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dition 01
Bosch Rexroth GmbH | Electric Drives
BOS 6000 | 1070087074 / 01
and Controls
Title Type of Documentation Document Typecode Purpose of Documentation
Rexroth BOS 6000 User Manual DOK-PS6000-BOS6000****-AW01-EN-P The content of this manual refers to the structure and the functionality of the BOS 6000 user interface.
•
Record Record o f Revisions
Previous Previou s editions editi ons DOK-PS6000-BOS6000****-AW01-EN-P
Copyright
© Bosch
Release Release Date
Notes
06.2006
Rexroth Electric Drives and Controls GmbH, 2006
Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. 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).
Validity
Published by
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The given information does not release the user from the obligation of own judgement and verification. It must be remembered that our products are subject to a natural process of wear and aging. 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 62/78-7 28 Abt.: BRC/PAW1
Bosch Rexroth GmbH | Electric Drives
BOS 6000 | 1070087074 / 01
and Controls
Title Type of Documentation Document Typecode Purpose of Documentation
Rexroth BOS 6000 User Manual DOK-PS6000-BOS6000****-AW01-EN-P The content of this manual refers to the structure and the functionality of the BOS 6000 user interface.
•
Record Record o f Revisions
Previous Previou s editions editi ons DOK-PS6000-BOS6000****-AW01-EN-P
Copyright
© Bosch
Release Release Date
Notes
06.2006
Rexroth Electric Drives and Controls GmbH, 2006
Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. 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).
Validity
Published by
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The given information does not release the user from the obligation of own judgement and verification. It must be remembered that our products are subject to a natural process of wear and aging. 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 62/78-7 28 Abt.: BRC/PAW1
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Contents
Contents The BOS 6000 Help System................................................9 Software version.........................................................................9 Activating Help ............................ ............................ .................10 Description of of the symbols in the menu menu lines ...........................11 ......................... ..11 Show (Unhide)/Hide.............................................................11 Previous (Back) ........................................................ ........................... ............................. ...........11 Next ............................. ............................. ...........................11 ........................... 11 Start page (Home) ............................ ............................. ......11 Print ..................................................... ........................ ............................. ............................ ....11 Show Contents (structure) view ...............................................12 ........................... ....................12 Keyword search........................................................................12 Text search...............................................................................13 Use favorites ..................................................... ......................... ............................ .......................14 Including topics topics in the Favorites list....................... list .....................................14 ..............14 Displaying the topics in the Favorites list.............................14 Deleting topics from the Favorites list..................................15 Renaming the topics topics in the Favorites Favorites list .............................15 ......................... ....15
Safety Instru Inst ruct ctio ions ns ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........17 ....17 Why” and “What for”? ....................................................... ........................... ............................ ........17 Symbols used...........................................................................18 Proper use................................................................................19 Qualified personnel ...................................................... ........................... .......................................20 ............20 Safe working practices ...................................................... ........................... ..................................21 .......21 Trademarks, copyright..............................................................22
Getting to know the BOS 6000 user interface.................23 Basics.......................................................................................23 Overview of the interface structure...........................................24 Meaning of important icons ...................................................... ......................... ............................. 26 Functions in the menu line ...................................................... ........................... ............................28 .28 File | Para. data import/export | Export …............................28 File | Para. data import/export | Import …............................28 File | Exit ............................ .................................................. ........................... .......................28 28 Edit | Programming.......................... Programming ........................................................ .............................. ......28 Edit | Diagnosis....................................................................28 Edit | Setup ............................ ............................. .................29 Edit | Correction ........................................................ ........................... ............................. ...........29 Edit | Oscilloscope function..................................................29 Edit | Export Export record record set ...................................................... .......................... ............................ ..29 Edit | Autobackup.................................................................29
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Edit | Timer change..............................................................29 Edit | Copy ..................................................... ........................ ............................. ......................29 Edit | Firmware Firmware changing ................................................... ......................... ............................29 ..29 Edit | Login...........................................................................29 Language.............................................................................29 Functions | Timer reference.................................................30 Functions | Spot reference...................................................30 Functions | Prewarning ...................................................... ........................... .............................30 ..30 Functions | Error table ............................ .............................30 ........................... ..30 Functions | Network overview..............................................30 Functions | Protocol ....................................................... ........................... ............................ ......30 Functions | Compare ..................................................... ......................... ............................ ......30 Functions | Parameter overview ............................ ..............30 Functions | Rights administration.........................................30 Help | Help ..................................................... ......................... ............................ ......................30 Help | About ............................ ............................ .................30 The available windows ........................................................ ........................... ............................. .....31 Login....................................................................................31 Timer Reference..................................................................32 Add/ChangeTimer........................ Add/ChangeTimer.................................................... ............................ ............35 Connection set-up................................................................38 Programming ...................................................... .......................... ............................ .................41 Programming: Schedule ...................................................... .......................... ............................ 42 Programming: Seq. Pg.2 ............................ .........................55 ......................... 55 Programming: Stepper.........................................................61 Programming: General ...................................................... .......................... ............................ ..72 Programming: Electrode......................................................80 Programming: Thyristor-Unit-Parameter.............................. Thyristor-Unit-Parameter..............................93 93 Diagnosis.............................................................................96 Diagnosis: Diagnostics I/O...................................................97 Diagnosis: Users Diagnostics I/O ......................................100 .......................... ............100 Diagnosis: Start Simulation................................................101 Diagnosis: Timer-Information.............................................104 Diagnosis: Last Weld.........................................................106 Setup ........................................................ ........................... ............................. .........................107 ......................... 107 Setup: Stepper curves ....................................................... .......................... ............................. 108 Setup: Tipdress curves......................................................110 Setup: Fault-Setup.............................................................111 Setup: Communication Communication ............................ ..........................112 .......................... 112 Correction ....................................................... .......................... ............................. ...................116 Correction: Correction........................................................117 Spot Reference..................................................................119 Prewarning.........................................................................121 Error table..........................................................................123 Network overview ............................ .............................. ....125 Protocol..............................................................................127 Compare............................................................................131 Parameter Overview............................. Overview ............................. ............................. 133 Set Access Level .................................................... ......................... ......................................134 ...........134 FTP-Upload ............................ ............................ ...............134 Backup...............................................................................136 Restore ..................................................... ......................... ............................ .........................136 ......................... 136 Autobackup............................................... Autobackup.................... .................................................... .........................137 137
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Timer change.....................................................................139 Copy ..................................................................................140 Firmware change...............................................................141 Para.-Data Import/Export (Parameter-Backup) .................143 Para.-Data Import/Export (Parameter-Restore).................144 Set Counter........................................................................145 Current calibration .............................................................146 Force calibration ................................................................147 Corresponding Programs...................................................148 Spot Comment...................................................................149 Detail Info...........................................................................150
How to …..........................................................................153 Exit BOS 6000........................................................................153 Log in timers to BOS 6000 ..................................................... 153 Delete timers from BOS 6000 ................................................154 Change the communication data of logged-in timers .............155 Export Timer Reference .........................................................156 Import Timer Reference .........................................................156 Print Timer Reference ............................................................156 Copy Timer Data ....................................................................157 Export timer data (backup) .....................................................158 Restore Timer data (download)..............................................159 Compare Timer Data..............................................................160 Influence data comparison at program start...........................162 Define access levels for individual objects.............................163 Copy the contents of a numerical input field ..........................165 Sort tables ..............................................................................166 Filter tables.............................................................................166 Show / Print / Export logs .......................................................167 Change parameters and transfer to timer ..............................169 Export spot reference.............................................................171 Export spot reference to an Excel file..................................... 171 Import spot reference .............................................................171 Print spot reference................................................................172 Compare spot reference.........................................................172 Enter/change spot references ................................................172 Display spot comments ..........................................................172 Delete spot references ...........................................................173 Show electrode status ............................................................173 Confirm electrode change ......................................................174 Set electrode counter .............................................................175 Export parameter data to ASCII file........................................175 Import parameter data from ASCII file....................................176 Replace a defective timer.......................................................177 Upgrade the timer firmware....................................................179 Reset faults ............................................................................181 Add fault information ..............................................................183 Perform current calibration.....................................................184 Perform force calibration ........................................................187
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Fault messages ...............................................................191 Stop / No 24V.........................................................................191 Stop circuit closed ..................................................................191 Weld without Command .........................................................192 Control stop ............................................................................192 Power-Unit not ready..............................................................192 External Over-Temperature....................................................193 Cooling temperature too high .................................................193 Transformer temp too high .....................................................193 Battery-Low ............................................................................194 Memory deleted......................................................................194 Data download started ...........................................................194 No schedule programmed......................................................194 Hardware Fault.......................................................................195 I/O-Bus Fault ..........................................................................196 Half-Cycle Monitoring.............................................................196 Circuit Breaker Off..................................................................196 Sync / Power Fault .................................................................196 Synchronization OK................................................................197 Start Inhibited .........................................................................197 Sequence externally cancelled...............................................197 Program Parity Fault ..............................................................197 24V off/to low..........................................................................198 Supply Voltage Fault ..............................................................198 Timer switched on ..................................................................198 Power voltage to high.............................................................198 Power voltage off/to low .........................................................199 Power voltage off/to low receipt .............................................199 No Weld external....................................................................199 Weld external .........................................................................200 No Weld internal.....................................................................200 Weld internal ..........................................................................200 With stroke, with weld.............................................................200 No stroke, no weld..................................................................200 %I too large/Force/Pressure too high/PHA is too high ...........200 Extend stepping request.........................................................201 Extended electrode life Near End of Stepper .........................201 End of stepper........................................................................201 End of stepper........................................................................202 Electrode changed .................................................................202 Stepper exceed ......................................................................202 Prewarning reached ...............................................................202 Dress-Request reached .........................................................202 Dressing necessary................................................................203 Max. number of spots welded before dressing.......................203 Electrode dressed ..................................................................203 Tipdress prewarning...............................................................203 Electrode life tipdress.............................................................203 Cutter blade changed.............................................................204 Cutter1: Cutter not running.....................................................204 Cutter1: Dressing process aborted.........................................204 Cutter1: Max. mill duration exceeded.....................................204
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Cutter1: Temperature fault ..................................................... 204 Cutter1: Motor protection trip..................................................205 Cutter1: Emergency-Stop.......................................................205 Cutter2: Cutter not running.....................................................205 Cutter2: Dressing process aborted.........................................205 Cutter2: Max. mill duration exceeded.....................................205 Cutter2: Temperature fault ..................................................... 206 Cutter2: Motor protection trip..................................................206 Cutter2: Emergency-Stop.......................................................206 Phase Angle prewarning reached ..........................................206 Maximum Phase Angle Reached...........................................206 Secondary monitoring circuit is open .....................................207 Secondary monitoring circuit is shorted .................................207 Termination of Weld / no current ............................................207 No voltage 1.HW ....................................................................208 Primary Voltage Measuring Fault - KUR Mode ......................208 Reweld By Timer Active .........................................................208 Inhibit Monitoring Mode Active ...............................................208 No Weld..................................................................................208 Without regulation, without monitoring ...................................209 No current …..........................................................................209 Low Current … .......................................................................209 Over Current … ......................................................................209 Low Current-series of welds-… ..............................................210 Current measurement range exceeded … .............................210 Weld time too short …............................................................210 Weld time too long … .............................................................211 Diode Over Current ................................................................211 Diode defect ...........................................................................211 Overcurrent or Earth-fault.......................................................212 Max. primary current reached ................................................212 Driver-Fault.............................................................................213 No weld contactor enable.......................................................213 Isolation contactor feedback fault...........................................213 No Weld Enable or Weld Pressure Input Gun 1.....................213 No Weld Enable or Weld Pressure Input Gun 2.....................213 No Water Flow Gun 1.............................................................214 No Water Flow Gun 2.............................................................214 Weld Contactor Gun 1 Open ..................................................214 Weld Contactor Gun 2 Open ..................................................214 Weld Contactor Gun 1 Did Not Open.....................................214 Weld Contactor Gun 2 Did Not Open.....................................214 Monitor contact open..............................................................215 Mains Power Balance Monitoring Activated ...........................215 Mains Power Balance Monitoring Ok .....................................215 Auxiliary contactor monitor.....................................................215 Fault-Reset.............................................................................216 Welding-Fault Reset...............................................................216 Slave error..............................................................................216 Current Measurement Range Exceeded................................216 Scaling: Communication error ................................................216 Scaling: no valid measuring value received ........................... 217 Scaling: no measuring value received....................................217
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Scaling: protocol fault.............................................................217 Scaling: wrong mode..............................................................217 Scaling: Sequence aborted ....................................................218 Scaling: current out of range ..................................................218 Scaling: Diff. primary / secondary current too large ...............218 Scaling: result invalid..............................................................219 Force monitoring: time too long..............................................219 Force monitoring: time too short.............................................219 Force monitoring: Force/Pressure too high ............................219 Force monitoring: Force/Pressure too low .............................220 Error US measurement ..........................................................220 Error US control loop..............................................................220 PSQ Sequence Cancelled......................................................221 USP not calculated.................................................................221 USP too high ..........................................................................221 USP too low............................................................................221 spot repetition with US ...........................................................221 PSQ hardware fault ................................................................222 PSQ internal communication error .........................................222 PSQ temperature too high......................................................222 USP temperature too high......................................................222 USP hardware fault ................................................................223 PSQ watchdog fault................................................................223 PSQ not available...................................................................223 PSQ sequence error...............................................................223 USP communication error ......................................................223 US measuring loop fault.........................................................224 PSQ memory deleted.............................................................224 PSQ ok ...................................................................................224
Glossary ...........................................................................225 Index ................................................................................. 235
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The BOS 6000 Help System
The BOS 6000 Help System
In this chapter, you will find basic information concerning the BOS 6000 Help system.
Software version Help version:
2.0
Valid as of BOS software version:
1.14.5 (20.12.2004)
Note:
(10.05.2005)
For more information on BOS: File Readme.chm (Directory "Bosch Rexroth AG"): System requirements, installation, update or removal of the software. File History.htm (English) or file History_GER.htm (German) (Directory "Bosch Rexroth AG"): Modification history of the individual BOS versions. via menu item Help | About…: Part numbers, version data
Copyright 2002-2006. All rights reserved, including applications for protective rights.
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The BOS 6000 Help System
Reproduction or distribution by any means subject to our prior written permission. All information is provided for reference only and is subject to change at any time. No liability is accepted.
Activating Help The Help system can be activated in different ways: •
via Help menu item in a BOS 6000 window
•
via Help command button (if available and not dimmed)
•
via F1 butto n if any window of the BOS 6000 interface is active.
Note:
In many areas, the Help is “context-sensitive“. That means that the current system status (active window, input field below mouse pointer) is detected and a suitable help topic is called up when Help is invoked by pressing F1.
The Help window displayed is divided into 3 major areas: •
top : Menu line. Here, you may choose various Help functions.
•
left : Display area for the following functions: Show Contents (structure), Keyword search, Text search and Use favorites.
•
right : Field for displaying the contents of the subjects.
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The BOS 6000 Help System
Description of the symbols in the menu lines The following functions/icons are offered in the menu line of the Help window:
Show (Unhide)/Hide •
Shows or hides the left window area containing the “Content”, “Index”, “Find” and “Favorites” tabs.
•
While you navigate through the Help topics, the system remembers all topics viewed in the order they have been called. Previous (Back) jumps back one position towards the beginning of the navigation path.
•
If Previous (Back) has been pressed at least once, Next jumps forward one position towards the end of the navigation path.
•
Jumps directly to the first Help topic.
•
Opens the ”Print help topics” window. You can choose whether you only want to print the current Help topic or its sub-topics as well (if existent). Then you confirm your choice by pressing OK and follow your computer’s print dialog.
Previous (Back)
Next
Start page (Home) Print
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The BOS 6000 Help System
Show Contents (structure) view In the left window area, you can view the structure of all available Help topics. 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Content” tab in the left window area. The available Help topics are shown in a tree structure. By clicking on a Help topic, the system displays the description relating to the contents.
Note:
Book symbols represent a topic with sub-topics. To show/hide sub-topics, you simply have to double-click on the book symbol.
Note:
To fully extend the structure tree or to close the branches except the main topics, move the mouse pointer to the left window area, press the right mouse button and then select “Open all” or “Close all” in the pop-up menu appearing.
Keyword search 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Index” tab in the left window area. All keywords are listed in alpha-numerical order in the keywords list. The description relating to the topic can be displayed by double-clicking on an index entry. 3. For searching, enter the desired term in the “Find keyword“ field. After each character input, the system will select a corresponding keyword from the index list. For this purpose, it compares the string entered to the available index entries. If no exact entry match is found, the system will choose the lower next keyword from the list according to the sort sequence. 4. Click on the Show (View) command button to view the relevant description.
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The BOS 6000 Help System
Text search 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Find” tab in the left window area. 3. For searching, enter the desired term(s) in the “Find term“ field. If necessary, you may use the wildcard character “*” for any possible string. The individual search terms can be logically combined by the AND, OR, NEAR, NOT operators and the bracket symbols “(“ and “)”. The search itself is not casesensitive, however, the operators have to be written in capital letters. Example: The query “help AND (version NOT 2003)” will find all topics containing both the terms “help” and “version”, but not “2003”. 4. Use the check boxes in the lower left part of the window to define the desired search scope. 5. Click on the List topics command button to list all topics that match the query. Now, the relevant topics can be displayed by double-clicking on a list entry or by clicking on the Show (View) command button after having selected a topic.
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The BOS 6000 Help System
Use favorites Topics that are frequently needed or especially important can be included in the permanent Favorites list that is listed in alphanumerical order (and can even be given a different name there!). Thus, after closing and re-opening the Help function, the topics of interest are immediately displayed again.
Including topics in the Favorites list 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Use the functions "Contents (structure)", "Keyword search", "Text search" or "Use favorites" in order to display the relevant contents. 3. Click on the “Favorites” tab in the left window area. In the lower left display area, the system will enter the name of the topic in the “Current topic” field. 4. If desired, you can change the topic name according to your requirements. The topics displayed can be included in the Favorites list under the name displayed by clicking on the Add command button.
Note:
Alternative to Add command button:
•
Right mouse click in Favorites list
•
Select menu item ”Add”.
Displaying the topics i n the Favorites list 1. If the left window area does not appear, you can show it using the Show (Unhide) menu line symbol. 2. Click on the “Favorites” tab in the left window area. 3. If there are any entries in the list, you can display the relevant topics by double-clicking on a list entry or by clicking on the Show (View) command button after having selected a topic.
Note:
Alternative to Show (View) command button:
•
Right-click on the desired topic in the Favorites list
•
Select menu item ”Show (View)”.
