PSx 6xxx630IO焊接控制器说明书

Rexroth PSx 6xxx.630Timer And I/O Level

1070087079Edition 02Technical Information Electric Drives and Controls Pneumatics Service Linear Motion and Assembly Technologies

Hydraulics

Rexroth PSx 6xxx.630Timer and I/O Level Technical Information DOK-PS6000-E/A630*****-FK02-EN-P This manual provides information about D the mechanical structure D the electrical connection (24 V supply and I/O) and D the functions of the PSI/PST integrated weld timer.Previous editions Status Comment DOK-PS6000-E/A630*****-FK02-EN-P 05.2006E Bosch Rexroth AG, 2006Unless expressly authorized, any copying of this document and utilization and disclosure of its content is not allowed. Damages will be payable in case of contravention. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1).The data given in this document only intend to describe the product and must not be understood as guaranteed properties in the legal sense. We reserve the right to modify the contents of this Documentation and the availability of the products.Bosch Rexroth AG Postfach 11 62D-64701 Erbach, Germany Berliner Stra?e 25D-64711 Erbach, Germany Tel.:+49 (0) 60 62/78-0Fax:+49 (0) 60 62/78-4 28Dept.: BRC / PAW1Title

Type of Documentation

Type of documentation

Purpose of the documentat.Follow ?up of modifications Note on ind. property rights

Legal validity

Published by

Table of Contents

Table of Contents

Page

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1Safety Instructions1?1

1.1Possible Safety Markings on the Product1?1

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1.2Safety Instructions in this Manual1?2

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1.3Intended Use1?3

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1.4Qualified Personnel1?4

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1.5Installation and Assembly1?6

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1.6Electrical Connection1?9

1.7Operation of the Product1?10

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. . . . . . . . . . . . . . . . .

1.8Retrofits and Modifications by the User1?11

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1.9Maintenance, Repair1?12

1.10Working Safely1?13

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.11CE mark1?14

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2Overview2?1

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2.1Type codes2?1

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2.2Features of PS 6000 series2?2

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2.3Programming and Operation2?5

2.4Hardware Installation2?6

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. . . . . . . . . . . . . . . . . . . . .

2.4.1Timer front (without I/O module)2?8

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2.4.2Front of the I/O module ”DEV-NET”2?10

3Timer Functions3?1

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3.1Main Components of a Welding Station3?1

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3.2Types of welding modes3?2

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3.2.1Single Spot3?2

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3.2.2Seam mode3?3

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3.3Program schedule3?4

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3.3.1Programmable Current Blocks3?4

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3.3.2Impulse Mode3?5

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3.3.3Slope (Current Ramp)3?7

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3.3.4Programmable Times3?8

3.4Regulation Modes3?11

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3.4.1Phase Angle (PHA)3?11

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3.4.2Constant Current Regulation (CC)3?12

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3.5Current Prewarning and Limitation3?14

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3.5.1Current Prewarning3?14

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3.5.2Current Limitation3?14

3.6Monitoring3?15

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3.6.1Current Monitoring3?15

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3.6.2Timeout3?20

3.6.3Time monitoring Monitor Stepper3?20

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3.7Interlock3?21

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3.8Measuring Circuit Test3?21

3.9Limitation of the 1st Half Cycle (for PST only)3?22

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3.10Automatic Spot Repetition3?23

Table of Contents

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3.11Electrode Maintenance3?25

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3.11.1Wear Factor and Wear per Welded Part3?25

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3.11.2%I Stepper (Stepper)3?27

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3.11.3Tipdressing of Electrodes3?27

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3.11.4Prewarning and End of Stepper3?28

3.11.5Prewarning Table3?28

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3.12Tip Replacement (Tip Wear Monitoring )3?29

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3.13Electrode Force3?29

3.14Scaling3?31

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3.1

4.1Force scaling3?31

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3.1

4.2Current Scaling3?33

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3.15Corrections3?35

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3.16Weld Transformer Selection (PSI only)3?35

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4Technical data4?1

4.1Integrated weld timer4?1

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4.2I/O Module ”DEV-NET”4?2

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5Electrical Connection5?1

5.1Interference Suppression5?1

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5.2Integrated weld timer5?2

. . . . .

5.2.1Output of the Internal 24 VDC Voltage Source (X4)5?2

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5.2.2Supply of the Timer Logics (X4)5?3

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5.2.3Supply of External Devices (X5)5?4

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5.2.424 VDC Voltage Distribution (X4)5?4

5.2.5Pressure Control and Feedback (X2)5?7

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5.2.6KSR Sensor (X3)5?9

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5.2.7Main switch trigger (X8) (only with PST)5?11

5.2.8Fan connection (X4)5?13

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.9Programming unit (X1)5?13

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5.3I/O Module ”DEV-NET”5?14

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5.3.1Power Supply (X10)5?14

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5.3.2DeviceNet Connection5?16

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5.3.3Signal outputs and inputs5?16

6I/O Signal Descriptions6?1

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6.1Input Signals6?1

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6.1.1Alphabetical Overview6?1

6.1.2Start6?2

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6.1.3Selection of program / spot6?3

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6.1.4Automatic program selection active6?4

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6.1.5Spot selection ready6?4

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6.1.6Ignition on, external6?5

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6.1.7Reset fault6?6

6.1.8Error Reset with WC6?7

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6.1.9Error Reset with Spot Repeat / WC6?8

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6.1.10Acknowledgement ’Tips Have Been Dressed’ x6?9

6.1.11Acknowledgement ’Tips have been replaced’ x6?11

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. . . . . . . .

6.1.12Acknowledgement ’Tips have been replaced’ x6?13

Table of Contents

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6.2Output Signals6?15

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6.2.1Alphabetical Overview6?15

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6.2.2Prewarning Tip Replacement x6?15

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6.2.3Tip Replacement x6?16

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6.2.4Prop. Valve Selection6?16

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6.2.5Sheet Thickness6?17

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6.2.6Sheet Thickness Tolerance6?17

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6.2.7Weld Complete (WC)6?18

6.2.8Control Ready6?19

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6.2.9Welding faults6?20

6.2.10Weld/No Weld6?21

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6.2.11Without Monitoring6?21

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6.2.12Without Regulation and Without Monitoring6?22

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6.2.13Automatic Program Selection Active6?22

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6.2.14Tipdress Prewarning6?22

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6.2.15Tipdressing Request x6?22

6.2.16Prewarning x6?23

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6.2.17End of Stepper Electrode x6?23

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6.2.18Spot Selection Taken Over6?23

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6.2.19Status6?24

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7Maintenance7?1

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7.1Battery7?1

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7.2Firmware7?1

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8Status and Error Messages8?1

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9CE Declaration of Conformity9?1

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10Timer Diagrams10?1

A Appendix A?1

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1Abbreviations A?1

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A.2Index A?2

Table of Contents Notes:

Safety Instructions

1Safety Instructions

The products described were developed, manufactured and tested in

compliance with the fundamental safety requirements of the EU machi-

nery directive. These products normally pose no danger to persons or

property if used in accordance with the handling stipulations and safety

notes prescribed for their configuration, mounting, and proper operation.

Nevertheless, there is some residual risk!

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

commissioning the products or programming the welding system.

Store this manual in a place to which all users have access at any time!

The content of this manual refers to

D the mechanical structure

D the electrical connection (24 V supply and I/O) and

D the functions

of the PSI/PST integrated weld timer.

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

ply units have their own manuals.They complete this manual!

L Therefore, please pay attention to the following documentation as well:

D For PST 6xxx:

Thyristor power unit, technical information (1070 080 059)

D For PSI 6xxx:

Medium-frequency inverters, technical information (1070 080 058) 1.1Possible Safety Markings on the Product

Warning of dangerous electrical voltage!

Warning of hazards associated with batteries!

Electrostatically sensitive components!

Lug for connecting PE conductor only!

Function ground, ground with low parasitic voltage

Connection of shield conductor only

Safety Instructions

1.2Safety Instructions in this Manual

DANGEROUS ELECTRICAL VOLTAGE

This symbol is used to warn of dangerous electrical voltage. The

failure to observe the instructions in this manual in whole or in part may

result in personal injury.

DANGER

This symbol is used wherever insufficient or lacking compliance with in-

structions may result in personal injury.

CAUTION

This symbol is used wherever insufficient or lacking compliance with in-

structions may result in damage to equipment or data files.

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

ces.

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

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

ked by black vertical bars in the margin.

Safety Instructions

1.3Intended Use

The product described

D serves in connection with a welding transformer and the appropriate

power supply unit for

?resistance welding of metals

and

D is suitable for operation in industrial environments in accordance with

the following standards:

?EN 50178

?EN 50081-2

?EN 50082-2

?EN 60204-1

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

enterprises class A equipment may only be used if it does not inad-

missibly interfere with other equipment.

It is not intended for any other use!

DANGER

Any non?intended use of the devices may cause injury to the user

or third parties, as well as damage to the device, the workpiece to

be machined, or to the environment.

Therefore, our products must never be used for any other than

their respective intended purpose!

.For operation in residential environments, in trade and commercial

applications and small enterprises, an individual permit of the na-

tional authority or test institution is required; in Germany, please

contact the Regulierungsbeh?rde für Telekommunikation und

Post (RegTP) or its local branch offices.

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

storage, assembly and installation as well as careful operation.

Safety Instructions

1.4Qualified Personnel

The requirements as to qualified personnel are based on the require-

ment profiles defined by the ZVEI (Zentralverband Elektrotechnik und

Elektronikindustrie ? German Electrical and Electronic Manufacturers’

Association) and the VDMA (Verband deutscher Maschinen- und Anla-

genbau ? German Engineering Federation) in:

Weiterbildung in der Automatisierungstechnik

edited by: ZVEI and VDMA

Maschinenbau Verlag

Postfach 71 08 64

D-60498 Frankfurt.

This manual is designed for technicians and engineers with special wel-

ding training and skills. They must have a sound knowledge of the soft-

ware and hardware components of the weld timer, the power supply

used, and the welding transformer.

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

modification of program parameters is reserved to properly trained per-

sonnel! This personnel must be able to judge potential hazards arising

from programming, program changes and in general from the mechani-

cal, electrical, or electronic equipment.

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

cribed otherwise in this manual, are reserved to specialized personnel.

Tampering with the hardware or software, ignoring warning signs atta-

ched to the components, or non-compliance with the warning notes gi-

ven in this manual can result in serious bodily injury or property damage.

Only skilled persons as defined in IEV 826-09-01 (modified) who are fa-

miliar with the contents of this manual may install and service the pro-

ducts described.

Such personnel are

D those who, being well trained and experienced in their field and fami-

liar with the relevant standards, are able to analyze the work to be car-

ried out and recognize any hazards.

D those who have acquired the same amount of expert knowledge

through years of experience that would normally be acquired through

formal technical training.

DANGER

An exception are persons with cardiac pacemakers!

The strong magnetic fields occurring in resistance welding may

affect the proper functioning of pacemakers. This may be fatal or

cause serious personal injury!

Therefore, persons with pacemakers must stay clear of resistance

welding systems.

We recommend that warning sings as per DIN 40023 are posted at

every entrance to manufacturing shops housing resistance-wel-

ding equipment.

Safety Instructions

No entry for persons with cardiac

pacemakers!

Danger!

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

mation is available from our training center (Phone: +49 (60 62) 78258.

Safety Instructions

1.5Installation and Assembly

DANGEROUS ELECTRICAL VOLTAGE

Danger of life during installation work while systems are switched

on!

Make sure that all plant sections undergoing operations during the

installation are deenergized and sufficiently protected against

accidental reclosing!

DANGER

Non-workmanlike installation or mounting may lead to personal

injury or damage to property.

Therefore, it is essential that you take the technical data (environ-

mental conditions) into account for installation or mounting.

Installation or mounting must be carried out by skilled personnel

only.

DANGER

Insufficient degree of protection may be life-threatening or cause

damage to property!

The degree of protection of the products described is IP 20.

They must be installed in switchgear cubicles providing a degree

of protection of no less than IP 54.

DANGER

Danger of injury and of damage to property through incorrect in-

stallation!

Devices and, in particular, operating means, must be installed so

as to be properly safeguarded against unintentional operation or

contact.

DANGER

Danger of personal injury and damage to property through inade?

quate fastening!

The place for installing the modules, and their method of fastening,

must be suitable for their weight!

Safety Instructions

DANGER

Injuries and bruises may be caused by lifting weights which are too

heavy or by sharp metal edges!

Due to the weight of certain modules, their installation and assem?

bly must be carried out properly and with suitable lifting equip?

ment.

DANGER

The safety and accident prevention regulations as amended shall

be observed!

Wear a protective helmet, safety shoes and gloves!

CAUTION

Short circuits!

When cut-outs are drilled or sawed in switchgear cubicles, metal

burr may get into modules already installed there. Or, when coo-

ling water lines are connected, water may leak into the modules in-

stalled.

The possibility of short circuits occurring in the process or even

the destruction of the devices cannot be entirely ruled out.

Therefore, guard any existing modules well before you install a

new module! Any and all warranty excluded in case of non-com-

pliance.

CAUTION

Heat accumulation!

Modules must be mounted with a minimum clearance of 100 mm

on top and at the bottom. Without this minimum clearance, heat

may accumulate and cause inverter failure.

CAUTION

Leaks in the cooling water circuit may cause consequential da-

mage!

Cooling water leaks may damage adjacent components. There-

fore, when mounting watercooled modules, always ensure that

other devices in the switchgear cabinet are well protected against

leaking cooling water.

Safety Instructions

CAUTION

Risk of damage to property by insufficient water quality in the coo?

ling water circuit!

Deposits in the cooling system may reduce the water flow, thus im?

pairing the performance of the cooling system with time.

Therefore, you should ensure that your cooling water has the follo?

wing properties:

D pH value 7 to 8.5

D Degree of hardness D max10 German degrees

(1 German degree = 1.25 British degrees = 1.05 US degrees = 1.8

French degrees)

D Chlorides max. 20 mg/l

D Nitrates: max. 10 mg/l

D Sulfates max. 100 mg/l

D Insoluble substances:max. 250 mg/l

T ap water usually meets these requirements. However, an algicide

should be added.

L For information about dimensions and installation accessories of the

product as a whole as well as information about the cooling system,

please refer to the manuals of the power supply units (see page 1?1).

Safety Instructions

1.6Electrical Connection

DANGER

Danger of personal injury and damage to property through mis-

sing or false interpretation of fault messages!

Therefore, closing of the transformer temperature contact (ther-

mostatic switch, break contact) must inhibit the connected timer!

As regards fault analysis, see also section 8.

DANGER

Danger of life through inappropriate EMERGENCY-STOP facili-

ties!

EMERGENCY-STOP facilities must be operative in all modes of the

system. Releasing the EMERGENCY-STOP facility must by no

means result in an uncontrolled restart of the system! First check

the EMERGENCY-STOP circuit, then switch the unit on!

CAUTION

Connection or signal lines are to be laid out in such a manner that

stray capacitive or inductive pick?ups do not affect any device

functions!

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

fore, power and control cables must be routed separately. The

effect of interfering cables on interference?sensitive ones can be

minimized by maintaining the following distances:

> 100 mm if cables are run in parallel for < 10 m,

> 250 mm if cables are run in parallel for > 10 m.

Install the product close to the welding units to avoid cable

lengths > 25 m wherever possible.

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

connections and the EMC of the system as a whole in the manuals of the

power supply units (see page 1?1).

L Make sure that all contact surfaces are bright, i.e. free of paint, plastic

coating or dirt/oxidation.

Safety Instructions

1.7Operation of the Product

DANGER

Magnetic field strengths that exceed the limit values according to

VDE 0848 Part 4 must be reckoned with in the area of resistance

welding systems. Limit values for extremities can be exceeded,

especially in the case of manual tongs.

In cases of doubt, you should measure the field strength and take

additional measures to ensure safety and health at work. Please

comply with regulation BGV B11 of the German Berufsgenossen-

schaft (professional association) ”Unfallverhütungsvorschrift

elektromagnetische Felder”.

DANGER

The strong magnetic fields occurring in resistance welding may

affect the proper functioning of pacemakers. This may be fatal or

cause serious personal injury!

Therefore, persons with pacemakers must stay clear of resistance

welding systems.

We recommend that warning sings as per DIN 40023 are posted at

every entrance to manufacturing shops housing resistance-wel-

ding equipment:

No entry for persons with cardiac

pacemakers!

Danger!

DANGER

Danger of personal injury and damage to property if devices are

operated before they have been properly installed!

The devices are designed to be installed in housings or switch-

gear cabinets and must not be operated unless properly installed

and switchgear cabinet doors are closed!

Safety Instructions

DANGER

Danger of bruises through electrode movement!

All users, line designers, welding machine manufacturers and

welding gun producers are obliged to connect output signals

which initiate the electrode movement so that the applicable sa-

fety regulations are complied with.

For example, by means of ”Two-handed start”, fences, light bar-

riers etc. the risk of bruises can be considerably reduced.

CAUTION

Overheating through inappropriate or insufficient cooling.

The temperature inside the housing must stay within the specified

range.

Air?cooled medium?frequency inverters must always be operated

under forced?air cooling conditions. Convection cooling will not

be sufficient!

Air?cooled medium?frequency inverters must always be operated

under forced?air cooling conditions. Condensation on water?car?

rying components must be prevented.

1.8Retrofits and Modifications by the User

DANGER

Modifications to the product may endanger the safety of the unit!

The possible consequences include death, severe or light injury

(personal injury), damage to property or environmental hazards.

Therefore, please contact us prior to making any modifications.

This is the only way to determine whether changes can be made

without any problems.

Safety Instructions

1.9Maintenance, Repair

DANGEROUS ELECTRICAL VOLTAGE

Prior to any maintenance work ? unless described otherwise ? the

system must always be switched off and sufficiently secured!

If required with the system being active, any measuring or testing

work must be carried out by qualified electricians.

DANGER

Lithium batteries can cause skin burns or explode in case of im-

proper handling!

Therefore, do not forcefully open batteries, do not attempt to

charge or heat up batteries over 100degrees C!

CAUTION

Please use only spare parts approved by us!

Use only original replacement batteries! In any case, spent batte-

ries and accumulators should be disposed of as hazardous waste!

CAUTION

Observe all precautions for ESD protection when handling modu-

les and components! Avoid electrostatic discharges!

The following protective measures must be observed for modules and

components sensitive to electrostatic discharge (ESD)!

D The following protective measures must be observed for modules

and components sensitive to electrostatic discharge (ESD)!

D Electrostatic discharge Personnel responsible for storage, transport,

and handling must have training in ESD protection.

D ESD-sensitive components must be stored and transported in the

prescribed protective packaging.

D Staff, worktables and all devices and tools coming into contact with

electrostatic sensitive devices must be applied to the same potential

(e.g. grounded).

D grounding Wear an approved grounding bracelet. The grounding bra-

celet must be connected with the working surface through a cable

with an integrated 1 M W resistor.

D ESD?sensitive components must never come into contact with char-

geable objects, including most types of plastics.

D When electrostatic sensitive devices are installed in and removed

from a system, this system must be de?energized.

Safety Instructions

1.10Working Safely

DANGER

If the start signal is present on fault reset (acknowledge), the weld

timer immediately starts the program sequence! Hazardous ma-

chine movements may be the result!

Therefore, before fault reset, you should make sure that there are

no persons in the danger zone of the welding equipment!

DANGER

During operation of the welding equipment welding splashes are

to be expected! They may cause eye injuries or burns.

Therefore:

? wear protective goggles

? wear protective gloves

? wear flame retardant clothes

DANGER

Danger of injury from sheet metal edges and danger of burns from

weld metal!

Therefore:

? wear protective gloves

CAUTION

The strong magnetic fields occurring in the resistance welding

process may cause permanent damage to wrist watches, pocket

watches, or cards with magnetic stripes (e.g. EC cards).

Therefore, you should not carry any such items on you when wor-

king in the immediate vicinity of the welding equipment.

Safety Instructions

1.11CE mark

CAUTION

The CE mark for thyristor unit ? welding transformer combinations

(see section 9) refers to industrial applications.

For other combinations/applications, the certificate must be deri?

ved from the above or, if necessary, a new certificate must be is?

sued. This is the duty of the line constructor / user.

The described product is an application variant that, due to its cha?

racteristics, cannot satisfy the regulations for terminals, machines

or systems from the start. Therefore, it may be used only as descri?

bed.

The electrical and mechanical safety and the ambient environment

(foreign bodies, moisture) must be evaluated on the terminal when

it has been installed.

The EMC characteristics of this product may change after it has

been installed. As a result, a check of the EMC characteristics of

the end product (terminals, machine, systems) by the manufactu?

rer of the end product is advisable.

Overview

2Overview

The PS 6000 series combines the following devices in one housing:

D Welding timer and

D Power supply unit.

The integrated weld timer is used for controlling the integrated power

supply unit and is suitable for

D Spot welding (e.g. in connection with a robot)

D Projection welding

D Repeat mode (e.g. manual welding guns) and

D Seam welding (e.g. roll seams).

In addition to a variation of timers whose main differences lie in their I/O

connection to the higher-level PLC/robot unit and in their functionality,

there are also

different power supply units (MF inverters/thyristor power supply

units) with different cooling systems (air/water) of several different per-

formance classes available for controlling the welding transformers.

2.1Type codes

The product name contains information about the corresponding pro-

duct variation:

PS_ 6___._____

Mains voltage

(only for MF inverters):

1:400?480 V AC

2:480?690 V AC

Cooling:

L:Air

W:Water

Type of timer

First number: I/O field bus interface

1:24 V

2:PROFIBUS

3:INTERBUS

6:Device Net

7:Ethernet

2.+

3. number: Number of version

Performance class of the power supply unit

Type of power supply unit:

T:Thyristor power supply unit

I:Medium frequency inverter

Example:

PSI 6100.100 L1:Weld timer with 24 V I/O

MF inverter

Air?cooled

Mains supply 400?480 V AC

Type code of PS 6000 series

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