(refer to 1.SQZ).
☞ An SQZ greater than 0 must be programmed in all instances.
Shortest possible SQZ: 16 ms.
☞ During the SQZ, the timer checks whether or not the connected measu
ring loop is faultless by performing an ohmic resistance measurement
for secondary current measurement.
In the event of a fault (refer to page 98), the timer aborts the welding
program and clears the "Timer ready" output signal.
☞ At the end of the SQZ the timer checks whether a high level is present at
the digital input X2/4. Otherwise, the timer extends the SQZ by max. 5
seconds before the schedule is aborted and a fault message is output.
☞ At the end of the SQZ the timer also checks the status of the 3 related
I/O pairs ”Transformer x” and ”Feedback Transformer x”.
Please refer to page 120 and 128 for detailed information.
PreWLD (PreWLD, pre-heating time)

Refer to page 41.
1.CT (1st cool time)

If a value greater than 0 has been programmed, it separates the first
and the second current block. Serves to reduce stress in the parts to be
welded.
Refer to page 41.
☞ The 1.CT can only be programmed if PreWLD is greater than 0.
MainWLD (main weld)

Refer to page 42.
2.CT (2nd cool time)

If a value greater than 0 has been programmed, it separates the indivi
dual impulses in impulse mode. Serves to reduce stress in the parts to
be welded.
Refer to page 43.
☞ The 2.CT can only be programmed if impulse mode has been activated
("Impulse" parameter > 1). Exception: Seam operation.
UST (upslope time / time of current rise)

Refer to page 44.
DST (downslope time / current decrease time)

and Controls
Timer functions
Refer to page 44.
PstWLD (PstWLD / post-heating time)

Refer to page 42.
3.CT (3rd cool time)

If a value greater than 0 has been programmed, it separates the second
and the third current block. Serves to reduce stress in the parts to be
welded.
Refer to page 41.
☞ The 3.CT can only be programmed if PstWLD is greater than 0.
HLD (Hold time)

Is used to fix the parts welded together while cooling down. No current
flows during this period of time.
The welding gun opens when the HLD has elapsed. If no welding fault
has been detected, the WELD COMPLETE (WC) output signal is output
(refer to page 122).
and Controls
Timer functions
3.5 Regulation modes

There are different regulation modes available in the weld timer:
• Phase angle (PHA)
• Constant-current-regulation (KSR)
• UIR regulation (UIR; optional)
The regulation mode to be used by a program can be selected with a
high degree of flexibility. A distinction is made between the following
possibilities:
• Standard mode:
The regulation mode setting (PHA or KSR) applies to all weld times
of a program.
• Mixed mode:
All weld times of a program can be assigned different regulation
modes (PHA or KSR).
☞ If activated in a program, UI regulation only applies to the MainWLD. In
connection with the PreWLD and the PstWLD, only PHA or KSR can be
used.
☞ Regulation and monitoring are functions that are independent of each
other! For this reason, the command %I values can be separately pro
grammed for regulation and monitoring.
Refer to Section 3.7.1 starting on page 52.
3.5.1 Phase angle (PHA)

Special case.
PHA mode does not involve regulation of an actual value (e.g. current)
but only controls the power unit. For PSI, that means that the pulse
width is influenced.
PHA features:
• The %I values are programmed as scale values (%I).
Programmable range: 0.0 to 100.0 %I.
Programming resolution: 0.01 %I
• No regulation takes place.
• The resulting amount of current in the secondary circuit depends on
the secondary circuit resistance and the secondary voltage.
• A current sensor is not necessary from the point of view of regulation
technology.
☞ Current or time monitoring can be activated in PHA mode.
A current sensor is absolutely necessary for current monitoring. If the
integrated current sensor is not used, a current sensor must be provi
ded on the secondary side.
and Controls
Timer functions
Power
system
Welding
transformer Electrodes
Programming:
Commanded %I value
in %I
Power unit
for display Current sensor

without current Actual current value (only required with
purposes only
monitoring current monitoring on
the secondary side)
with current
Measured value Actual current value
monitoring
preparation
Actual value display
kA-actual current
mean phase value
in %I
Current monitoring
Status
- Tolerance band Error
programmable reference
current
(in kA)
Principle of open-loop PHA mode
3.5.2 Constant-current regulation (KSR)

Standard application (e.g. with robot guns).
In KSR mode, current regulation is active. For this purpose, the actual
current is scanned by a current sensor (programmable: secondary or
primary side) and permanently compared to the programmed current. A
downstream current controller uses the difference between actual/pro
grammed value to drive the pulse width in the power unit and to ensure
that the programmed current is reached.
KSR features:
• The %I values are programmed in kilo-Amps (kA).
Programmable range: 0.5 to 250 kA
(can be restricted by parameter settings and the power unit used).
Programming resolution: 10 A
• There is closed-loop control of the current in the secondary circuit.
and Controls
Timer functions
• Eliminates the influence of the secondary circuit resistance on the

weld (e.g. transfer resistance between electrode and part to be
welded).
• A current sensor is absolutely necessary from the point of view of re
gulation technology. If the integrated current sensor is not used, a
current sensor must be provided on the secondary side (refer to
page 96).
Programming: Power
Commanded current system
value in kA
Welding
transformer Electrodes
-
Closed-loop
controller
Power unit
Current sensor
(only required for
Measured value Actual current value measurement on the
preparation secondary side)
Actual value display
kA-actual current
mean phase value in
%I
Current monitoring
Status
- Tolerance band Error
programmable reference
current
(in kA)
Principle of KSR regulation mode with secondary current sensor
3.5.3 UIR regulation (UIR)
☞ This function is only available if the U/I controller system PSQ 6000
XQR is present and the "UI Regulation" option has been activated!
The U/I controller measures not only the welding current, but also the
voltage at the electrodes. In this way, more profound information can be
obtained with respect to the welding process, and an adaptive interven
tion by the controller can be achieved.
☞ Detailed information in documentation no. 1070 087072.
and Controls
Timer functions
3.6 %I prewarning and limitation
3.6.1 %I prewarning
The "%I prewarning" parameter can be used to specify
• the minimum %I value generated that is to trigger the "Phase angle
warning reached " message.
As a result, the timer may draw the operator's attention to an imminent

%I limitation - due to, e.g., line losses in the secondary circuit - in KSR
regulation mode.
☞ The parameter value must be lower than the value for the %I limitation.
3.6.2 %I limitation
☞ First, you should enter the parameters of %I prewarning.
The "%I limitation" parameter is used to define the maximum permitted
%I value that may be generated by the power unit/inverter.
If the %I limitation responds, the timer will output the message "Maxi
mum phase angle".
☞ The input value for %I limitation has an absolute effect!
The "%I correction" (refer to page 75) and "%I stepper" (refer to
page 62) functions can trigger a %I limitation response for this reason.
☞ The parameter value must be greater than the value for the %I prewar
ning.
☞ In some timer types, this value cannot be changed in BOS. In these ca
ses, it is internally fixed to 100 %I.
and Controls
Timer functions
3.7 Monitoring
The timer is capable of monitoring the weld for the following quantities :
• Current (refer to Sect. 3.7.1)
• Time (refer to Sect. 3.7.2 starting on page 57).
Both monitoring functions can be separately turned on and off.
An activated monitoring function checks the relevant actual value
against programmable reference values and tolerance bands.
As the "current" and "time" parameters influence the amount of heat in
the spot, a correct setting of the reference values and activated monito
ring functions are essential measures and conditions for quality ass
urance.
☞ The reference values used for current monitoring can be programmed
independent of the regulation parameters. Changing the regulation
command values does not influence the monitoring parameters!
If he has suitable access privileges, the user may set new reference va
lues manually, or accept a measured actual value as the new reference
value.
Other monitoring functions available:
• Monitor stepper:
acts in conjunction with current monitoring if stepper/dressing cur
ves are active. Also refer to page 57.
• Monitoring the process quality (UIP) and stability (PSF):
acts in conjunction with UI regulation and the "Q-Stop" function. Also
refer to page 78.
3.7.1 Current monitoring
Tolerance ranges
In current monitoring, the actual current determined by rms value mea
surement is compared to the "tolerance band".
Whether or not the timer interprets a measured actual current as "ac
ceptable" depends on the programming of the tolerance band. The fol
lowing values are decisive for the definition of the tolerance band:
• Reference current in kA
• positive tolerance as a percentage of the reference current
(upper tolerance band).
Actual values above the upper tolerance band generate the mes
sage type ”High current ...”.
• negative tolerance as a percentage of the reference current
(lower tolerance band).
Actual values below the lower tolerance band generate the message
type ”Low current ...” or "No current ...".
and Controls
Timer functions
ÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇ
High current ... upper tolerance band
(in %)
Tolerance
Reference current in kA
band
Current ok
ÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇ
Low current ... / No current...
lower tolerance band
(in %)
Principle: Tolerance band
Conditional tolerance range
In addition to qualifying welds as “good/bad", it is often also desirable to

be timely informed about the trend of the current values. Especially, an
increasing number of actual current values in the lower range of the to
lerance band is of interest. Gradual faults of the system (e.g. slow incre
ase in cable resistance in the secondary circuit prior to an interruption of
a cable) may result in such effects. An inappropriate reference current
value setting may also result in actual current values in the lower range
of the tolerance band.
For this reason, the following parameters are additionally available in
connection with the tolerance band:
• "conditional tolerance band" (in % of the reference current) and
• "Reweld Factor".
The "conditional tolerance band" parameter defines the program-speci
fic upper limit of the conditional tolerance range. The lower limit is de
fined by the "lower tolerance band" parameter.
The "Reweld Factor" determines the program-specific number of
consecutive welds for a spot that may be within the conditional tole
rance range.
If the number of consecutive welds within the conditional tolerance
range is higher, the message "Series of welds below lower threshold
point ..." will be output.
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
(in %)
Reference current in kA
with respect to a single
measurement:
Current ok
Conditional tolerance band (in
conditional %)
tolerance range
(in %)
Low current ... / No current...
"Series of welds below lower

spots welded threshold point" message
Example: Principle of the conditional tolerance band with a Reweld Factor = 4

and Controls
Timer functions
☞ Messages can be defined as either "welding faults" or "warnings". While

an event defined as a "warning" does not inhibit the timer, a "welding
fault" must always be followed by "Fault reset" (refer to page 137) to
start the next welding schedule.
Current monitoring modes
Since a total of 3 independent current blocks can be programmed (refer

to page 41), it is necessary to handle current monitoring with the requi
red degree of flexibility.
For this reason, a distinction is made between "Standard" and "Mixed"

monitoring modes.
• Standard mode:
the entire current profile (1st, 2nd and 3rd current block including
cool times) is included in rms value measurement.
The complete current profile is represented by a single actual value,
and monitored by a single tolerance band.
Although this simple and often sufficient monitoring mode keeps the
amount of data to be processed low, any cool times that may have
been programmed and different amounts of current in the individual
blocks alter the measured result.
The reference current to be indicated should be determined by test
welds in this case. If you only use the MainWLD without impulse ope
ration, you can specify the commanded current programmed for re
gulation as reference current as well.
Tolerance band
Reference
current
1st * *
block 3rd block
PreWLD 1.CT 2nd block 3.CT PstWLD
*: 2.CT
Measuring time
Principle of "Standard" monitoring mode
• Mixed mode:
The rms value is measured separately for each current block and
monitored by individual tolerance bands (for 1st, 2nd and 3rd current
block). The programmed cool times are not accounted for in the de
termination of the actual value for the individual current blocks.
This results in higher transparency of the individual current blocks,
however, the amount of data to be processed is larger.
In mixed mode, you can generally use the commanded currents pro
grammed for regulation as reference currents as well.
and Controls
Timer functions
Reference Reference current

current
Reference
1st current
block 3rd block
t1 t2 t3
Measuring time 1 2nd block Measuring time 3
: Tolerance band Measuring time 2 = t1 + t2 + t3
Principle of "Mixed" monitoring mode
Fade-out time and trail current

In the previous explanations, the current curve as a function of time was
represented by an ideal graph (in rectangular shape). In reality, howe
ver, there is a current upswing and downswing at the beginning and
after the end of any weld time. Due to their very nature, these effects
affect rms value measurements. For this reason, programming different
values as the commanded and reference current (in connection with
current monitoring) may be necessary.
The course of measurement can be specifically influenced using the
"fade-out time" and "trail current" functions:
• Fade out time:
indicates the period of time after the start of a weld time during which
the measured current values should not be used in the determina
tion of the rms value. The total upswing process can thus be faded
out if the setting is made correctly.
Current
Irms_1
Irms_2
Time
Fade out time
Weld time
Irms_1: Fade out time accounted for

Irms_2: Fade out time not accounted for
Effect of the fade out time
Use of the fade out time

• In connection with the "Slope" function (refer to page 44):
you should program the same value for the fade-out time as for
the upslope time (UST).
• when welding very thick sheets and great immersion depths (gun
projects far into the material).
and Controls
Timer functions
• in connection with current calibration:

Reference ammeters also have a "fade-out function" (e.g. Miya
chi: "First Cycle"; to specify the first cycle of the weld time whose
measured values are to be considered).
In connection with current calibration, you should make sure that
the metering device used has been set to the timer's current fade-
out time setting.
• Trail current:
indicates whether or not the downswing process at the end of a weld
time is to be included in the calculation of the rms value (trail current
ON). If trail current is switched off, rms measurement of the current
value will exactly terminate at the end of a weld time.
Current
Time
Weld time Trail current
Trail current
A programmed fade-out time will always start

• at the beginning of a current block
• at the beginning of an impulse.
A programmed trail current will always start
• at the end of a current block
• at the end of an impulse.
2nd block
1st
block 3rd block
Fade out time:

Trail current:
Start times of fade-out time and trail current
☞ The programmed fade out time is identical for all weld times and for all
welding programs!
Therefore, you should make sure that the fade out time is always
shorter than the shortest programmed weld time.
☞ The programmed trail current is identical for all weld times and for all
welding programs!
and Controls
Timer functions
☞ If the only quality criterion for your application is the amount of heat app
lied to the spot weld (amount of heat: Q 9 i2 x t x R), you should program
0 for the fade-out time and switch the trail current ON.
3.7.2 Time monitoring

Time monitoring can be separately configured for each program and
compares the actual time required for the complete current profile to a
programmed reference time.
The actual time is defined as the period of time from the beginning of the
first current block until the end of the last current block including all cool
times, if programmed.
In this way, it can be ensured that no excessive weld time changes can
be made manually in the individual welding programs.
The following values are decisive for programming time monitoring:
• Time monitoring ON/OFF
• Reference time.
• Permitted time tolerance with respect to the programmed reference
time.
Actual times above the permitted time tolerance generate the mes
sage type ”Weld time too long ...”.
Actual times below the permitted time tolerance generate the mes
sage type ”Weld time too short ...”.
Permitted time tolerance
1st * *
block 1.CT 3rd block
3.CT
PreWLD 2nd block PstWLD
*: 2.CT
Reference time
Principle of time monitoring
3.7.3 Monitor stepper

Is used in conjunction with the electrode maintenance functions
• "Stepper" (refer to page 62) and
• "Tip dressing" (refer to page 63)
for monitoring the programmed %I stepping.
In this way, it can be ensured that no excessive changes can be made
manually with respect to the individual stepper or tip dress curves.
If %I stepping is active, the timer changes the programmed %I subject
to the electrode count value.
"Monitor stepper" offers you the possibility of programming separate
stepping percentages for all individual stepper or tip dress curves which
are then used as reference values for monitoring.
and Controls
Timer functions
3.8 Latching
When the SQZ has elapsed, the timer will start to be latching in the wel
ding modes "single spot" and "repeat". In latched condition, the
PreWLD to PstWLD including HLD will continue to be executed even
when the corresponding start signal has been reset.
☞ Signal latching can only be cancelled by opening the stop circuit (refer
to page 103).
☞ Signal latching is not available in "seam" welding mode. If the "Start" in
put signal is reset during a weld time in "seam" mode, the timer will com
plete the cycle just initiated and continue with the hold time.
For latching, also refer to input signal "Start 1" on page 112.
and Controls
Timer functions
3.9 Measuring loop test

This function checks the relevant current sensor circuit for interruption
and short-circuit during the squeeze time while secondary measure
ment is active. Faults in the area of the cables/current sensor can be
detected in time by this function.
If a fault has been detected, the weld timer will abort the running welding
program before initiating the first programmed weld time and generate
a corresponding message ("Measuring circuit open" or "Measuring cir
cuit shorted").
To activate the function, switch the "Measuring loop check" parameter
"On".
Conditions:
• Parameter "Inhibit monitoring mode" has been switched off and
• "Current monitoring" function (refer to page 52) has been switched
on.
☞ Messages can be defined as either "faults" or "warnings". While an
event defined as a "warning" does not inhibit the timer, a "fault" must
always be followed by "Fault reset" (refer to page 137) to start the next
welding schedule.
CAUTION Excessive weld current possible!

Both messages ("Measuring circuit open" or "Measuring circuit
shorted") must be defined as "faults" in any case.
Otherwise, the controller receives incorrect actual value information,
or no information at all. As a result, the controller may fully activate the
power unit initially.
After a max. time of 40 ms, the welding schedule will be aborted, and
the message "Termination of Weld/no current" will be output ("no cur
rent" refers to actual value measured).
3.10 Automatic spot repetition

This function serves to reduce the need for operator interventions in the
event of sporadic welding faults of the type "Low current ..." or "No cur
rent".
Conditions:
• Current monitoring is active and
• "Monitoring stopped" function has been turned off.
Automatic spot repetition can be turned on and off separately for each
welding program using the "Reweld" parameter.
When automatic spot repetition has been activated, the timer is able to
automatically repeat an improper welding schedule once - starting with
SQZ - if "Low current ..." or "No current" has been signaled. In this case,
the gun will remain closed after the improper schedule, and the pro
grammed squeeze time, weld times and hold time are repeated.
If the reweld results in a proper weld, the welding system will continue
running normally afterwards. If the reweld results in another fault, the
corresponding message will be output ("Low current ...", "No cur
rent ...").
and Controls
Timer functions
It may be a problem that every single spot may have to be rewelded in

the event of bad fits or electrodes that do not have optimum contact with
the metal in extreme cases if reweld has been activated. As a result, the
cycle time may strongly increase without even being noticed.
For this reason, the timer offers the global parameter "Max. rewelds"
(maximum number of spot repetitions).
An internal counter is reset to 0 whenever a weld is ok after the first att
empt. In return, the counter is incremented if the current remains below
the "lower tolerance band" and automatic rewelds have been activated.
Automatic rewelds are carried out only if the internal counter value is
lower than/equal to the "Max. rewelds" parameter. If this is not the case,
the timer will generate the "Series of welds below lower threshold ..."
message.
(in %)
Current ok Reference current in kA
(in %)
: The weld that
triggered automatic
spot repetition. Low current ... / No current...
"Series of welds below lower

Welds threshold point" message
Example: Principle of automatic spot repetition using "Max. rewelds" = 4
☞ Messages can be defined as either "faults" or "warnings". While an

event defined as a "warning" does not inhibit the timer, a "fault" must
always be followed by "Fault reset" (refer to page 137) to start the next
welding schedule.
and Controls
Timer functions
3.11 Electrode maintenance

In the course of their life, electrodes are subject to process-related wear
(count value; refer to Sec. 3.11.1) which manifests itself by a larger con
tact surface, among other features.
Wear
Enlarged contact area through electrode wear
The timer offers two methods of compensating this effect:

• automatic %I stepping (Stepper, refer to page 62) and
• Tip dressing (refer to page 63).
Both methods can be used in isolation and in combination.
3.11.1 Count factor and Wear per component

Electrode wear depends on different factors, such as programmed %I,
thickness and material of the parts to be welded.
For as long as only one material type of identical thickness is welded in
the course of an electrode's life with identical %I, the number of welds
that can be performed before an electrode is worn and must be re
placed can be predicted based on experience. Electrode wear can be
mapped by a "spot counter" in this case. The spot counter is simply in
cremented by "1" after each spot welded.
However, if different materials or material thicknesses are welded in the
course of the electrode life, the wear per spot no longer is constant. A
spot counter is inappropriate in this case.
For this reason, the electrode wear is monitored by a "count value" in
tegrated in the timer.
Using this function, the timer increments the count value after each spot
welded by the "count factor". As a result, the count value cannot only be
incremented by "1" (like the spot counter), but rather by any desired va
lues.
As it is possible to specify the count factor that fits the weld performed
by each individual program, proper recording of the electrode's wear is
ensured.
Wear per component
The parameter "Wear per component" is used to enter the wear occur
ring on the electrode when a single part is welded. This value is used by
the timer to calculate the number of parts that can be welded by an elec
trode until the End of Stepper is reached. The number of remaining
parts is displayed in the "Warning table" (refer to page 63).
and Controls
Timer functions
Example:
6 welds have to be performed on a part.
Every single spot (P1 to P6) is generated by a separate welding pro
gram (Prog1 to Prog6).
The upper 3 spots (P1 to P3) have to weld 2 sheets, the lower 3 spots
(P4 to P6) have to weld 3 sheets, each.
Consequently, electrode wear is higher for spot welds P4 to P6 (greater
material thickness). For this reason, the program-specific count factor is
defined by the value "1" for Prog1 to Prog3, and by 1.5 for Prog4 to
Prog6.
The resulting wear per component is 7.5.
☞ The count factors in this example are of an exemplary nature only. In
practice, they are determined in advance with respect to the materials
and thicknesses used.
Counts:
0 1 2 3
(new electrodes)
P1. P2. P3.

CF=1 CF=1 CF=1
P6. P5. P4.

CF=1.5 CF=1.5 CF=1.5
CF: Count factor 7,5 6 4,5
Example: Determining the count value
3.11.2 %I stepping (Stepper)

%I steppping keepts the current density constant in the spot weld
constant throughout the electrode life although the spot increases in
size.
For this purpose, separate stepper curves can be defined for up to 10
different types of electrodes. A stepper curve defines the percentage by
which the programmed %I is to be automatically increased subject to
the actual electrode count.
%I increase in %
(with reference to the programmed %I)
max. permitted
counts
100
Stepper curve
Count value
0
Principle of %I stepping
☞ The resulting %I change can be monitored using the "Monitor stepper"

function (refer to page 57).
and Controls
Timer functions
3.11.3 Tip dressing

Tip dressing periodically restores the desired contact surface
throughout the electrode life.
For this purpose, the electrodes must be dressed accordingly in an
electrode dressing station whenever a certain count is reached.
The timer requests tip dressing by issuing the "Tip dress required" out
put signal (refer to page 124).
The additional possibility of defining up to 10 different tip dressing cur
ves provides for optimum adaptability to different electrode types. A tip
dress curve defines the percentage by which the programmed %I is to
be automatically increased subject to the actual electrode counts.
☞ The resulting %I change can be monitored using the "Monitor stepper"
function (refer to page 57).
☞ The "Dress new electrode" parameter is used to activate initial dres

sing.
If initial dressing is active, the timer first requests tip dressing via output
signal ”Start tip dress request” when an electrode has been replaced.
For new electrodes, this serves to, e.g.
- obtain a defined size of plug
- obtain a defined application angle
- remove a protective coating.
☞ The timer can control and monitor an external tip dressing device. Also
refer to "Cutter motor control" function starting on page 64.
3.11.4 Warning and end of stepper

When the maximum acceptable count value is reached, new electrodes
have to be used.
In this context, the output signals
• "Prewarning" (refer to page 124)
• "End of stepper" (refer to page 124)
are available. They are only used if the electrode maintenance func
tions have been activated ("Stepper" parameter: ON).
3.11.5 Warning table

The warning table provides an overview of and quick access to all
important information and operations with respect to electrodes whose
electrode maintenance function is active.
• Weld timers to which the individual electrodes have been assigned,
• actual counts (percentage, numerically and graphically).
The graphic representation is color coded. Any imminent warnings,
tip dress requests or the reaching of the end of stepper can be
quickly detected.
• Remaining parts that can still be manufactured using the respective
electrode.
• Resetting one or several count values after a tip change.
and Controls
Timer functions
3.12 Cutter motor control / Tip dress management

The timer can control and monitor an external tip dressing device. The
following options can be configured using the "Cutter mode" parameter
(BOS):
• Mode "Off":
robot or PLC control the cutter. The timer does not generate any fault
messages for the cutter motor.
• Mode "Electric drive":
The timer controls a cutter with an electric cutter drive.
The dressing time is preconfigured by the programmable cutter duty
cycle.
• Mode "Pneumatic drive":
The timer controls a cutter with a pneumatic cutter drive.
The dressing time is preconfigured by the programmable number of
cutter revolutions.
3.12.1 Mode "Off"
Signals used
• Inputs:
"Spot number bit x"
"Tips have been dressed"
• Outputs:
"Tip dress required"
"Tip dressed"
Schedule
1. The timer generates the "Tip dress required" output signal as soon
as the selected electrode tip is to be dressed. In this condition, more
welds can be performed using the electrode in question.
If welding is no longer possible using the electrode in question (max.
count value reached, and parameter "Stop at end of stepper" = ON),
the electrode first has to be dressed in order to continue welding.
2. An external control instance (robot, PLC) or the operator will ensure
proper tip dressing.
3. Proper tip dressing is signaled by a positive signal edge when the
relevant electrode number has been selected ("Spot number bit x"
inputs) at the "Tips have been dressed" input.
4. The timer will increment the tip dress counter of the relevant elec
trode, reset the count value to "0", clear the "Tip dress required" and
generate ”Tip dressed”.
☞ The "Tip dressed" timer output will be cleared again by the next program
start.
and Controls
Timer functions
3.12.2 Mode "Electric drive"

Signals used
• Inputs:
"Tip dress motor on (Air/Elec)"
"Tip dress - motor overload tripped" (discrete signal)
"Tip dress - motor current tripped" (discrete signal)
"Spot number bit x"
• Outputs:
"Tip dress - enable circuit" (discrete signal)
"Tip dress sequence running"
"Tip dress OK"
"Tip dressed"
Schedule
2. An external control instance (robot, PLC) or the operator selects a
welding program for tip dressing, moves the gun to the tip dressing
device and requests the timer to start the cutter motor by selecting
"Tip dress motor on (Air/Elec)".
☞ "Tip dress motor on (Air/Elec)" must remain active until the end of the
dressing process ("Tip dressed" output becomes high, refer to step 8.)!
Otherwise, the timer will abort the tip dressing process and generate
Error 407 (Tip dress fault - sequence aborted).
3. The timer will verify the program-specific parameter "Cutter mode":
If mode = Off, it will abort the cutter process and generate Error 405
(Tip dress fault - invalid weld schedule selected).
Otherwise, it will start the cutter motor by energizing the discrete out
put "Tip dress - enable circuit" and inform the external control in
stance by setting "Tip dress sequence running". Consequently, the
external control instance has to close the gun immediately. The cut
ter force used is defined by the "base pressure value" parameter of
the selected welding program.
4. The timer will monitor the cutter motor using the "Tip dress - motor
overload tripped" and "Tip dress - motor current tripped" input si
gnals.
Signal Level Timer response
High -
Tip dress - motor over
load tripped Error 406. Tip dress fault - current
Low
overload detected on the el. motor
Error 400. Tip dress fault - excessive
Tip dress - motor cur High
current detected on the el. motor
rent tripped
Low -
and Controls
Timer functions
5. The timer sets the "Tip dress OK" output when the programmed cut
ter duty cycle has been completed. "Tip dress - enable circuit" conti
nues to be high.
The external control instance then opens the gun and confirms "Tips
have been dressed" by a positive edge at the input when the relevant
spot number has been selected ("Spot number bit x" inputs).
trode and set its count value to "0".
7. Then, the timer clears the "Tip dress - enable circuit" and "Tip dress
sequence running" outputs. The cutter motor is stopped.
8. The timer informs the external control instance that tip dressing has
been completed without errors by energizing the "Tip dressed" out
put and resets the following outputs to low level:
- "Tip dress required"
- "Tip dress OK"
- "Tip dress sequence running"
"Tip dressed" will be cleared again by the next program start.
☞ If an error occurs while tip dressing, the following applies:
”Tip dress required”: 1
"Tip dress sequence running": 1
”Tip dress - enable circuit”: 0
"Tip dress OK": 0
"Tip dressed": 0"
and Controls
Timer functions
3.12.3 Mode "Pneumatic drive"
Signals used
• Inputs:
"Tip dress motor on (Air/Elec)"
"Tip dress - RPM sensor" (discrete signal)
"Spot number bit x"
• Outputs:
"Tip dress - enable circuit" (discrete signal)
"Tip dress sequence running"
"Tip dress OK"
"Tip dressed"
Schedule
2. An external control instance (robot, PLC) or the operator selects a
welding program for tip dressing, moves the gun to the tip dressing
device and requests the timer to start the cutter motor by selecting
"Tip dress motor on (Air/Elec)".
☞ "Tip dress motor on (Air/Elec)" must remain active until the end of the
dressing process ("Tip dressed" output becomes high, refer to step 9.)!
Otherwise, the timer will abort the tip dressing process and generate
Error 407 (Tip dress fault - sequence aborted).
3. The timer will verify the program-specific parameter "Cutter mode":
If mode = Off, it will abort the cutter process and generate Error 405
(Tip dress fault - invalid weld schedule selected).
Otherwise, it will start the cutter motor by energizing the discrete out
put "Tip dress - enable circuit" and wait for the cutter to start (positive
edge at input "Tip dress - RPM sensor" (discrete signal))..
4. As soon as the first positive edge is detected by the timer at the "Tip
dress - RPM sensor" input, it will inform the external control instance
by setting "Tip dress sequence running". Consequently, the external
control instance has to close the gun immediately. The cutter force
used is defined by the "base pressure value" parameter of the selec
ted welding program.
5. The timer now counts the number of impulses arriving at the "Tip
dress - RPM sensor" input.
If no additional positive edge is detected within 500 ms, it will gene
rate Error 401 (Tip dress fault - no feedback detected from the pneu
matic drive).
6. When the number of programmed cutter revolutions (impulses) has
been reached, the timer sets the "Tip dress OK" output. "Tip dress -
and Controls
Timer functions
enable circuit" continues to be high.

The external control instance then opens the gun and confirms "Tips
have been dressed" by a positive edge at the input when the relevant
spot number has been selected ("spot number bit x" inputs).
trode and set its count value to "0".
8. Then, the timer clears the "Tip dress - enable circuit" and "Tip dress
sequence running" outputs. The cutter motor is stopped.
9. The timer informs the external control instance that tip dressing has
been completed without errors by energizing the "Tip dressed" out
put and resets the following outputs to low level:
- "Tip dress required"
- "Tip dress OK"
- "Tip dress sequence running"
"Tip dressed" will be cleared again by the next program start.
☞ If an error occurs while tip dressing, the following applies:
”Tip dress required”: 1
"Tip dress sequence running": 1
”Tip dress - enable circuit”: 0
"Tip dress OK": 0
"Tip dressed": 0"
and Controls
Timer functions
3.13 Electrode force
Each welding program includes the information concerning the force to

be used by the electrode to squeeze the parts to be welded together (in
kilo Newton: kN).
The following is available to output the force actuating variable:
• an analog signal at X2 (refer to page 92).
• 8 serial output signals (”Pressure output Bit xx”; refer to page 130).
The value of the analog output signal that corresponds to the pro
grammed force (pressure) is calculated using an internal characteristic.
The internal characteristic can be generated as follows:
• automatically by force calibration (refer to Sec. 3.14.1 staring on
page 71),
or
• manually using the "Conversion factor" parameter (characteristic
slope in kN/Volts or kN/mA) and "Zero adjust" (parallel shift of
characteristic in Y direction in kN).
Thus, the characteristic can be adjusted to the working range of the ac
tuators used.
programmed force in kN
"max. pressure"
-
Zero adjust
+
Force actuating variable
0
"max. pressure":
electrode-specific parameter for limiting the maximum max. analog force actuating variable at X2 that can be
programmable electrode force. output (hardware-specific, e.g. 10V)
progr. force value (in kN) + zero adjust (in kN)

analog force actuating variable =
conversion factor (in kN/Volt or kN/mA)
Characteristic for analog output of force actuating variable
☞ In order to ensure that the programmed force actually acts on the elec
trodes, the characteristic has to be properly set!
☞ In the course of force calibration, the timer automatically calculates the

values necessary for the "Conversion factor" and "Zero adjust" parame
ters. For this reason, these parameters must not be manually changed
afterwards!
and Controls
Timer functions
In addition to programming a constant electrode force for the complete

welding schedule, the timer offers the following enhanced fuctions:
• Pressure profile:
10 different force values can be separately programmed for each
welding program which can be activated at certain points of time wi
thin the welding schedule.
• Pressure stepping:
depending on the stepper or tip dress curve selected, you can define
the percentage by which the programmed base pressure value is to
be automatically increased subject to the actual electrode count va
lue.
and Controls
Timer functions
3.14 Calibration
☞ Calibrate force first, and current afterwards!
3.14.1 Force calibration

☞ If you are using the 8 serial output signals ("Pressure output bit x"; refer
to page 130), the device dependent force calibration of the force gener
ating unit has to be performed in the force generating unit first!
In addition, you should remember that the digital force actuating vari
ables must be properly interpreted by the force generating unit!
The "Force calibration" function is used to adjust all components of the
timer system that are involved in force generation to your reference
force meter (e.g. pressure pickup). This feature has the following
advantages:
• Input of gun force in Kilonewton (kN)
• precise reproducibility of logged force values (ISO 9000)
• The force values of all calibrated systems are comparable to each
other and can be transferred to additional systems.
• Comparable documentation.
☞ According to its principle, the weld timer also works without force
calibration. However, the benefits listed above cannot be achieved un
less force calibration has been performed.
CAUTION Danger of damaging guns!

If force calibration is not used, the timer cannot generate a proper refe
rence between the programmed force and the analog force actuating
variable to be output (for controlling the gun force).
Thererfore, the actual force acting on the gun may differ considerably
from the programmed force.
Possible consequences include improper welds and even damages to
the gun.
For this reason, the base pressure value to be programmed must be
determined empirically - starting with "0" - for each electrode force
required and whenever guns have been replaced if force calibration is
not carried out!
Conditions for force calibration:

• Proportionate control valve, servo gun or other suitable device capa
ble of converting the force actuating variable output by the timer into
a mechanical force at the gun.
• external reference force meter with a suitable measuring range.
• programming terminal with BOS software (for operation and measu
red value input) is connected.
For force calibration, specify 2 different values of the force actuating va
riable in the % unit of measurement (with respect to the maximum value
that can be output), measure the resulting forces between the electro
des using the reference force meter and enter the forces measured in
the timer (in kN). The timer will then calculate all of the data required for
calibration.
and Controls
Timer functions
The following things should be especially noted for force calibration:
L The following applies for the 2 values of the force actuating variable
used for force calibration:
• if possible, the higher value should generate the force that is ma
ximally used for welding (upper end of the force working range).
• The two values should differ by a minimum of 20 %.
• The force used for tip dressing should not be allocated to the normal
working range (because it is usually lower).
• If you do not know the values you have to enter for force calibration,
first perform force calibration tests using low values in order to check
the force adjusted at the gun. Thus, you avoid overloading or dama
ging the gun during force calibration. Then, you should increase the
input values by new force calibration processes until the higher input
value generates the maximum force used for welding.
L Use the same reference force meter for all plants that should be compa
rable.
L Perform calibration for each gun of the welding equipment and whene
ver a gun has been replaced.
L Verify any calibration made by comparing the base pressure values
programmed for a test welding program with the actual values on the
gun.
Make sure that the test programs work without current and that no per
sons are at risk during the measurements (e.g. as a result of robot mo
vements).
L Repeat calibration whenever a component that is actively involved in
force generation has been replaced (weld timer, proportionate control
valve, gun, ...).
☞ Force calibration changes the "Conversion factor" and "Zero adjust" pa
rameters (in Stepper Parameters, also refer to page 69). For this rea
son, these parameters must not be manually changed once force
calibration has been completed!
and Controls
Timer functions
3.14.2 Current calibration

The "Current calibration" function is used to adjust the entire measuring
and control loop of the timer system to your reference welding ammeter.
This feature has the following advantages:
• reproducible, preconfigurable currents with a maximum error of less
than +/-2%
(with respect to the actual value of the reference welding ammeter)
• precise reproducibility of logged current values (ISO 9000)
• The currents of all calibrated systems are comparable to each other
and can be transferred to additional systems
• Comparable documentation.
☞ The weld timer also works without current calibration.

However, the benefits listed above cannot be achieved unless current
calibration has been performed.
Conditions for current calibration:
• internal current sensor or external sensor connected to X3 (cf.
page 96)
• external reference welding ammeter with a suitable current sensor.
• programming terminal with BOS software (for operation and measu
red value input) is connected.
• Before proceeding with current calibration, you should make sure
that force generation works properly (cf. force calibration (cf.
page 71)).
For current calibration, enter 2 different %I values in scale values (%I),
measure the currents resulting in the secondary circuit with the refe
rence ammeter, and enter the current values measured in the timer.
The timer will then calculate all of the data required for calibration.
The following things should be especially noted for current calibration:
L The current sensor of the reference welding ammeter must have been
properly installed in the secondary circuit. That means:
- always connect it in the same location
- vertically to the current-carrying conductor
- sensor cable points away from current-carrying conductor
L The following applies for the 2 %I values (in %I) used for current calibra
tion:
• the higher %I value should be at the upper end of the normal working
range of your welding plan.
• the two values should differ by a minimum of 20 %I.
L Use the same reference ammeter for all plants that should be compara
ble.
L Set your reference welding ammeter to "DC" type of current and the ap
propriate measuring range.
L Programmed fade-out times or an active trail current are also effective
with current calibration!
Therefore, you should check prior to the calibration process whether
the corresponding functions are offered by your reference welding
ammeter, and whether they have been properly set.
and Controls
Timer functions
L Calibration should always be performed without parts to be welded with

the electrodes closed.
L Perform calibration for each gun of the welding equipment and whene
ver a gun has been replaced.
L Verify any calibration made by performing a test weld and comparing
the current displayed on the timer with the current displayed on the refe
rence welding ammeter.
L Repeat calibration whenever a component that is actively involved in
the control loop has been replaced (weld timer, transformer, sensor ...).
and Controls
Timer functions
3.15 Corrections
Using the timer's correction function you can change
• the %I, and
• the pressure (electrode force).
Corrections are programmed as a percentage of the corresponding
base values.
Thus, the welding schedule can be quickly adjusted to process-specific

requirements without the need to change the originally programmed
base values.
The following types of correction can be activated

• electrode-specific correction:
acts on a specific electrode/gun (= Corr.(E)), and
• program-specific correction:
acts on a specific program (= Corr.(P)).
The two types of correction always act in addition to one another.
☞ If the %I correction is changed, the reference current to be monitored is

also internally adjusted (influenceable via konfiguration tool).
☞ The maximum correction values that can be input can be limited
globally for the whole timer. This limitation can be set to any value in the
range of +/-20%.
and Controls
Timer functions
3.16 Welding transformer data

In order to ensure that the power unit works properly, the timer must be
given information concerning the welding transformers used. For this
purpose, the transformer-specific parameters have to be properly set.
L The availability of some parameters depends on the settings of the
"type" and "number" parameters.
Therefore, you should first set the "type" and "number" parameters to
suit your application.
"Type" parameter
Type designation of the PSG transformer according to the rating plate
(e.g. "PSG 3100.00"). Other necessary parameters are set internally
depending on the PSG designation.
When third-party welding transformers are used, please set the "Other
transform." type.
"Type of connection" parameter
"serial" or "parallel". Only available if "Number" > 1.
"Number" parameter
Number of transformers (of the same type!) used
"Turns ratio" parameter
Ratio between primary and secondary winding. The parameter is requi
red for the conversion between the primary and secondary current if in
tegrated current sensors are used for current measurement in the
primary circuit (primary current regulation: e.g., used with transformers
that do not have an integrated KSR sensor).
"Nominal current" parameter
maximum secondary current. The maximum welding current will be limi
ted to this value.
"Type of diode" parameter
type of diode used by the welding transformer.
"Number of parallel diodes" parameter
Number of diodes connected in parallel in the transformer.
"(Diode) Monitoring" parameter
Activation/deactivation of the diode monitoring function
When this function is active, the timer interrupts the welding schedule
as soon as the present calculated diode junction temperature ("Diode
temperature" parameter) exceeds the specified "Switch-off tempera
ture".
CAUTION Possibility of destroying the power unit or the welding transformer!

If diode monitoring is not active, the diodes of the welding transformer
are no longer monitored. In the event of excessive load, this may result
in considerable damage to the welding equipment.
Therefore, diode monitoring should always be switched on.
and Controls
Timer functions
CAUTION The diode monitoring function is ineffective if the boundary con

ditions are not complied with!
Since a calculated actual value is used for diode monitoring, a number
of essential boundary conditions have to be satisfied for the function
to work properly:
• Proper setting of the "Type of diode" and "Number of parallel di
odes" parameters
• Cooling water temperature lower than/equal to 30 degrees
Centigrade
• Cooling water flow quantity is 8 to 10 liters/min.
"Diode temperature" parameter

Refer to "(Diode) Monitoring" parameter.
"Switch-off temperature" parameter
Refer to "(Diode) Monitoring" parameter.
and Controls
Timer functions
3.17 Q Stop (Quality Stop)

☞ The function requires
- active voltage measurement (UIR parameter "Measurement": ON)
- active UIR monitoring "Process stability" or "UIP"
Using the "Q Stop" function, the weld timer can detect any problems oc
curring in the process quality (UIP) or process stability (PSF) parame
ters, which can be signalled to the operator and/or the PLC adaptive
controller (refer to "Q Stop" output signal, page 127).
With the help of a program-specific, configurable supervision, first the
UIP or PSF values must be defined which are to be detected as basi
cally problematic by the timer. Basically, the timer only accounts for UIP
or PSF values within the "conditional tolerance band" (refer to example
in Fig. on next page).
In addition, you have to define the threshold for the timer that has to be
exceeded in order to actually signal the problems occurred as an error
to the process.
The following response patterns can be implemented:
• program-specific Q Stop:
any problematic events occurring will be considered program-speci
fic and evaluated accordingly.
For each welding program, there is a separate internal counter which
is automatically incremented or reset to "0" by the timer, depending
on problematic UIP and/or PSF values.
If the program-specific Q stop counter exceeds a configurable, pro
gram-specific repeat factor, the "Q stop" signal will be output inclu
ding the "Q stop spots in series" (2107) error message.
The timer will reset the non-program-specific counter if the following
requirements are met:
• after a configurable, program-specific number of immediately
consecutive quality welds. Thus, sporadic errors do not trigger a
Q stop.
• when a Q Stop error has been reset and the next weld is accepta
ble.
• component-specific Q Stop:
any problematic events occurring will be considered regardless of
the program and evaluated accordingly.
An internal, non-program-specific counter is automatically incre
mented by the timer depending on problematic UIP and/or PSF va
lues.
If the non-program-specific Q stop counter exceeds a configurable,
global limit value, the "Q stop" signal will be output including the "Q
stop component" (2106) error message.
The timer resets the non-program-specific counter if the following
requirements are met:
• positive edge at the "component end" input.
and Controls
Timer functions
☞ If particularly strict quality requirements apply to certain spot welds (e.g.

special spots), the relevant program-specific repeat factors can be set
to "0".
As a result, the very first problematic event occurring will immediately
trigger a program-specific Q stop and an error message "Q stop special
spot" (2108) will be output.
in connection with UIP only:

upper tolerance band
(in %, with reference to the
reference value)
Reference value for

Process stability (PSF) or
process quality (UIP) in connection with PSF:
Reference value = 100
conditional tolerance conditional tolerance band (in

range %, with reference to the
Only PSF or UIP values reference value)
in this range may trigger
Q-Stop errors.
(in %, with reference to the
reference value)
Conditional tolerance range in conection with Q-Stop function

and Controls
Timer functions
3.18 Isolate weld contactor

Function
The timer requests a higher-level monitoring instance to isolate the
weld contactor.
Isolating the weld contactor is useful
• as a safety function during an electrode change
• If no new program start is given within 60 s of the end of a welding
schedule
• in the event of a fault in the welding contactor area.
Signals used
• Inputs:
"Weld contactor closed" (discrete signal, refer to page 111)
"Weld contactor enable" (serial signal, refer to page 111)
• Outputs:
"Close weld contactor" (discrete signal, refer to page 125)
3.19 Weld Circuit Degradation (WCD)
Function
The WCD function serves to detect anomalies in the welding circuit.

For this purpose, the timer calculates the relationship between the wel
ding current and the phase angle at the end of a welding schedule, and
monitors the result for compliance with predefined tolerances.
If the value is outside the tolerance range, the timer will generate the
corresponding warning.
and Controls
Technical data
4 Technical data
4.1 Integrated weld timer
Degree of protection IP 20
Operating voltage +24 VDC; +20 %, -15 %
with max. +/-5 % ripple
Nominal current at 24 V PSI: approx. 1.5 A
(without I/O module and without PST: approx. 1.0 A
additional consumers at X5)
Making 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 Centigrade
Temp. for storage/transport -25 ... +70 degrees Centigrade
Air pressure 0 ... 2,000 m a.m.s.l.
Air humidity Condensation is not permitted.
Climatic category 3K3 according to EN60721-3-3
Number of programs 256 (0 ... 255)
Programming on location V24/RS232 interface, electrically isola
ted. X1 port: 9-pol. D-Sub
Field bus for programming Ethernet.
(Option)
Operating software (firmware) in flash memory; can be reloaded via
software (optional) using interface
X1 (V24): via ”WinBlow” SW
X51 (Ethernet): via ”FWUpdate” SW
Program memory buffered RAM memory
Buffer battery Lithium battery type AA 3.6 V
for buffering the RAM data and the in
ternal clock in case of POWER OFF.
Battery life approx. 2 years
Pressure control via analog output (at X2):
0 to +10 V, max. 20 mA or
0 to 20 mA or
4 to 20 mA (at max. 500 ohms).
digitally via serial I/O array:
"Pressure Output Bit x" outputs;
8 bits, binary coded;
Value range: 0 ... 255 increments;
255 increments corresponds to 100%
of max. analog output value
and Controls
Technical data
Pressure / Force feedback digitally at X2 Pin 4:

logic 1: +16 V ... +30 V, 20 mA
logic 0: -1 V ... +4 V.
analog at X2 Pin 3:
0 V ... +10 V.
analog at X9 Pin 4:
0 V ... +10 V,
Sensitivity: 1 kN/V.
Desired input can be selected by para
meter setting.
Electrodes max. 32 (no. 0 to no. 31)
4.2 I/O Module ”DEV-NET” (PSI 6xxx.637)

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

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 6 byte, max. 48 signals (0 to 47)
Signal output field via DeviceNet 6 byte, max. 48 signals (0 to 47)
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
☞ For the I/O signals to be exchanged between the robot/PLC and the
timer via the I/O module, refer to Sect. 5.3.3 starting on page 104.
and Controls
Technical data
4.3 I/O module “I/O DISK” (PSI 6xxx.737)

Function:
Linking the timer I/O to the higher-level PLC or the robot
• via discrete 24 V signals at X11 to X13 (parallel I/O).
Operating voltage (at X10) +24 V= ; +20 %, -15 %

Power input max. 2 A
subject to circuitry connected to the
signal inputs/outputs
Power loss 0.5 VA per active input
2.4 VA per active output
Signal inputs (X12, X13) logic 1: +16 V...+30 V, 20 mA
logic 0: -1 V...+4 V
Signal outputs (X11)
O00...O12: +24 V, max. 0.1 A, short-circuit-
proof
☞ For the I/O signals to be exchanged between the robot/PLC and the
timer via the I/O module, refer to section 5.3.3 starting on page 104.
☞ All serial signals are exchanged between the robot/PLC and the weld
timer via the Ethernet field bus module (Ethernet IP)!
Refer to section 5.3.5 starting on page 107.
and Controls
Technical data
Notes:
and Controls
Electrical connection
5 Electrical connection
5.1 Interference suppression

Noise is caused by switching peaks and can interfere with the timer di
rectly or through coupling with connecting lines. Therefore, measures
must be taken to suppress noise.
L Eliminate all noise at its very source. Where this is not possible, the
noise suppression elements must be attached as close as possible to
the source of noise.
L First make sure that proper noise suppression is available for all
components containing inductive elements or switchgear.
L Noise suppression equipment must be installed resistant to fracture be
cause strong vibration may occur on machines.
DIODE RC element
+ ~
GND MP
Diode, suitable for small DC voltage RC element for AC voltage relays and AC
relays motors
DIODE AND ZENER DIODE RC element
+
GND
DI-ZD attenuation element for large DC voltage RC element for spark quenching with
contactors and defined dropout times inductive load
Noise suppression examples
☞ The following table serves as an example only. The rating of the ne
cessary components depends on the actual load situation.
Resistance Capacitor Diode

24 VDC - - 1 N 5060/ZL 12
48 VDC - - 1 N 5060/ZL 22
110 VAC 220 Ohm / 1 W 0.5 uF 400/600 V
220 VAC 220 Ohm / 5 W 0.1 uF 500 V
440 VAC 220 Ohm / 5 W 0.1 uF 1,000 V
and Controls
5.2 Integrated weld timer

☞ For technical data, refer to Sect. 4.1 on page 81.
5.2.1 Output of the internal 24 VDC voltage generator (X4)

Connection: to X4; STKK, grid 3.5 mm, 14-pole,
max. 1.5 mm2.
Mating connector is comprised in the delivery.
Cable length: (from power source to consumer)
max. 10 m at 0.75 mm2
max. 75 m at 1.5 mm2
Cable type: unshielded, VDE 0281, 0812 (e.g.: Ölflex)
A 24 VDC voltage supply is available at X4 which is derived from the line
voltage by the power unit.
☞ Power supply by the internal 24 VDC voltage generator and thus the
operativeness of the devices supplied by it is ensured only if line power
is supplied to to the line input of the power unit!
Timer
X4
max. 2.5 A
+24 VDC 5
Can be used, e.g., for
0V 8 supplying the control logic and
the I/O module.
Internally generated 24 VDC voltage supply
L When using the internal 24 VDC voltage generator, the following notes
should be observed:
• max current-carrying capacity: 2.5 A
• for power supply to control logic:
When the line voltage is switched off at the line input of the power
unit, the timer is also turned off. In this state
- programming, diagnosis or visualization via the timer, and
- communication are no longer possible between the timer and the
PLC/robot.
• for power supply to the I/O module:
When the line voltage is switched off at the line input of the power
unit, the I/O module is also turned off. In this state
- communication is no longer possible between the timer and the
PLC/robot via the I/O module.
☞ If these conditions are not suitable for your application, the 24 VDC sup
ply to the timer and/or the I/O module must be provided by external
power supply units!
and Controls
5.2.2 Logic supply of the weld timer (X4)

max. 1.5 mm2
Cable length: (from power source to consumer)
max. 10 m at 0.75 mm2
The control logic must be supplied with 24 VDC.
Timer
X4
10 24VDC
int. logic Power infeed for power supply
11 0V to the internal control logic
Logic supply input of the timer
The voltage source to be used for supplying the timer is defined by the
other circuitry connected to X4. Options:
• Supply by the unit's internal power generator (refer to page 86).
• Supply via an external power supply unit.
For this purpose, only a few jumpers have to be inserted/removed at X4.
☞ For more information concerning the connections to X4, please refer to
Sect. 5.2.4 starting on page 89.
Whereas voltage supply by the unit's internal voltage generator is
preferably used in stand-alone systems (e.g. suspended systems, be
cause no additional 24 VDC power supply units are required), external
power supply units are the preferred solution in networked systems
(timer can be programmed by the line PC even if the welding network is
switched off).
L Any external voltage sources used must be designed according to the

principles of "safety separation" in accordance with the Low-Voltage Di
rective (2006/95/EC).
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5.2.3 Power supply to external units (X5)

Connection: to X5/X9; STKK, grid 3.5 mm, 2- or 6-pole,
max. 1.5 mm2.
Mating connectors are comprised in the
delivery.
Cable length: subject to the circuitry connected to X4. Refer to
description below.
For the 24 VDC supply of an external device (e.g. proportionate control
valve or force sensor).
The maximum current-carrying capacity/cable length connected to X5
is subject to the voltage source used and the total cable length between
the source and the external consumer. The max. current load on X5
must not exceed 0.5 A.
Timer
X4
10 24VDC Power infeed for supply to

int. logic - internal control logic and
11 0V
- X5
max. X5
0.5 A 1 24VDC 24VDC
2 0V
0V
Jumpers are external consumer

X9 required if a (e.g. force sensor)
force sensor is
1 used !
2
4 Ext./Signal
GND
5
6 D
Connection option for power supply to external consumers (in this case, e.g.
to force sensor)
and Controls
Timer
X4
10 24VDC Power infeed for supply to

int. logic - internal control logic and
11 0V
- X5
external
X5 consumer
max.
0.5 A
1 24VDC
2 0V
Standard connection option for power supply to ext. consumers
L Please make sure that the maximum current load (source, connections)
and cable lengths specified are not exceeded!
☞ The voltage source to be used for supplying X5 is defined by the other
circuitry connected to X4.
The unit's internal power generation (refer to page 86) as well as an
external power supply unit can be used here. For this purpose, only a
few jumpers have to be inserted/removed at X4.
For more information concerning the connections to X4, please refer to
5.2.4 24 VDC voltage distribution (X4)

max. 1.5 mm2.
Cable length:: (from power source to consumer)
max. 10 m at 0.75 mm2
The internal circuitry connected to X4 ensures considerably easier wi

ring of the 24 VDC supply branches leading to the timer and the I/O mo
dule. Different supply options can be implemented by inserting or
removing a few jumpers without modifying the other wiring in the switch
cabinet.
For this purpose, the relevant power source is connected to X4/6
(24 VDC) and X4/7 (0 V).
and Controls
Some possible options are described below. After that, you can find the
figures showing the relevant wiring.
The option to be selected depends on the requirements of your applica
tion.
1. The timer and the I/O module receive power supply from the internal
24 VDC voltage generator.
Used for: preferably on stand-alone systems.
Advantage: no separate power supply unit required.
Disadvantage: 24 VDC is only generated if line voltage is present at
the line input of the power unit.
2. The I/O module receives power supply from the internal 24 VDC vol
tage generator, the timer from the external power supply unit.
Used for: networked systems.
Advantage: Programming, diagnosis and visualization are still
possible when the line voltage has been switched off
at the line input of the power unit.
Potential separation is possible between the timer
and I/O modules with discrete inputs/outputs (paral
lel I/O).
Disadvantage: No I/O communication between the timer and the
PLC/robot possible when the line voltage has been
switched off at the line input of the power unit.
3. The timer and the I/O module receive power supply from a joint
external 24 V power supply unit.
Used for: preferably for networked systems.
Advantage: I/O communication between the timer and the PLC/
robot, programming, diagnosis and visualization are
still possible when the line voltage has been
Disadvantage: no potential separation is possible between the
timer and I/O modules with discrete inputs/outputs
(parallel I/O).
4. The timer and the I/O module receive power supply from separate
external 24 V power supply units.
Used for: networked systems.
Advantage: I/O communication between the timer and the PLC/
robot, programming, diagnosis and visualization are
still possible when the line voltage has been
Potential separation is possible between the timer
and I/O modules with discrete inputs/outputs (paral
lel I/O).
Disadvantage: 2 external power supply units required.
and Controls
re. Option 1: re. Option 2:

Timer Timer
X4 X4
1 to I/O module 1 to I/O module

(refer to page (refer to page
2 102) 2 102)
3 Stop circuit 3 Stop circuit
(refer to (refer to
4 page 103) 4 page 103)
24VDC 24VDC
5 5
internal internal
voltage 6 voltage 6
generator generator
7 7
8 8
0V 0V
9 9
24VDC 24VDC 24VDC
10 10
internal internal
logic 11 logic 11 0V
0V 0V
12 12 external power
supply unit
re. Option 3: re. Option 4:

Timer Timer
X4 X4
1 to I/O module 1 to I/O module

(refer to page (refer to page
2 102) 2 102)
3 Stop circuit 3 Stop circuit
(refer to (refer to
4 page 103) 4 page 103)
24VDC 24VDC
5 5
internal internal
voltage 6 24VDC 6 24VDC
voltage
generator generator
7 0V 7 0V
8 external power 8 external power

0V supply unit 0V supply unit
9 9
24VDC 24VDC
10 10 24VDC
internal internal
logic 11 logic 11 0V
0V 0V
12 12 external power
supply unit
Wiring examples
and Controls
5.2.5 Pressure control and feedback (X2, X9)

Connection: to X2/X9; STKK, grid 3.5 mm, 5-pole,
max. 1.5 mm2.
Cable length: max. 50 m at 0.5 mm2
max. 100 m at 0.75 mm2
Cable type: shielded
(e.g.: NFL 13, Metrofunk; LiYCY)
In addition to the digital transmission of the force actuating value (refer

to signals "Pressure output bit x", page 130), an output signal is availa
ble at X2, pin 1, which can be used to drive a proportionate control valve
or a servo gun, for example. The type of output signal can alternatively
be programmed as
• Voltage signal (0 to +10V; max. 20mA),
• Current signal 0 to 20mA or
• Current signal 4 to 20 mA.
☞ The quantities influencing the amount of output voltage at X2 are de

scribed from page 69 onward.
☞ The output signal at X2 is immediately output after a welding spot (pro
gram) has been selected, rather than after program start!
The options indicated below are available to signal gun closed or pro
grammed force reached to timer. The required option can be selected
through the “Operating mode” parameter in the “Programming / Elec
trode” BOS window:
• Operating mode ”without”:
digital feedback via input terminal X2, pin 4.
The timer will only leave SQZ and change over to WLD when the in
put has been set (for required voltage, refer to Sec. 4.1, page 81).
Otherwise, the timer extends the SQZ by max. 5 seconds before the
schedule is aborted and a fault message is output.
Timer
X2
1 e.g. to
Pressure control
proportionate
GND 2 control valve
3
digital pressure input 4
Shield 5 D
• Operating mode ”Pressure”:

analog feedback via input terminal X2, pin 3.
The timer measures the active voltage at the end of the SQZ and
compares the actual value with the analog output voltage at X2 pin 1,
taking into account the tolerance (”Force tolerance band” parame
and Controls
ter).
If the actual value is outside the tolerance range, the timer extends
-while continuously checking the actual value - the SQZ by max. 5
seconds. If the actual value stays outside the tolerance range, the
timer will abort the schedule and generate the message ”Welding
fault force monitoring: force too high/low".
Timer
X2
Pressure control 1 e.g. to

proportionate
GND 2 control valve
analog pressure input 3
0 ... 10 V
4 Note:
For information on the supply
Shield 5 D of a force sensor, please refer
to page 88.
• Operating mode ”Force”:

analog feedback via input terminal X9, pin 4.
The timer measures the active voltage at the end of SQZ, converts
the actual value into a force value (1 V is equivalent to 1 kN) and com
pares the result with the current force programmed value, taking into
account the tolerance range (“Force tolerance band” parameter).
If the actual value is outside the tolerance range, the timer extends
-while continuously checking the actual value - the SQZ by max. 5
seconds. If the actual value stays outside the tolerance range, the
timer will abort the schedule and generate the message ”Welding
fault force monitoring: force too high/low".
Timer
X2
Pressure control 1 e.g. to
proportionate
GND 2 control valve
Shield 5 D
X9
3
analog pressure input
4
0 ... 10 V; 1 V = 1 kN
Ext./signal GND (1) 5
Shield 6 D
Note:
For information on the supply
(1): GND is the reference potential both for of a force sensor, please refer
terminal X9/4 and for the supply voltage of a to page 88.
force sensor (X5/1).
and Controls
Which sensors and which input signals are used for feedback depends
on the relevant application. Thus the pressure control and feedback, for
example, can also be processed via PLC program (if the proportionate
control valve and feedback are not connected to the timer itself but to
the PLC or the robot).
Furthermore, applications without feedback or using no proportionate
control valve may be possible.
For this reason, some different connection variants have been shown in
the following figures.
L If your plant does not provide a feedback signal, you should make sure
that the parts to be welded are optimally squeezed together before the
beginning of the weld time!
Sufficiently long squeeze times have to be programmed in this case.
If the squeeze time is too short, strong expulsion will be experienced!
This may result in damages to the electrodes and workpiece.
☞ If the pressure control and feedback are performed by the PLC program
completely, the PLC or robot must not start the welding program unless
the proper gun / electrode condition has been ensured.
If this is the case, the shortest possible SQZ will be programmed in all
welding programs (PSI: 16 ms).
Proportionate control valve

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

and Controls
Proportionate control valve

Valve supply
+24VDC
X2
0V
Pressure control signal 1 D
GND for terminals 1 and 4 2 D D
3
Feedback 4
D
Shield 5 D D
X4
+24 VDC 5
voltage generation
inside the unit 8
0V
Connection of a proportionate control valve without feedback
☞ The connection option ”without feedback” is applicable if

- the proportionate valve does not supply a feedback signal, or
- the feedback signal is connected to PLC/robot.
X2
Pressure control signal 1
GND for terminals 1 and 4 2
3
Feedback 4
Shield 5
X4
+24 VDC 5
voltage generation
inside the unit 8
0V
Wiring without proportionate control valve
☞ The connection option ”Wiring without proportionate control valve” is

applicable if
- no proportionate control valve is used, or
- proportionate control valve and feedback signal are connected to PLC
or robot.
and Controls
5.2.6 CCR sensor (X3)

max. 1.5 mm2.
Cable length: max. 100 m (with recommended cable type)
Cable type: shielded, core area min. 0.75 mm2,
(e.g.: 2 x 2 x 0,75 mm2 LiYCY,
Order no.: 1070 913 494)
The timers contain an integrated constant-current regulation (CCR).

Using this function, the timer controls the current flow in the secondary
circuit in such a manner that the programmed command current is ac
tually reached.
In this way, it is possible to compensate for any process- and handling-
induced fluctuations of the transfer resistance between the electrodes
and the part to be welded and back to the electrodes.
This regulation requires a sensor that signals the current flown in the
primary or secondary circuit of the welding transformer to the timer.
A current sensor installed in the secondary circuit can be connected to
the toroid input (X3, pin 1 and 2).
X3
Toroid input 1
Toroid input 2
Shield 3 D
4
5
Shield connection to terminal 3 of X3 only ! Secondary circuit
Connecting the CCR sensor on the secondary side
The timer ist able to set 3 discrete output signals (”Transformer x”; refer
to page 128) as a function of the actual programmed electrode:
• Electrode 1 up to 9: transformer 1 / CCR sensor 1
By using an external switching device, up to 3 transformers / CCR sen

sors can be connected to the PSI.
For details, refer to the next illustration.
☞ The electrode numbers 0, 30 ans 31 are not assigned to a transformer /
CCR sensor.
For this reason, when the output signal ”Transformer x” has been output
last, it will not changed when electrode 0, 30 or 31 is activated.
and Controls
Transformer 3
Transformer 2
Transformer 1
Secondary circuit 1
D
X3
external
Toroid input 1
switching
Toroid input 2 D
Shield 3 D
4
Secondary circuit 2
5
D
Shield connection only at X3 terminal 3!
A suitable device for transformer switching is required additionally!

Secondary circuit 3
Principle of CCR switching; application with for example 3 separate welding circuits (transformers).
☞ All PSI units also have an integrated current sensor for the primary cir
cuit of the welding transformer. This gives you the possibility to choose
between secondary and primary measurement (using the BOS soft
ware).
With weld times > 1 s or for temporary suppression in the event of a sen
sor failure in the secondary circuit, however, you have to change over to
primary measurement.
☞ All PSI units have been prepared for extension using the PSQ 6000
XQR controller system (U/I controller). The existing CCR sensor is
equally required for using this functionality.
In order to ensure the proper operation of the sensor, the following
points should be noted:
L When installing the sensor, it must be ensured that it is protected
against damages resulting from the part to be welded and from expul
sion.
The place of installation should be selected at the greatest possible
distance from current busbars and high-current cables. This will reduce
the noise resulting from external fields. Please also note the cable spe
cifications provided above.
Do not use any magnetizable metal parts for fastening the cable but rat
her copper or brass.
and Controls
L Make sure that the current conductor is routed through the middle of the
sensor in the straightest line possible. The voltage induced in the sen
sor (and thus the measured quantity) reaches its maximum if the con
ductor runs vertically to the sensor level.
L If the sensor is used on mobile equipment, such as robots, certain parts
of the cable are subject to strong mechanical stress (e.g. trailing cable).
In these cases, therefore, you should use suitable cables and design
the construction of the connecting lines so as to ensure a quick, trouble-
free replacement in the event of a fault.
L The cable shield should only be connected to the weld timer!
L Make sure that the timer's complete control loop is readjusted in regular
intervals in order to avoid measuring errors (current calibration). An
external reference welding ammeter is required for this purpose.
Measuring loop check

During the squeeze time, the timer checks whether or not the connec
ted measuring loop is faultless by performing an ohmic resistance mea
surement. Problems in the sensor-line-connector assembly can be
detected by this check.
The following testing criteria apply:
Ohmic resistance measured Result
< 7 ohms Measuring loop short-circuit
12 to 950 ohms Measuring loop ok
> 1100 ohms Measuring loop open
☞ If measured values are in the intermediate ranges, they cannot be

clearly evaluated.
In the event of a fault, the timer aborts the welding schedule and clears
the "Timer ready" output signal.
and Controls
5.2.7 Transformer temperature monitoring (X3)

max. 1.5 mm2.
Cable length: max. 100 m (with recommended cable type)
Cable type: shielded, core area min. 0.75 mm2,
(e.g.: 2 x 2 x 0,75 mm2 LiYCY,
Order no.: 1070 913 494)
The timer has a temperature monitoring input which ensures protection
of the connected welding transformer.
An excessive temperature is signalled to the timer via a floating contact
that opens if the transformer gets too hot.
In the event of overtemperature (message: Transformer temp too high),
the timer will complete a running welding process in single or repeat
spot mode, while immediately interrupting a seam operation.
A restart is not possible unless the transformer temperature has retur
ned to values below the critical limit.
☞ The cores for the transformer temperature and the CCR sensor may be
in a common connection line. We offer suitable cables containing 4 co
res for this purpose.
X3
1 Welding transformer
2
Shield 3 D
temperature 4
temperature 5
Temperature contact
Shield connection to terminal 3 of X3 only !
Connection for monitoring the welding transformer temperature
Of course, applications can be implemented involving welding trans

former temperature monitoring not by the timer, but rather by a PLC.
L In these cases, you should also make sure that the PLC inhibits additio
nal welding schedules if the permitted temperature range is exceeded!
If the timer is not supposed to monitor the welding transformer tempera
ture, the following wiring has to be made:
X3
1
2
3
temperature 4
Jumper
temperature 5
Transformer temperature not monitored by timer

and Controls
5.2.8 Fan connection (X4)

max. 1.5 mm2.
Cable type: unshielded, VDE 0281, 0812
(e.g.: Ölflex)
Operating thresholds: Fan ON: greater than/equal to 55 degrees
Centigrade
Fan OFF: lower than/equal to 40 degrees
Centigrade
(with reference to the heat sink temperature)
☞ Not all of the timer types have been prepared for temperature-con
trolled 24 VDC connection of an external forced ventilation system (max.
2 A). Refer to terminal diagram of the individual type.
Forced ventilation modules are used in various "Schweisskoffer" types,
for example.
X4 Fan module
1
+24 VDC 13 +24 VDC
PE
0V 14
2
0V
to PE bar
Connecting an external fan module

and Controls
5.2.9 Programming device connection (X1)

Connection: at X1; D-sub, 9-pole, at the cable via socket
Cable length: max. 20 m (with recommended type of cable)
Cable type: shielded, core cross section min. 0.2 mm2,
Capacitance max. 2.5 nF
(e.g.: 3 x 2 x 0.2 mm2 LifYCY, Metrofunk)
Transmission rate: 19200 bits/s
Parameters: 8E1 (8 data bits, even parity, 1 stop bit)
Transmission: PS5000 block protocol with CRC16
Point-to-point connection of the programming terminal (PC/laptop

computer with BOS software for administration, diagnosis, archiving,
backup) can be achieved using the RS232 interface X1.
X1 PC (COM1 or COM2)
1
RX 2 2 RX
3 3
TX TX
4
4
5
GND 5 GND
6
7
8
9
Connector Connector
Ensure screen continuity through large-area connection to metal
housing of the plug connection.
☞ Networking the timer not only offers faster data transfer, but also the
possibility of jointly managing several timers using a single program
ming terminal.
For networking, you can use
• the optional Ethernet module.
and Controls
5.3 I/O communication to Robot/PLC

Depending of the type of timer, different communication paths are used
to communicate with the robot/PLC.
I/O communication related to the timer type PSI 6xxx.637:

The communication is primarily handled via DeviceNet (copper cable;
refer to page 104). In addition, there are a few discrete 24 VDC signals
required.
Therefor, the PSI 6xxx.637 uses the I/O module ”I/O DEV NET.
Discrete I/O signals: refer to Sect. 5.3.3 starting on page 104.
Serial I/O signals. refer to Sect. 5.3.5 starting on page 107.
I/O communication related to the timer type PSI 6xxx.737:

The communication is primarily handled via Ethernet IP.
In addition, there are some discrete 24 VDC signals required.
Therefor, the PSI 6xxx.737 uses the ethernet field bus interface to com
municate via serial I/O (6 byte input field / 6 byte output field) and the I/O
module ”I/O DISK” to connect the required discrete 24 VDC signals.
Discrete I/O signals: refer to Sect. 5.3.4 starting on page 105.
Serial I/O signals: refer to Sect. 5.3.5 starting on page 107.
5.3.1 Power supply (X10) of the used I/O modules

max. 1.5 mm2.
Cable length:: (from power source to consumer)
max. 10 m at 0.75 mm2
(e.g.: Ölflex)
☞ For other technical data, refer to Sect. 4.3, page 83.
A total of 2 connection options are possible:
1. Connection of the I/O module supply at X4 of the timer, or
2. direct connection of the I/O module supply to separate 24 VDC power
supply unit.
☞ If the I/O module is connected to X4 of the interface module (1. connec
tion option), the unit's internal power generator (refer to page 86) as
well as an external power supply unit can be used. For this purpose,
only a few jumpers have to be inserted/removed at X4.
For more information concerning the connections to X4, please refer to
L Any external voltage sources used must be designed according to the
principles of "safety separation" in accordance with the Low-Voltage Di
rective (2006/95/EC).
L If potential separation is necessary between the I/O and the timer, the
timer and the I/O module must be operated at different 24 VDC power
supply units!
and Controls
L You should ensure that the proper functioning of the stop circuit (refer to
figures below) is guaranteed by any connection option used!
In the event of dangerous conditions at the welding system or the in
tentional switch-off of the weld timer, the inputs and outputs of the I/O
module must be set to LOW level. For this purpose, an external monito
ring device must open the floating contact and thus interrupt power sup
ply to X10.
If the stop circuit is open, the timer signals "Stop / No 24V". This mes
sage is self-acknowledging, i.e. it automatically disappears when the
stop circuit is closed.
Used I/O modules: I/O module Timer

PSI 6xxx.637: PSI 6xxx.737:
”I/O DEV-NET” ”I/O DISK”
X10 X4
24VDC 1 1
0V 2 2 0V
24VDC 3 3
0V 4 4 24VDC
internal jumper floating contact
between: Load: 24 VDC,
Terminals 1 and 3 max. 3 A
Terminals 2 and 4
Stop circuit
Connection of the I/O module supply at X4 of the timer
I/O module Stop circuit 24 VDC power

supply unit
floating contact
X10 Load: 24VDC,
max. 3A
24VDC 1 24VDC
0V 2 0V
24VDC 3
0V 4
internal jumper
between:
Terminals 1 and 3
Terminals 2 and 4
Direct connection of the I/O module supply to separate

24 VDC power supply unit
L Use terminal 3 of X10 as a 24V source for driving the inputs at X11.
Use terminal 4 of X10 as 0V reference potential for X11.
L Due to the internal jumper at X10, the incoming supply voltage can also
be passed on to additional equipment.
Please make sure in such cases, however, that the maximum current
load (voltage source, connections) and cable lengths are not excee
ded!
and Controls
5.3.2 DeviceNet Connection (PSI 6xxx.637 only)

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 spe
cification
previous following
Weld timer DevNet node
DevNet 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 5.3.5.
Value (dec) : ON
DeviceNet node address (0 - 63): : OFF
DIP switch #
00
01
02
03
04
05
06
07
08
09
10
12
63
11
1 1
2 2
NA 3 4 ...
4 8
5 16
6 32
7
DR
8
125Kb= 7 off and 8 off
500
500
250
125
off on
250Kb= 7 on and 8 off = DeviceNet baud rate (kBd)
500Kb= 7 on and 8 on
Setting DeviceNet node address (NA) and DeviceNet baud rate (DR)
5.3.3 Discrete signal outputs / inputs (PSI 6xxx.637)

Connection X11, X12: Plug-in terminal, spacing 3.5 mm,
max. 1.5 mm2.
Mating connector included in shipment.
Type of cable: unshielded, VDE 0281, 0812 (e.g.: Ölflex)
☞ For further technical data, please refer to chapter 4.3 on page 83.
For information regarding the functionality of all signals, please refer to
chapter 6.
and Controls
from PLC/robot/control panel

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

Width: 6 byte.
Input signals are assigned to the individual bits (bit
0 to bit 47).
For assignment, please refer to page 107.
serial with
DeviceNet
through X13
Output field (status word)
Width: 6 byte.
Output signals are assigned to the individual bits (bit
0 to bit 47.
For assignment, please refer to page 107.
Description
X12 refer to page
I0 WELD CONTACTOR CLOSED 111
I1 TIP DRESS - RPM SENSOR 111
I2 TIP DRESS - MOTOR OVERLOAD TRIPPED 111
I3 TIP DRESS - MOTOR CURRENT TRIPPED 111
I4 not used
I5 FEEDBACK TRANSFORMER 1 120
X11
O0 CLOSE WELD CONTACTOR 125
O1 MAGNET VALVE 125
O2 TIP DRESS ENABLE CIRCUIT 127
O3 not used
O4 not used
O5 TRANSFORMER 1 128
X10
+24V Supply input 102
0V Supply input 102
+24V Signal voltage output for passive switch elements 102
0V Reference potential for outputs at X11 102
Assignment of all discrete signal in-/outputs (”I/O DEV-NET”, PSI 6xxx.637)
5.3.4 Discrete signal outputs / inputs (PSI 6xxx.737)

Connection: STKK, grid 3.5 mm, max. 1.5 mm2.
X11: 14-pol.;
X12: 8-pol.;
X13: 16-pol.;
Mating connectors are comprised in the
delivery.
and Controls

(e.g.: Ölflex)
☞ For more technical details, refer to Sect. 4.3 from page 83
The functionality of all signals is described in Sect. 6.
from PLC/robot/control panel Description

X13 to PLC/robot/control panel refer to page
I0 not used
I1 WELD CONTACTOR CLOSED 111
I2 TIP DRESS - RPM SENSOR 111
I3 TIP DRESS - MOTOR OVERLOAD TRIPPED 111
I4 TIP DRESS - MOTOR CURRENT TRIPPED 111
I5 not used
I9 not used
I10 not used
I11 not used
I12 not used
I13 not used
+24V Signal voltage output for passive switching elements
X12
I14 not used
I15 not used
I16 not used
I17 not used
I18 not used
I19 not used
I20 not used
X11
O0 not used
O1 CLOSE WELD CONTACTOR 125
O2 MAGNET VALVE 125
O3 TIP DRESS ENABLE CIRCUIT 127
O4 not used
O5 not used
O9 not used
O10 not used
O11 not used
O12 not used
O12 not used
0V reference potential for the outputs
X10
+24V Power supply input 102
0V Reference potential 102
+24V Power supply input 102
0V Reference potential 102
Assignment of all discrete signal in-/outpus (”I/O DISK”; PSI 6xxx.737)

and Controls
5.3.5 Serial signal outputs / inputs (PSI 6xxx.637 and .737)
Input field Output field

Bit Signal name Description Bit Signal name Description
Refer to page Refer to page
00 START 1 112 00 WELD COMPLETE (WC) 122
01 TIPS HAVE BEEN DRESSED 118 01 TIP DRESS REQUIRED 124
02 WELD CONTACTOR ENABLE 111 02 PREWARNING 124
03 ELECTRODES HAVE BEEN REPLACED 119 03 END OF STEPPER 124
04 FAULT RESET 115 04 TIMER READY 129
05 FAULT RESET WITH WELD COMPLETE 117 05 WELD FAULT 129
06 FAULT RESET WITH REWELD 116 06 WITHOUT WELD PROCESS MONITORING 130
07 WELD ON EXTERNAL 114 07 WELD ON (WITH WELDING CURRENT) 123
08 SPOT NUMBER ”1” (Bit 00) 113 08 START TIP DRESS REQUEST 130
09 SPOT NUMBER ”2” (Bit 01) 113 09 NEW ELECTRODE 125
10 SPOT NUMBER ”4” (Bit 02) 113 10 PRESSURE INSIDE TOLERANCE AREA 130
11 SPOT NUMBER ”8” (Bit 03) 113 11 UI REGULATION ACTIVE 127
12 SPOT NUMBER ”16” (Bit 04) 113 12 UI MONITORING ACTIVE 127
13 SPOT NUMBER ”32” (Bit 05) 113 13 Q STOP 127
14 SPOT NUMBER ”64” (Bit 06) 113 14 not used
15 SPOT NUMBER ”128” (Bit 07) 113 15 not used
16 SPOT NUMBER ”256” (Bit 08) 113 16 STATUS ”1” (Bit 00) 126
32 OPERATE FORCE SENSOR 120 32 PRESSURE OUTPUT BIT 00 130
33 CALIBRATE GUN RESISTANCE 111 33 PRESSURE OUTPUT BIT 01 130
34 not used 34 PRESSURE OUTPUT BIT 02 130
40 END OF COMPONENT 111 40 ACKNOWLEDGE END OF COMPONENT 127
41 TIP DRESS MOTOR ON (AIR/ELEC) 111 41 TIP DRESSED 127
42 not used 42 TIP DRESS OK 127
43 not used 43 TIP DRESS SEQUENCE RUNNING 127
44 not used 44 not used
Assignment of the input and output field

and Controls
Notes:
and Controls
I/O signal descriptions
6 I/O signal descriptions

In this section, you will find a description of all I/O signals from the per
spective of the timer. Any references to signal names in the text below
will be marked by quotation marks ("signal name").
☞ For the assignment of the discrete input/output signals of the "I/O DISK
R2ED" I/O module, refer to Sec. 5.3.3 starting on page 104.
☞ For the I/O array assignment of the serial signals (via Ethernet-CC mo
dule), refer to Sect. 5.3.4 starting on page 105.
and Controls
6.1 Input signals
6.1.1 Alphabetic overview
Signal name Page
CALIBRATE GUN RESISTANCE 111
ELECTRODES HAVE BEEN REPLACED 119
END OF COMPONENT 111
FAULT RESET 115
FAULT RESET WITH REWELD 116
FAULT RESET WITH WELD COMPLETE 117
FEEDBACK TRANSFORMER X 120
OPERATE FORCE SENSOR 120
SPOT NUMBER 113
START 1 112
TIP DRESS - MOTOR CURRENT TRIPPED 111
TIP DRESS - MOTOR OVERLOAD TRIPPED 111
TIP DRESS - RPM SENSOR 111
TIP DRESS MOTOR ON (AIR/ELEC) 111
TIPS HAVE BEEN DRESSED 118
WELD CONTACTOR CLOSED 111
WELD CONTACTOR ENABLE 111
WELD ON EXTERNAL 114

and Controls
6.1.2 Weld contactor enable

A high signal at the input informs the timer that the welding circuit is
ready for welding.
If this signal is not present when program start is initiated with welding
current, the timer will generate the fault message "No weld contactor
enable".
Also refer to function "Isolate weld contactor", from page 80.
6.1.3 Weld contactor closed

Feedback from the process that the weld contactor is closed.
The input is scanned at the end of SQZ.
If it is not high while the discrete output "Close weld contactor" is active,
the timer generates the fault message "Weld contactor gun 1 open".
The input is scanned again 200 ms after the discrete output signal
"Close weld contactor" has become low.
If it is still high, the timer generates the fault message "Weld contactor
gun 1 did not open".
6.1.4 Calibrate gun resistance

Message from the process indicating that the timer has to readjust the
gun resistance together with the next weld schedule.
6.1.5 Tip dress - motor overload tripped

Also refer to "Cutter motor control" starting on page 64
6.1.6 Tip dress - motor current tripped

6.1.7 Tip dress - RPM sensor

6.1.8 Tip dress motor on (air/elec)

6.1.9 End of component

Acts in connection with the "Q Stop" function (refer to page 78):
A positive edge at the input informs the timer that a component has
been completed. As a result, the weld timer resets the internal Q Stop
counter actual value.
and Controls
6.1.10 Start 1
A positive edge at the input initiates acceptance of the currently selec
ted program (via spot number; refer to page 113) if the timer is "Ready"
Schedule:
1. The welding program is started.
The 1.SQZ is executed, if programmed.
2. SQZ starts.
The welding schedule can be aborted by resetting "Start1" until the
end of SQZ.
☞ During the SQZ, the timer checks whether or not the current measuring
loop connected to X3 is faultless by performing an ohmic resistance
measurement.
In the event of a fault (refer to page 98), the timer aborts the welding
program and resets the "Timer ready" output signal.
3. If "Start 1" remains active beyond the end of the SQZ, the signals be
come latching in single and repeat mode. In latched condition, the
PreWLD to PstWLD will continue to be executed even if ”Start 1" has
been reset.
In seam operation, only a current cycle that has been initiated will be
completed when "Start 1" has been reset.
☞ Signal latching can only be cancelled by opening the stop circuit (refer
to page 103).
☞ Whether or not the weld times are performed with welding current
depends on the "Weld on external" input signal (refer to page 114).
4. HLD is running.
5. The "Weld complete" output (refer to page 122) acknowledges the
end of the welding schedule.
Start
t
1.SQZ SQZ 1.CT MainWLD 3.CT PstWLD HLD t

PreWLD
Start latching
Latching with single spot
Start
1.SQZ SQZ PreWLD 1.CT n x MainWLD HLD t
"Start" is reset during the MainWLD in seam operation.

and Controls
6.1.11 Spot number

The 24 input signals are available for selecting the desired spot num
ber.
For this purpose, the binary coded spot number is provided to the in
puts. Then, the timer can determine the corresponding program num
ber from the spot number using the spot reference table.
: High level of the corresponding signal
Value
Input signal (dec)
Spot numberbit 0 1
Spot numberbit 1 2
Spot numberbit 2 4 ...
Spot numberbit 3 8
Spot numberbit 4 16
: :
Spot numberbit 24 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
selected spot number: 11 ...
Binary coded selection of a spot via input signals ”Spot number”
☞ The spot number in binary code must be transmitted to the timer via the
IO module in a single PLC IO cycle.
Otherwise, the data transmitted in the relevant cycle would be interpre
ted as separate spot numbers and consecutively selected.
☞ As soon as a welding program has been selected, the timer will output
the programmed force:
• to X2 as analog output value (refer to page 92), and
• at the outputs "Pressure output bit x" as a digital value (refer to page
130).
and Controls
6.1.12 Weld on external

Sometimes, it is necessary to execute a welding program without weld
ing current (e.g. in order to optimize the cycle time of the welding line, or
for other adjustment/testing purposes).
For this purpose, an external device (robot, PLC, key-operated switch
on control panel) can specify by this input signal
1. whether the timer is to generally execute all welding programs wi
thout current, or
2. whether the timer may influence this decision (with/without welding
current) itself based on the parameter configuration.
Re. item 1.:
If "Weld on external" has not been set, all welding programs of the timer
will always be executed without welding current, regardless of any other
control parameter settings. The power unit will not be driven in this case.
Re. item 2.:
If "Weld on external" has been set, the response depends on the follow
ing parameters:
• Weld internal (acts globally on all programs of the timer), and
• program-specific ignition (is part of any welding program and only
active in the relevant program).
A welding program can only be executed with weld current if
• "Weld on external" is high, and
• Weld internal and
• the program-specific ignition are all activated.
This behavior corresponds to an AND logic for all 3 conditions men

tioned.
☞ To feed back this AND logic to an external device, the "Weld on" output
signal is used (refer to page 123).
and Controls
6.1.13 Fault reset

☞ For more information on faults, refer to page 137!
A positive signal edge results in
1. "Fault reset".
This signal is only used in order to restore the "Ready" state of the timer.
The following applies to the "Ready" state:
• a new welding schedule can be started
• the READY LED at the timer's front is lit (see page 32).
• the "Timer ready" output signal is set (see page 129).
The timer does not perform any other activities.
☞ If the fault occurred during a welding schedule, it is possible that the gun
is still closed, and that the robot still is in the current welding position, for
example.
☞ The "Cooling device temperature too high" fault first have to be acknow
ledged by pressing the RESET button on the front side of the timer be
fore the timer can be returned to "Ready" state by activating "Fault
reset".
☞ In addition to "Fault reset", a number of other activities can be initiated

using the "Fault reset with reweld" (refer to page 116) and "Fault reset
with weld complete" (refer to page 117) input signals. Please follow the
cross-references provided.
and Controls
6.1.14 Fault reset with reweld
☞ For basic information on faults, please refer to page 137!
A positive signal edge leads to

1. ”Fault reset” and subsequent
2. repetition of the welding program schedule provided that the ”Start 1”
input signal is still active.
If the repetition is completed without another fault, the ”Weld com
plete (WC)” signal will be set.
WARNING Dangerous machine movements possible!

The signal ”Weld Complete (WC)” initiates the robot's positioning to the
next weld spot.
Therefore, make sure to avoid dangerous situations at the welding sta
tion caused by ”Fault reset with reweld”!
”Fault reset with reweld” is used

• in connection with robots and
• in connection with the the faults ”Low current” and ”Low current -
series of welds”.
☞ In connection with other faults, please note the signal ”Fault reset with
weld complete”. Refer to page 117.
If the fault ”Low current” or ”Low current - series of welds” occurs while a
part is being welded, the robot usually remains at the welding position
with the gun closed. Via ”Fault reset with reweld”, it is now possible
• to repeat the current, faulty spot weld.
L If, after that, another fault occurs, please use ”Fault reset with weld
complete”.
☞ ”Fault reset with reweld” can also be initiated via the GUI (BOS).
and Controls
6.1.15 Fault reset with weld complete (WC)
☞ For basic information on faults, please refer to page 137!
A positive signal edge leads to

1. “Fault reset” and subsequently
2. to the setting of the ”Weld complete (WC)” signal if the ”Start 1” input
signal is still active.
WARNING Dangerous machine movements possible!

The signal ”Weld Complete (WC)” initiates the robot's positioning to the
next weld spot.
Therefore, make sure to avoid dangerous situations at the welding sta
tion caused by ”Fault reset with weld complete”!
”Fault reset with weld complete” is used

• in connection with robots and
• in connection with all faults except ”Low current” and ”Low current -
series of welds”.
☞ In connection with the faults ”Low current” and ”Low current - series of
welds”, please note the signal ”Fault reset with reweld”. Refer to page
116.
If a fault occurs while a part is being processed, the robot will normally
still be in welding position with the electrode gun closed. It is now possi
ble to input ”Fault reset with weld complete" in order to continue proces
sing at the next spot weld.
L Make sure to mark and check the spot where the fault occurred!
☞ ”Fault reset with weld complete” can also be initiated via the GUI (BOS).
and Controls
6.1.16 Tips have been dressed

A positive edge tells the timer that the tip dressing procedure activated
by the "Tip dress required" (refer to page 124) has been completed.
Schedule:
1. The timer first determines the relevant electrode number. For this
purpose, it interprets the signal pattern present at the "Spot number"
inputs. Then, the timer can determine the corresponding program
number using the spot reference table. Knowing the corresponding
program number the timer is able to get the relevant (programmed)
electrode number.
2. The corresponding dressing counter is incremented.
3. The relevant count value is set to 0.
4. The "Tip dress required" signal is reset for the relevant electrode
Example. The following settings are used:

Stepping: On
Stepper: is active (if Stepper final %I > base %I)
Tip dressing: On (if max. dressings > 0. Here: max. dressings = 3)
Dressing curve: is active (if Dressing final %I > base %I)
Count factor: 1.0
Count starting range (offset): 0
Stepper count range: 100
max. counts: 100 (= counts with stepper range offset)
Tip dress request: 10 (= 10 before max. count)
Prewarning: 30 (= 30 before max. count)
%I 1. Tip dressing 3. Tip dressing End of stepper

2. Tip dressing
Stepper final %I
Final %I after cutting
Base %I
90 90 90 70 Current count
0 0 0 100

Time
"Tip dressed"
Time
Example: Tip dressing schedule

and Controls
6.1.17 Electrodes have been replaced

A positive edge tells the timer that the electrode replacement procedure
initiated by "Prewarning" (refer to page 124 or "End of stepper" (refer to
page 124) has been completed.
☞ The completed electrode change can be alternatively acknowledged at
the BOS user interface ("counter reset" function).
Schedule:
1. The timer first determines the relevant electrode number. For this
purpose, it interprets the signal pattern present at the "Spot number"
inputs. Then, the timer can determine the corresponding program
number using the spot reference table. Knowing the corresponding
program number the timer is able to get the relevant (programmed)
electrode number.
2. The relevant dressing counter is set to 0.
3. The relevant count value is set to 0.
4. The "Prewarning" and "End of stepper" signals are reset for the rele
vant electrode.
Example. The following settings are used:

Stepping: On
Stepper: is active (if Stepper final %I > base %I)
Tip dressing: On (if max. dressings > 0. Here: max. dressings = 3)
Dressing curve: is active (if Dressing final %I > base %I)
Count factor: 1.0
Count starting range (offset) : 0
Stepper count range: 100
max. counts: 100 (= counts with stepper range offset)
Tip dress request: 10 (= 10 before max. count)
Prewarning: 30 (= 30 before max. count)
Stop at end of stepper: Off
%I 1. Tip dressing 3. Tip dressing End of stepper

2. Tip dressing
Stepper final %I
Final %I after cutting
Base %I
70 0 Current count
100
"Prewarning"
Time
"End of stepper"
Time
"Electrodes have been replaced"

Time
Example: Electrode change procedure
For details concerning the integrated cutter control, refer to page 64.
and Controls
6.1.18 Feedback transformer x

Using the ”Feedback transformer x” input signals, the timer is able to
verify the correct reaction of the system on the related ”Transformer x”
output signals (refer to Page 128).
For this purpose the related IO pair must reach the same state at the
latest to the end of SQZ. If not, the timer extends SQZ automatically
(max. 1 second).
In case of not reaching in time the same state, the weld sequence will be
interupted with the error message ”Contactor monitoring - contactor-
disconnector”.
There is also a monitoring of the related IO pair beyond SQZ until the
initiation of the PstWLD. If state differs, the weld sequence will be inte
rupted with the error message ”Contactor monitoring - contactor-
disconnector”.
6.1.19 Operate force sensor

An external device like Robot or PLC can use this serial signal input to
initiate the measuring process of an external force sensor unit.
Therefore the status of the serial input signal is to be mirrored at the dis
crete signal output at terminal X9 Pin 1.
and Controls
6.2 Output signals
6.2.1 Alphabetic overview
Signal name Page
ACKNOWLEDGE END OF COMPONENT 127
CLOSE WELD CONTACTOR 125
END OF STEPPER 124
MAGNET VALVE 125
NEW ELECTRODE 125
OPERATE FORCE SENSOR 128
PRESSURE INSIDE TOLERANCE AREA 130
PRESSURE OUTPUT BIT x 130
PREWARNING 124
Q STOP 127
START TIP DRESS REQUEST 130
STATUS 126
TIMER READY 129
TIP DRESS ENABLE CIRCUIT 127
TIP DRESS OK 127
TIP DRESS REQUIRED 124
TIP DRESS SEQUENCE RUNNING 127
TIP DRESSED 127
TRANSFORMER x 128
UI MONITORING ACTIVE 127
UI REGULATION ACTIVE 127
WELD COMPLETE (WC) 122
WELD FAULT 129
WELD ON (WITH WELDING CURRENT) 123
WITHOUT WELD PROCESS MONITORING 130

and Controls
6.2.2 Weld complete (WC)

The "Weld complete" output signal informs the connected peripherals
(PLC/robot) that a welding schedule has been completed.
As a result, the next step of the processing schedule can be initiated.
The logic generating the WC signal is active in the following cases:
1. with single spot and repeat mode after each spot
2. with seam operation (e.g. roll seam welds) at the end of the seam
3. after "Set WC" (only possible in BOS)
☞ The duriation of the WC depends on the "Start 1" input signal. Refer to
"WC period".
Options 1. to 2. offer the possibility of making various settings to adjust
the WC to your application:
• automatic output of WC after a proper weld only, or also after a
defective weld
• point of time in which the WC is to be set (refer to "WC start time").
WC period
Normally, the timer automatically resets the "Weld complete" signal as
soon as it detects a negative edge at the "Start 1" input.
However, one could imagine certain plant statuses in which the "Start 1"
signal has already been reset before the WC was set. In this case, a
trigger on the negative edge of "Start" is not helpful. For this reason, the
timer checks when the WC is set whether "Start 1" is still present, and
responds as follows:
"Start 1" is set: WC is reset by a negative edge of "Start 1"
"Start 1" is not set: WC is reset when the preconfigured WC period
(BOS, default setting: 20 ms) has elapsed.
"Start" is no longer present:

programmed WC duration is
Start 1 executed.
t
WC
t
WLD HLD progr. duration
"Start" is still present:

neg. edge resets WC
Start 1
t
WC
t
WLD HLD
WC duration depending on "Start 1" signal
☞ The programmed WC duration is also executed with the function ”Start

simulation” (BOS)!
and Controls
WC Start time
The time on which the "Weld complete" is to be output can be pro
grammed within +/- 1000 ms with respect to the end of HLD.
Restriction:
The WC output cannot take place earlier than 20 ms after the start of the
HLD.
Default setting:
End of the HLD less 20 ms (refer to "example").
Thus, the WC start point can be accelerated to occur in the HLD, or can
be delayed.
neg. value pos. value
WC
t
WLD HLD
Accelerating/Delaying the WC start time
Example: "high-speed robot communication"

If the "Weld complete" signal is used for positioning to the next spot, the
WC start time can be accelerated in order to compensate for constant
response times (caused by signal processing by the robot, drive or
PLC). This results in shorter cycle times.
CAUTION Possibility of damaging the plant by positioning movements with

closed gun!
Therefore, please make sure that the gun is already open when the ro
bot starts to move!
6.2.3 Weld on (with welding current)

Using the "Weld on" output signal, you can check whether the currently
selected welding program is executed
• with current (output is high), or
• without current (output is low).
A welding program can only be executed with weld current if

• "Weld on external" is high (refer to page 114), and
• weld internal (parameter input via BOS), and
• the program-specific ignition (parameter input via BOS) are all ac
tivated.
As a result, "Weld on" corresponds to the result of an AND logic for all 3
conditions mentioned.
and Controls
6.2.4 Tip dress required

Will be set, when tip dressing is required (BOS; value ”Max. Count
minus value ”Tip dress request”), provided that it is permitted to dress
the electrode tips again at that moment. The output signal informs the
PLC/robot that the active electrode tip has to be dressed as soon as
possible (concerning tip dressing, refer to page 63).
"Tips have been dressed" (refer to page 118) resets the "Tip dress re
quired".
If the robot detects a "Tip dress required", it must move the relevant
electrode to the dressing tool when the maximum count has been rea
ched at the latest. Depending on the setting of the "Stop at end of
stepper" parameter setting (BOS), the timer is inhibited and waits for the
"Tips have been dressed" input signal.
☞ It depends on the programming of the robot at what point of time it will
detect the "Tip dress request"!
In many cases, the relevant robot inputs will only be scanned when a
new part is processed, and no scanning will take place after each spot
during part processing. This behaviour presupposes that the time in
terval between the output of the "Tip dress require" signal and reaching
of maximum count is sufficiently long. This is the only way to ensure that
the complete part can be welded before the maximum count is reached.
Alternatively (but by taking sufficient "electrode reserves" into ac
count!), it may also be possible to deactivate the "Stop at end of
stepper" function.
6.2.5 Prewarning
Will be set, when the ”prewarning mode” is reached (BOS; value ”Max.
Count minus value ”Prewarnung Count”). The output signal informs the
PLC/robot that the active electrode will soon reach the end of stepper,
and that it has to be replaced for this reason.
The output signal is
• set by ”Start 1”, if the active electrode is in ”prewarning mode”
• updated at the end of the weld time
• reset by "End of stepper" (refer to section 6.2.6).
6.2.6 End of stepper

Will be set when the ”Max. Count” value (BOS) is reached. The output
signal informs the PLC/robot that the active electrode has reached the
end of stepper.
☞ Whether or not additional spots can be welded when the end of stepper
has been exceeded, depends on the programming of the timer ("Stop at
end of stepper" parameter)
The output signal is
• set by ”Start 1”, if the active electrode has reached the end of stepper
• updated at the end of the weld time
• reset by "Electrodes have been replaced" (refer to page 119).
and Controls
If the robot detects "End of stepper", it must move the relevant electrode
to a position in which it can be replaced (e.g. home position) when the
real maximum count of an electrode has been reached at the latest.
Depending on the setting of the "Stop at end of stepper" parameter
setting (BOS), the timer is inhibited and waits for the "Electrodes have
been replaced" input signal (refer to page 119).
☞ It depends on the programming of the robot at what point of time it will
detect the "End of stepper"!
In many cases, the relevant robot inputs will only be scanned when a
new part is processed, and no scanning will take place after each spot
during part processing. This behaviour presupposes that the time in
terval between the output of the "End of stepper" signal and reaching
the real maximum count of the electrode is sufficiently long. This is the
only way to ensure that the complete part can be welded before the ma
ximum count is reached. Alternatively (but by taking sufficient "elec
trode reserves" into account!), it may also be possible to deactivate the
"Stop at end of stepper" function.
6.2.7 New electrode

The output becomes high if the selected welding program has been as
signed to an electrode with actual counter value “0”.
6.2.8 Magnet valve

This signal is set at the beginning of the pre-squeeze time (1.SQZ) and
cleared at the end of the hold time (HLD).
6.2.9 Close weld contactor

This discrete output signal is set at the beginning of a welding schedule
if the serial input "Weld contactor enabled" is active and ignition is
turned on.
It will be reset when
• the serial input "Weld contactor enable" is reset, or
• a fault occurs, or
• no start signal was output for 60 seconds.
and Controls
6.2.10 Status
The 16 "Status” outputs are used by the timer to transmit its current
status in binary code to the robot/PLC.
Output signal Value : High level of the corresponding signal

(dec)
Status bit0 1
Status bit1 2
Status bit2 4
Status bit3 8
Status bit4 16 ...
Status bit5 32
Status bit6 64
Status bit7 128
:
Status bit 16 32768
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:
Output of current timer status in binary code

The following messages have currently been defined:
Code
Meaning
(dec)
00 OK
80 Stop open circuit/ no +24V
81 Current without command
84 Battery low
85 Memory deleted == RAM checksum error
86 Data download active
87 no welding program == invalid parameters
88 Hardware fault
89 I/O bus fault
90 Half cycle monitoring
91 Main switch tripped
92 External temperature too high
93 Synchronization fault
94 Weld sequence inhibited
95 Parity fault
98 Programmed value too large (current/force)
99 Welding process fault
100 Supply voltage fault
107 No weld contactor enable
120 Weld contactor 1 not closed
122 Weld contactor 1 did not open
124 No weld pressure
160 Cooling device temperature too high
164 Transformer overtemperature fault
165 Hardware fault driver module
166 24V Power supply fault
179 Conductor monitoring - contactor disconnector
400 Tip dress fault - excessive current detected on electric motor
401 Tip dress fault - no feedback detected from the pneumatic motor
405 Tip dress fault - invalid weld schedule selected
406 Tip dress fault - current overload detected on the electric motor
407 Tip dress fault - sequence aborted
2106 Q Stop component
2107 Q Stop spot in series
2108 Q Stop special spot
and Controls
6.2.11 Tip dress enable circuit

Also refer to "Cutter motor control" function starting on page 64.
6.2.12 Tip dress sequence running

6.2.13 Tip dress OK

6.2.14 Tip dressed

6.2.15 UI regulation active

Informs the user whether the UI regulation has been activated for the
currently selected welding spot (program):
Signal is high: regulation is active
Signal is low: regulation is not active
6.2.16 UI monitoring active

Informs the user whether the UI monitoring has been activated for the
currently selected welding spot (program):
Signal is high: monitoring is active
Signal is low: monitoring is not active
6.2.17 Q Stop
Acts in connection with the "Q Stop" function (refer to page 78):
If the output is high, a Q Stop fault is currently present.
"Fault reset" will reset the "Q Stop" signal.
☞ Other signals in connection with the "Q Stop" function:
- "End of component" (refer to page 111)
- "Acknowledge end of component" (refer to page 6.2.18)
6.2.18 Acknowledge end of component

and Controls
Acts in connection with the "Q Stop" function (refer to page 78) and ser
ves as acknowledgement signal for the "End of component" input (refer
to page 111).
"Acknowledge end of component" remains high for as long as "End of
component" is high.
6.2.19 Transformer x
By means of the discrete output signals ”Transformer x” (see page
120), the timer specifies which transformer / CCR sensor (measuring
circuit) is assigned to the active (programmed) electrode number.
These output signals can only be modified in connection with a positive
edge at the ”Start” input.
Here,
☞ The electrode numbers 0, 30 ans 31 are not assigned to a transformer /

CCR sensor.
For this reason, when the output signal ”Transformer x” has been output
last, it will not changed when electrode 0, 30 or 31 is activated.
Information concerning the assignment: see page 96.
Terminal assignment for the output signals: see page 104.
6.2.20 Operate force sensor

Use this discrete signal output at terminal X9 Pin 1 to initiate the measu
ring process of an external force sensor unit.
The output depends on the status of the serial input signal ”Operate
force sensor”.
and Controls
6.2.21 Timer ready
The output signal indicates that the timer is ready to weld.

In this state,
• you can start a new welding schedule (see page 112)
• the READY LED at the timer's front is lit (see page 32).
If an error occurs, the timer will be inhibited.
In this state,
• it is not possible to start a welding schedule
• the READY LED at the timer's front goes off
• the output signal ”Timer ready” is reset.
☞ For more fault and status messages, please refer to "Error list
PS5000/PS6000” (No. 1070 087 001).
There, you will also find information on fault elimination in addition to the
possible causes.
In order to restore the ”Ready” status of the timer after a fault, you may
proceed according to one of the following alternatives:
1. press the reset key at the timer's front (refer to page 32)
2. a positive edge at the ”Fault reset” input signal
(refer to page 115)
3. a positive edge at the ”Fault reset with weld complete” input signal
(refer to page 117)
4. a positive edge at the ”Fault reset with reweld” input signal
(refer to page 116)
5. operation via software (”Fault reset”, ”Fault reset with weld comple
te” and ”Fault reset with reweld” are also possible via BOS).
6.2.22 Weld fault

If a fault occurs during the welding process,
• the timer sets the "Weld fault" output and
• clears the "Timer ready" output signal (refer to section 6.2.21).
Additional welding schedules cannot be started unless all active errors

have been corrected and acknowledged. Also refer to "Fault reset",
from page 115.
PS5000/PS6000” (No. 1070 087 001).
possible causes.
☞ Whether an event is interpreted as a fault or a warning depends on the

settings in the ”Setup: Fault setup” window (BOS).
and Controls
6.2.23 Without weld process monitoring

Using this output signal, you can check whether the currently selected
welding program is executed
• with current monitoring (output is low), or
• without current monitoring (output is set).
CAUTION Possibility of defective welds!

When the current monitoring function is switched off, actual current va
lues outside the permitted tolerance bands do not result in faults!
Therefore, you must ensure that any welds performed without active
monitoring functions are sufficiently checked!
When a welding program is executed, current monitoring will be active

in the following cases only ("Without welding process monitoring" is not
active):
• the timer-specific inhibit monitoring function is switched off (BOS:
”Monitoring stopped” parameter
• program-specific current monitoring has been switched on for all
weld times (BOS: ”current monitoring” parameter.
6.2.24 Pressure output bit x

The digital outputs (8 bits) represent the value for the analog pressure
output at X2 pin 1.
Digital value range: 0 ... 255 increments;
255 increments corresponds to 100% of the max. possible analog value
at X2 pin 1.
Immediately after program selection, the signals are updated.
6.2.25 Start tip dress request

Informs the PLC/robot that an electrode requires initial dressing.
If the electrode specific parameter ”dress new electrode” (BOS) is swit
ched to ON, the signal will be set after the relevant electrode has been
replaced (refer to signal ”Electrodes have been replaced” page 119).
The output signal is only set under following conditions:
value ”Weld counts” and ”Act. val” (BOS; ”Programming:Stepper”
window) are both ”0”.
6.2.26 Pressure inside tolerance area

If force feedback at terminal X2 Pin 3 is used, the timer informs the ro
bot/PLC about the status of pressure monitoring by the output signal
”Pressure inside tolerance area”.
and Controls
Maintenance
7 Maintenance
7.1 Battery
A battery is integrated into the unit for buffering the main memory (con
taining all parameter settings for all welding programs) and the internal
clock.
Battery type: Lithium
Battery size: AA
Voltage: 3.6 V
Order no.: 1070 914446
The timer generates a fault or a warning (subject to configuration) when

the remaining battery power becomes critical. The BATTERY FAULT
LED at the timer's front is lit (see page 32).
If the event has been defined as a fault message, no welding schedule
is possible any more.
L Include battery replacement in the regular maintenance schedule of the

plant! Replacement: at least every 2 years.
CAUTION Damages through improper handling of electronic components!

Therefore, batteries must be replaced by authorized technical per
sonnel!
CAUTION Loss of data!

If no supply voltage is present and when the batteries have been remo
ved, data buffering is guaranteed for max. 24 hours only.
Therefore, have a new battery ready at hand for replacement and in
sert the new battery immediately after removing the spent battery.
Replacing the battery
L Please note the information concerning the disposal of batteries on

page 13.
The battery may be replaced while the timer is switched on.
1. Turn the battery cover on the front side of the unit (refer to page 32)
counter-clockwise and take out the spent battery.
2. Slightly hit the new buffer battery (of the same type!) on a firm surface
in order to destroy the internal oxide layer.
3. Then properly insert the new battery. Concerning the polarity, please
note the drawing on the front side of the timer.
4. Replace the battery cover to close the battery compartment.
Battery replacement is now complete.
and Controls
Maintenance
7.2 Firmware
Upon delivery, the most current firmware is installed on the timer. You
may display the firmware version using the programming terminal
(BOS).
In rare cases, it may be necessary to update the firmware.
CAUTION Damages through improper handling.

Therefore, firmware updates may only be performed at our request
and by authorized personnel only!
The following software tools are available:

• WinBlow (refer to Sect. 7.2.1):
• for firmware update of the timer via the V24 interface (X1).
☞ In order to perform a firmware update of an optional ultrasonic or U/I
controller system (PSQ 6000 XQR) integrated into the timer, the
”FWUpdate” software tool or alternatively the BQR user interface are
required!
• FWUpdate (refer to Sect. 7.2.2):
• for firmware update of the timer via the field bus interface (Ether
net)
• for a firmware update of an optional ultrasonic or U/I controller
system (PSQ 6000 XQR) integrated into the timer.
7.2.1 Firmware update via ”WinBlow”

For a firmware update, you need
• a pointed object for operating the ”boot” button (for position, refer to
page 32),
• a PC with ”WinBlow” software,
• a suitable connecting cable (timer <-> PC, for wiring, refer to
page 101) and
• the firmware as a *.hex file.
L Proceed as follows:
1. Connect one of the PC's V24 interfaces (COM1 or COM2) to the

timer's X1.
2. Start the ”WinBlow” software. Select the desired language and the
V24 interface used.
3. Select the path and file name of the firmware. Firmware files have the
file name 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 interrupt
the timer's 24 VDC power supply (refer to page 87).
and Controls
Maintenance
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.
☞ When the next step has been initiated, the power supply must not be
interrupted 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
(remove X4). Then reinstall X4.
The timer is booted with the new firmware.
The firmware update has been completed.
L Check the firmware version using the programming terminal (BOS).
7.2.2 Firmware update via "FWUpdate"

The following is needed to perform a firmware update
• a PC with the "FWUpdate" software installed,
• a working connection to the PC via the field bus interface (Ethernet),
• a BOS database installed on the PC with a valid timer reference
(BOS 6000 installed) and
• the firmware as a *.hex file.
L Proceed as follows:
1. Start the "FWUpdate" software.
When the software is started, it will search for a valid timer reference
(is read from the BOS6000 database) and show you all properly lin
ked timers in tabular format:
and Controls
Maintenance
2. Use the "SST-Firmware" (SST - German abbreviation of 'weld timer') or

”UIR-Firmware” command buttons to select the path and file name of
the desired firmware.
Firmware files have the file name extension ”.hex”.
The selected firmware file will be displayed in the corresponding in
put fields.
3. Select the timer(s) for which the firmware update is to be carried out
by ticking the proper checkboxes at the left margin of the lines.
To select/deselect all of the timers, use the checkbox at the left mar
gin of the table's header line.
4. Select the desired options for the firmware update by ticking the ap
propriate checkbox(es). These options will be applicable for all
selected timers.
The following options are available.
• ”Change after Load”:
The system will initiate reprogramming of the timer's internal flash
memory (if necessary, after all backup processes have been ac
tivated, refer to "Save Counter", "Backup", "UIR Backup"
options). During this process, the timer will copy the contents of a
dedicated RAM memory range to which data was stored using the
"FW Load" command button into the flash memory.
If "Change after Load" is not activated, the copying process must
be manually started later on in the course of the firmware update
by pressing the "FW Change" command button.
☞ Do not use ”Change after Load” unless none of the weld timers involved
actively participates in the production process for the duration of the
complete firmware update.
and Controls
Maintenance
• ”Quit after done”:

The program will be automatically closed after the firmware up
date (and the completion of Restore, if activated, refer to ”Save
Counter”, ”Backup”, ”UIR Backup” functions) of all selected
timers.
• ”Save Counter”:
All actual counter statuses (electrode and dressing cutter wear, if
programmed) will be saved on the programming terminal prior to
programming the flash memory and will be restored to the timer
after Timer Reset.
• ”Backup” and ”UIR Backup”:
All welding parameters or UI controller parameters will be saved
in the flash memory of the programming terminal prior to program
ming the flash memory and will be restored to the timer after Timer
Reset.
5. Check whether communication with the timers selected for the firm
ware update is still possible.
Click on the ”List” command button.
Communication works properly if all currently active firmware ver
sions are displayed in the new ”SW Version” window after a few se
conds.
Then close the ”SW Version” window.
Communication is interrupted if the firmware version is not dis
played, but rather the text: ”--N/A---”.
In this case, you should check whether the timer in question has
been properly connected, switched on, and completely booted. A fi
rewall activated on the programming terminal may also inhibit com
munication.
Then close the ”SW Version” window and check the communication
again.
6. Click on the ”FW Load” command button.
The currently selected firmware file (refer to step 2.) is loaded by the
programming terminal to a dedicated RAM memory range of the
timer. The progress is indicated by a status bar in the ”SST” (German
abbreviation of “WT - weld timer”) or ”UIR” field.
When loading has been completed, the system will display the new
firmware version loaded in the ”SST” or ”UIR” field.
If the firmware is generally suitable for the timer, the background of
the ”SST” or ”UIR” field will be green, otherwise it will be red. Only
suitable firmware versions can be programmed into the timer's flash
memory in the course of the process.
7. If activated (refer to step 4.: ”Save Counter”, ”Backup”, ”UIR Backup”
functions) the relevant data will be automatically saved on the pro
gramming terminal.
During this process, the message ”Backup” will be displayed in the
”Status” field.
8. If ”Change after Load” has been activated (refer to step 4.), repro
gramming of the flash memory is automatically initiated in the timer.
If the option has not been activated, you can start reprogramming
with the ”FW Change” command button.
and Controls
Maintenance
☞ While the flash memory is reprogrammed, the timers involved

• must not be disconnected from mains supply,
• cannot be used for welding tasks,
• are not ”Ready”.
As soon as programming starts, the "Wait" window will be displayed.

Wait until the "Wait" window is automatically closed (duration: ap
prox. 100s).
When reprogramming has been completed (duration: approx. 60s),
an automatic Reset will cause the timer to be rebooted.
9. If activated (refer to step 4.: "Save Counter", "Backup", "UIR Backup"
functions) the data backed up in step 7. will be automatically restored
from the programming terminal to the timer.
During this process, the message "Restore" will be displayed in the
"Status" field.
The firmware update has been completed.
L Make sure that the firmware update was properly carried out for all
selected timers.
Click on the "List" command button. All currently active firmware ver
sions are displayed in the new "SW Version" window that is now dis
played.
Then close the "SW Version" window and the "FWUpdate" software.
☞ A firmware version loaded into the dedicated RAM memory range of the
timer can also be displayed in the "SST" or ”UIR” field using the
"Dsp.FW" command button.
☞ The data of a timer that was saved last can also be manually restored to
the timer using the "Bkup+Ctr -> SST" command button without invo
king the procedure described above.
☞ Timer Reset can also be manually triggered by clicking on "SST Reset"

(Timer Reset) without performing the procedure described above.
and Controls
Status and fault messages
8 Status and fault messages

You are informed by the timer of all control-relevant events that might
occur during operation.
• Faults and
• Warnings.
☞ Whether or not an event is interpreted as a fault or a warning depends
on the parameter setting in the timer (BOS: Settings - Fault Setup).
☞ Display and logging of certain events can be suppressed using the BOS
configuration tool (configuration tool: Fault suppress).
The timer only uses code numbers for transmitting faults and warnings.
These code numbers are supplemented by plain text in the program
ming terminal or the line PC. This is designed to save memory
resources of the timer and to reduce communication times.
PS5000/PS6000 (No. 1070 087 001).
possible causes.
Effects on the controller

The following applies to the "Ready" state (= no fault is present)
• a new welding schedule can be started
• the READY LED on the timer's front panel is lit
• the "Timer ready" output signal is high (refer to page 129).
Inthe event of faults
• no welding schedule can be started
• the READY LED at the timer's front panel goes off (see page 32)
• the "Status" serial output signals (refer to page 126) indicate import
ant higher-level causes of faults.
• the "Timer ready" output signal is reset (refer to page 129).
In the event of warnings
• more welding schedules are permitted.
Reset faults
Both faults and warnings may be “self-resetting” or "non-self-resetting".
“Self-resetting” means that events are automatically reset by the timer
when the cause of the fault or the warning has been corrected. There
fore, they do not require a manual “Fault reset”.
Examples of self-resetting faults include:
- Stop / No 24V
- Mains voltage low or off
- Synchronization/mains/DC link voltage fault
"Non-self-resetting" faults can be reset via
• BOS software or
and Controls
Status and fault messages
• a positive edge of the "Fault reset" input signal (refer to page 115) or
• a positive edge of the ”Fault reset with WC" input signal (refer to page
117) or
• a positive edge of the ”Fault reset with reweld" input signal (refer to
page 116)
• manually at the timer's front panel via RESET button (refer to page
32).
☞ The error "Cooling device temperature too high" must always be manu
ally reset at the timer's front panel via RESET button!
and Controls
CE marking
9 CE marking
and Controls
CE marking
Notes:
and Controls
Timer diagrams
10 Timer diagrams
A number of timer diagrams have been provided as examples on the
following pages.
Timer diagrams
Timer diagrams
142
Start 1
Bosch Rexroth AG | Electric Drives

Spot selection (Spot number)
ÉÉ ÉÉ
Pressure feedback
Weld on external ÉÉ ÉÉ
and Controls
Pressure output ÉÉ ÉÉ
É
Weld complete (WC)
(Start/Duration before end of HLD can be programmed)
É
Pre-squeeze time
PSI 6xxx.637/.737 | 1070087130 / 01

Squeeze time
1st weld time (PreWLD)
1st cool time

2nd weld time (MainWLD)
3rd cool time

3rd weld time (PstWLD)
Hold time
Example of normal schedule, single spot

Timer diagrams
1070087130 / 01 | PSI 6xxx.637/.737

Start 1
Spot selection (Spot number)
ÉÉÉ ÉÉ
Pressure feedback
Weld on external ÉÉÉ ÉÉ
Pressure output ÉÉ É
É
Weld complete (WC)
(Start/Duration before end of HLD can be programmed) É
Electric Drives
and Controls
Pre-squeeze time
Squeeze time
1st weld time (PreWLD)
1st cool time
| Bosch Rexroth AG
2nd weld time (MainWLD)
3rd cool time
3rd weld time (PstWLD)
Hold time
143
Example of normal schedule, seam
and Controls
Timer diagrams
and Controls
Annex
A Annex
A.1 Abbreviations
AC Alternating Current kA Kilo-Ampere (amount of current)

BOS Bedienoberfläche Schweißen (Welding kN Kilo-Newton (force)
GUI)
KSR Constant-current regulation.
BQR User interface for U/I controller Keeps the current in the welding cir
CAN Controller Area Network; data bus cuit constant.
CT Cool time KUR Constant-voltage regulation
Time between the current impulses/ Compensates line voltage fluctuations.
blocks (1., 2., 3. CT) LT Power unit (thyristor or inverter)
Cyc Cycles. Refer to P. MF Medium Frequency
DC Direct current.
ms Milliseconds.
dimmed The relevant object or its text is shown
NBS Mains load limitation control
in grey color. In this condition, the rele
Monitors and influences the mains
vant functionality is inhibited, or cannot
load.
be activated for reasons of the very
system. OFF Off Time.
Time between two spot welds in which
DST Downslope time.
the solenoid valve is not driven. Relev
Time in which the %I decreases until
ant for Repeat mode only.
the end of the MainWLD.
EMC Electromagnetic compatibility Option Round object on the user interface for
button toggling a function on/off.
EOS End of Schedule. Refer to WC.
P Cycles (mains cycles)
ESD Electrostatic discharge.
With a line frequency of 50 Hz: 1 P ->
Abbreviation for all names that are re
20 ms.
lated to electrostatic discharge. e.g.
With a line frequency of 60 Hz: 1 P ->
ESD protection, ESD hazards, ESD-
16.6 ms
sensitive components.
PE Protective Earth. PE conductor.
FPO Freely programmable output.
Is not offered for all timers. PG Programming terminal/welding com
HLD Hold time. puter
Time after the last weld time in which PHA Phase angle
the parts to be welded can cool down.
PLC Programmable Logic Controller
HSA Main switch trip.
Post-heat Post-heating time, also referred to as
%I General abbreviation for heat. PstWLD or 3.WLD
May be specified in %I (scale values)
or kA Pre-heat Pre-heating time, also referred to as
Scale values (%I) PreWLD or 1.WLD
With thyristor power units: Measure PreWLD Refer to Pre-heat.
for the electrical phase value.
For MF inverters: Measure for the PSF Process stability.
pulse width. PSG Transformer-rectifier unit for PSI
Ignition Ignition: types.
Firing pulses for triggering the power
PSI Programmable weld timer with inverter.
unit are switched on and off
IMP Numer of impulses. PST Programmable weld timer with thyristor
Iimpulses forming the MainWLD. power unit.
IP Internet Protocol PstWLD Refer to Post-heat.
and Controls
Annex
Radio Refer to "Option button". Tool tip Explanatory text.

button Appears when the mouse pointer re
mains on an input field/object for a
REPEAT Repeat mode.
moment.
Operating mode for manually operated
systems. ÜK Monitoring contact
e.g. for monitoring the pressure inside
RO Relay output the cylinder (that closes the elec
Slope Current increase. trodes) or monitoring of the electrode
Current increases/decreases from an position (e.g. gun closed")
initial to a final heat value. UIP Process quality.
Solenoid Solenoid valve. UST Upslope time
Drives the gun cylinders for closing Time in which the %I increases from
the electrodes the beginning of the MainWLD.
SP Single spot operating mode. WC Weld complete contact.
For automatic and manual systems This signal is output when the sched
SQZ Squeeze time. ule has been completed.
Time that runs before the weld time. WLD Weld time
The electrodes squeeze the parts to A distinction is made between
be welded together. PreWLD (pre-heating time or 1.WLD),
Stepper %I stepping in order to compensate MainWLD (main weld time or 2.WLD),
for electrode wear and PstWLD (post-heating time or
3.WLD).
TCP Transmission Control Protocol. All 3 weld times can be programmed
TCP controls the way in which data is separately in terms of duration and %I.
exchanged between computers. It is a Impulses and slope values can only be
link-oriented, packet-switching trans programmed for the MainWLD.
port protocol and belongs to the range
WT Weld timer.
of Internet protocols (IP).
Weld timer, also referred to as resist
Temp. Temperature. ance weld timer or simply as timer.
and Controls
Annex
A.2 Index
% Dimensions, 26
%I prewarning and limitation, 51 Diode monitoring, 76
%I stepping, 62 Downslope time (DST), 44
Dressing, 63
A DST (downslope time), 44
AC, 145
Acknowledge end of component, 127 E
Air humidity, 81 Electrical connection, 18, 85
Air pressure, 81 Electrode change, 119
Assembly, 16 Electrode force, 69
Automatic spot repetition, 59 Electrode maintenance, 61
Electrodes have been replaced, 119
B EMC, 85, 145
Battery, 81 Emergency-Stop/Emergency-Halt facilities, 18
Battery disposal, 13 End of component, 111
baud rate, 104 End of stepper, 63, 124
Buffer battery, 81 Environmental protection, 13
EOS, 145
C ESD, 23, 145
Cables, 19 Protection, 23
Calibrate gun resistance, 111 Workplace, 23
Calibration, 71 ESD-sensitive components, 23, 145
CCR sensor, 96 Ethernet, 81
CE marking, 24, 139
Close weld contactor, 125 F
Code numbers, 137 Fade out time, 55
communication to Robot/PLC , 102 Fan connection, 100
Condensation, 81 Fault reset, 115, 137
Conditional tolerance range, 53 Fault reset with reweld, 116
Connection, 85 Fault reset with weld complete, 117
Programming device, 101 Faults, 137
Constant-current regulation, 49, 96 Features, 26
Cooling, 26 Field bus module, 30
Cooling water, 17 Firmware, 132
Chlorides, 17 Firmware update, 132
Degree of hardness, 17 via FWUpdate, 133
Insoluble components, 17 via WinBlow, 132
Nitrates, 17 Force, 69
pH value, 17 Force calibration, 71
Sulfates, 17 Force feedback, 92
Corrections, 75 Front side
Count factor, 61 I/O module, 35
CT (cool time), 46 Timer, 32
Current blocks, 41
G
Current calibration, 73
Grounding bracelet, 23
Current input, 82
Current monitoring, 52 H
Cutter motor control, 64 Hardware, 30
Hazardous materials, 13
D HLD (Hold time), 47
DC, 145 HSA (main switch trip), 145
Degree of protection, 81
DEV-NET, 34 I
DeviceNet baud rate, 104 I/O communication to Robot/PLC , 102
DeviceNet Connection, 104 I/O DISK, 35, 83
DeviceNet node address, 104 I/O interface, 30
Diagrams, 141 I/O module, 35, 83
and Controls
Annex
I/O Module ”DEV-NET”, 34, 82 Power loss, 82, 83

I/O module supply, 102 Power supply I/O modules, 102
Ignition, 123 Power supply to external units, 88
Impulse mode, 43 Pre-heating time, 41
Input signals, 110 Pressure control, 81, 92
Installation, 16 Pressure feedback, 92
Interference suppression, 85 Pressure inside tolerance area, 130
Isolate weld contactor, 80 Pressure output bit x, 130
Pressure profile, 70
K Pressure stepping, 70
KSR, 49, 145 Prewarning, 124
KUR, 145 Primary circuit, 97
Principal components
L of our electronic equipment, 13
Latching, 58, 112 of our packaging materials, 13
Line connection, 26 Process quality (UIP), 78
Logic supply, 87 Process stability (PSF), 78
M Programming, 29
Magnet valve, 125 Programming device, 101
Main components of a welding system, 37 Programs, 81
Maintenance, 23, 131 Proper use, 12
Making current, 81 PSF, 145
Manual guns, 39 PSG, 145
Measuring loop test, 59 PSI, 145
MF, 145 PSQ 6000 XQR, 28, 30, 50, 78, 111, 127
Mixed mode PST, 145
Monitoring, 54 Q
Regulation, 48 Q Stop, 78, 127
Modifications by the operator, 22 Qualified personnel, 14
Modules sensitive to electrostatic discharge, 23 Quality module, 30
Monitor stepper, 57
Monitoring, 52 R
Monitoring modes, 54 RC element, 85
Monitoring, welding process, 130 Recovery of materials, 13
Recycling, 13
N Regulation modes, 48
NBS, 145 Repairs, 23
New electrode, 125 Repeat, 39
node address, 104 Replacing the battery, 131
Nominal current, 81 Retrofits, 22
Reweld Factor, 53
O Robots, 39
OFF, 145 Roll seam, 40
offline, 29 RS232, 101
online, 29
Operate force sensor, 120, 128 S
Operating temperature, 81 Safe working practices, 24
Operating voltage, 81, 82, 83 Safety instructions, 11
Operation, 29 Schedule diagrams, 141
Output signals, 121 Seal weld, 40
Overview, 25 Seam operation, 40
Secondary circuit, 96
P self-resetting, 137
PG, 145 Sensor failure, 97
PHA, 48 Signal descriptions, 109
Phase angle, 48 signal outputs / inputs (PSI 6xxx.373), 104
PLC, 145 Signal outputs / inputs (PSI 6xxx.737), 105
Post-heating time, 42 Single spot, 39
Power input, 83 Slope, 44, 146
and Controls
Annex
Solenoid, 146 UI regulation active, 127

Spare parts, 23 UIP, 146
Spot number, 113 UIR, 50
Spot repetition, 59 Ultrasonic controller system, 28, 30
SQZ (squeeze time), 46 UST (upslope time), 44
Standard mode
Monitoring, 54 V
Regulation, 48 Voltage distribution, 89
Start 1, 112 Voltage generator, 86
Start tip dress request, 130
Status, 126 W
Stepper, 62, 146 Warning, 63
Stepper monitoring, 57 Warning table, 63
Stitch seam, 40 Warnings, 137
Storage, 81 WC, 122
WC period, 122
T WC Start time, 123
Teachware, 15 WCD, 80
Temperature, 99 Wear per component, 61
Time monitoring, 57 Weld Circuit Degradation, 80
Timer diagrams, 141 Weld complete, 122
Timer ready, 129 Weld contactor closed, 111
Tip dress - motor current tripped, 111 Weld contactor enable, 111
Tip dress - motor overload tripped, 111 Weld fault, 129
Tip dress - RPM sensor, 111 Weld on (with welding current), 123
Tip dress enable circuit, 127 Weld on external, 114
Tip dress management, 64 Welding modes, 39
Tip dress motor on (air/elec), 111 Welding output, 26
Tip dress OK, 127 Welding process monitoring, 130
Tip dress required, 124 Welding transformer data, 76
Tip dress sequence running, 127 Without weld process monitoring, 130
Tip dressed, 127 WLD (weld time), 41, 42
Tip dressing, 63 WT, 146
Tips have been dressed, 118
Tolerance ranges, 52 X
Toroid input, 96 X1, 101
Trail current, 55 X10, 102
Training, 15 X11, 104
Transformer temperature, 99 X12, 104
Transformer x, 128 X13, 104
Type designation, 25 X2, 92
X3, 96, 99
U X4, 86, 87, 89, 100
U/I controller system, 28, 30 X5, 88
UI monitoring active, 127 X9, 92
and Controls
.
and Controls
Bosch Rexroth
Electric Drives and Controls GmbH
Postfach 13 57
97803 Lohr, Deutschland
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Deutschland
Tel. +49 (0) 93 52-40-0
Fax +49 (0) 93 52-40-48 85
www.boschrexroth.de
Printed in Germany
DOK‐PS6000‐E/A637_737*‐FK01‐EN‐P

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1070087130 / 01 | PSI 6xxx.637/.

737 Electric Drives | Bosch Rexroth AG 1

Rexroth PSI 6xxx.637/.737 1070087130

Rexroth PSI 6xxx.637/.737 1070087130

Title Rexroth PSI 6xxx.637/.737

Type of documentation Technical Information

Documentation type DOK‐PS6000‐E/A637_737*‐FK01‐EN‐P

Purpose of the docu­ The present manual contains information on

Development of modifica­ Previous editions Status Note

Edited by Bosch Rexroth Electric Drives and Controls GmbH

3.10 Automatic spot repetition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6 I/O signal descriptions . . . . . . . . . . . . . . . . . . . . . . 109

7.2 Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

8 Status and fault messages . . . . . . . . . . . . . . . . . . 137

10 Timer diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

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

1.1 Possible icons on the product

Dangerous Electrical Voltage

Hazards associated with batteries!

Electrostatically sensitive components

Function ground, ground with low parasitic voltage

1.2 Safety instructions in this manual

DANGER The DANGER class of symbols is used wherever insufficient or lacking

WARNING The WARNING class of symbols is used wherever insufficient or lack­

CAUTION The CAUTION class of symbols is used wherever insufficient or lack­

L This symbol indicates the need to observe/perform certain things.

1. Any numbers, if present, mean

☞ This symbol is used to draw the user’s attention to special circum­

1.3 Proper use

WARNING Danger due to inappropriate use!

The product described

Any other application is deemed improper use!

CAUTION Risk of high-frequency interference!

☞ For operation in residential environments, in trade and commercial ap­

1.4 Environmental protection, recovery of materials and re-use

The products manufactured by us can be returned to us free of charge

The packaging materials are made of cardboard, wood and poly­

Principal components of our electronic equipment:

1.5 Qualified Personnel

WARNING Employing unqualified personnel or non-compliance with warning

WARNING Possible functional disturbance of cardiac pacemakers!

☞ We recommend posting a warning sign in sufficient proximity to the

Possible functional disturbance of cardiac pacemakers

The present documentation is designed for specifically trained engin­

Please note our comprehensive range of training courses.

For more information, you may also contact our

1.6 Installation and assembly

WARNING Dangerous Electrical Voltage!

WARNING Danger of life and damage to property through inadequate degree of

WARNING Possibility of personal injuries and damage to property in the event of

CAUTION Danger of short-circuit through metal burr or cooling water leaks!

CAUTION Overheating due to heat accumulation!

CAUTION Consequential damages due to leaks in the cooling fluid circuit!

CAUTION Deposits may cause the cooling system to fail!

L It must be ensured that operating panels are reachable ergonomically

1.7 Electrical connection

WARNING Dangerous Electrical Voltage!

WARNING Danger of life through inadequate PE conductor system!

WARNING Danger of life through inappropriate Emergency-Stop/Emergency-

L All connection cords and signal leads must be routed so as to prevent

1.8 Start-up and operation of the product

WARNING Possible functional disturbance of cardiac pacemakers!

☞ We recommend posting a warning sign in sufficient proximity to the

Possible functional disturbance of cardiac pacemakers

Purpose of the docu The present manual contains information on

Development of modifica Previous editions Status Note

WARNING The WARNING class of symbols is used wherever insufficient or lack

CAUTION The CAUTION class of symbols is used wherever insufficient or lack

☞ This symbol is used to draw the user’s attention to special circum

☞ For operation in residential environments, in trade and commercial ap

The packaging materials are made of cardboard, wood and poly

The present documentation is designed for specifically trained engin

CAUTION Possibility of overheating/condensation through inappropriate or in

PS_ 6_._ __

Slot for an optional quality module or ultra