Rexroth PSI 6xxx

The Drive & Control Company

Rexroth PSI 6xxx

UI regulation and monitoring

Edition 07Description of application1070087072

1070087072 / 07Bosch Rexroth AG PSI 6xxx |2�/�138

The data indicated below is intended to describe theproduct. Should information on its use be provided,such information represents application examplesand suggestions only. Catalog specifications shallnot be deemed as warranted quality. This information does not release the user from performing his own assessments and verifications. Our products are subject to natural wear and aging.

© This manual is the exclusive property of BoschRexroth AG, Germany also in the case of intellectual property right applications.Reproduction or distribution by any means subject toour prior written permission.

An example configuration is shown on the coverpage. The delivered product may therefore deviatefrom the picture.

Language version of the document: ENOriginal language of the document: DE

1070087072 / 07 Bosch Rexroth AGPSI 6xxx| 3�/�138

Contents

Contents

1 Regarding this documentation 5. . . . . . . . . . . . . . . . 1.1 Validity of the documentation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Additional documentation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Presentation of information 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.1 Safety instructions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.2 Icons 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.3 Designations 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.4 Abbreviations 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety instructions 9. . . . . . . . . . . . . . . . . . . . . . . . . .

3 General information on damage to property andproducts 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Scope of delivery 13. . . . . . . . . . . . . . . . . . . . . . . . . . .

5 General information on the „UI regulation“ option 155.1 Functions and options 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Requirements 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Information on assembly and connection 18. . . . . . . . . . . . . . . . . 5.3.1 ... for PSI 6x00 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2 ... for PSI 6xCx 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.3 Voltage tapping 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Firmware modifications 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Display of software version 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 Update Controller mode ALU/Steel electrode specific 24. . . . . .

6 Basics on resistance characteristic 25. . . . . . . . . . . . 6.1 „Normal“ weld 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Welds with insulating materials 30. . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Welds with expulsion 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Commissioning of UI regulation 33. . . . . . . . . . . . . . . 7.1 Basic requirements 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Determining the basic welding parameters 34. . . . . . . . . . . . . . . . 7.3 Generating reference curves 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.1 Requirements 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.2 Defining the resistance characteristic as reference curve 43. . 7.3.3 Recording by recorder 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 Activating UI regulation 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.1 Description of the most important UI parameters 54. . . . . . . . . 7.4.2 Special features for activated UI regulation 59. . . . . . . . . . . . . . 7.5 Deactivating the UI regulation 61. . . . . . . . . . . . . . . . . . . . . . . . . . .

8 UI monitoring parameters 63. . . . . . . . . . . . . . . . . . . . 8.1 Available parameters 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Information on the use of monitoring variables 67. . . . . . . . . . . . 8.3 Procedure for commissioning 69. . . . . . . . . . . . . . . . . . . . . . . . . . .


Contents

8.4 Deactivating UI monitoring 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Dynamic tolerance band adjustment 76. . . . . . . . . . . . . . . . . . . . . 8.5.1 Relevant parameters 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.2 Determination of the required parametrization 78. . . . . . . . . . .

9 For quick information 81. . . . . . . . . . . . . . . . . . . . . . . . 9.1 Status of the UI functionality 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.1 "Overview" topic, "Overview" tab 81. . . . . . . . . . . . . . . . . . . . . . . 9.1.2 PSQ status display 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Actual values determined for the last welding schedule 83. . . . . 9.3 Curve characteristics of the last 64 welds of a timer 84. . . . . . . . 9.4 Spot/expulsion overview 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Display of the PSF, UIP and FQF process variables 86. . . . . . . 9.6 UIR process overview 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Q Stop (Quality Stop) 91. . . . . . . . . . . . . . . . . . . . . . . . 10.1 Program-specific Q Stop 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Component-specific Q Stop 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 Exceptions 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 Special spots 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Configuration 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 Adhesive function 95. . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Required parameter setting 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Activation/deactivation of the adhesive function 98. . . . . . . . . . .

12 Static gun resistance compensation 99. . . . . . . . . . . 12.1 Setting of the gun resistance compensation 100. . . . . . . . . . . . . . 12.2 Activating the gun resistance compensation 104. . . . . . . . . . . . . . 12.3 Procedure after a gun replacement 104. . . . . . . . . . . . . . . . . . . . . . 12.4 Special cases 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 Thin-sheet function 111. . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 Required parameter setting 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2 Activating/deactivating the thin-sheet function 112. . . . . . . . . . . . . 13.3 Thinsheet with stepper 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 Force monitoring 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1 Required parameter setting 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2 Activation/deactivation of the force monitoring 120. . . . . . . . . . . . 14.3 Force monitoring in measuring loop check (with UIR V414) 121.

15 The „hot-staking“ mode 123. . . . . . . . . . . . . . . . . . . . . . 15.1 Required parameter setting 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2 Switching the „hot-staking“ mode on/off 124. . . . . . . . . . . . . . . . . .

16 Sheet Thickness Combination (STC) 125. . . . . . . . . . 16.1 Using the STC function 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 List of tables 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 List of figures 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 Abbreviations 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 Index 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Regarding this documentation

1 Regarding this documentation

This chapter includes important information on the use of the documentation.

� Inform yourself about the product before you work with it!

1.1 Validity of the documentation

The present documentation

• applies to the „UI regulation“ option of the PSI 6xxx weld timers

• is designed for Planning, assembly personnel, operators, start-up, service technicians, plant operators.

• provides information about

• Assembly (only needed for the PSQ 6000 XQR module)

• Electr. connection of the required sensors

• UI measurement, regulation, monitoring

• Additional functions which are based on UI measurement, regulation and monitoring

• Activating and deactivating individual functions

1.2 Additional documentation

Several documents are available for the product which are needed together for comprehensive information.

� Only start the product when you are at least familiar with and understand the documents marked with �.

Table�1: Necessary and supplementary documents

Title Doc. no. Document type

� PSI 6xxx: Weld timer with medium-frequency inverter

1070080028 Operating instructions

� PSI 6xxx.xxx xx: Weld timer withmedium-frequency inverter, type-specific supplement

dependingon type

Operating instructions (type-specific supplement)

� PSG xxxx: MF welding transformers

1070087063 Operating instructions

BOS 6000 online help 1070086446 Reference

PSI 6xxx: Process regulation andmonitoring for aluminium spot welding

R911172835 Description of application

�: required document

For which product?

Target group?

Topics dealt with?



1.3 Presentation of information

We use uniform icons, terms and abbreviations in this documentation.They will be explained in the following paragraphs.

1.3.1 Safety instructions

Safety instructions call your attention specifically to danger potentials orrisks.

We distinguish among the following places where safety instructionsmay be required:

• Basic safety instructions:

They are related to general important matters and apply to the complete documentation.You will find these safety instructions in Section 2 and 3 of the„PSI 6xxx: Weld timer with medium-frequency inverter“ operating instructions (Doc. no.�1070080028; also refer to page 5).

• Preceding safety instructions:

They refer to topic-related matters and are provided at the beginningof a chapter or at the beginning of a whole procedure.

• Integrated safety instructions:

They are related exactly to a separate procedure step and areprovided right before the relevant step within the procedure.

A safety instruction is always structured as follows:

• Warning sign (only in case of personal injury)

• Signal word to indicate the danger level

• Type and source of danger

• Consequences of failure to observe

• Action for averting danger.

Table�2: Example for the structure of a safety instruction

Warning sign + SIGNAL WORD

Type and source of danger!

Consequences of failure to observe!

� Action for averting danger!

� Further action(s) for averting danger.

Integrated safety instructions may be embedded in the format of theenvironment so that no ”visual” break in the action sequence is provoked. Therefore they do not necessarily use the layout shown in theexample but they do use the indicated structure.

Where?

Structure?



The safety instructions are classified into danger levels (dangerclasses). The signal word represents the danger level.

Table�3: Danger classes according to ANSI Z535.6

Signal word Meaning

DANGER Dangerous situation where death or serious physical injurieswill occur if it is not avoided.

WARNING Dangerous situation where death or serious physical injuriesmay occur if it is not avoided.

CAUTION Dangerous situation where light to moderate physical injuries may occur if it is not avoided.

NOTICE Situation where damage to property or the environment mayoccur if it is not avoided.

Table�4: Examples for classification of safety instructions

DANGER



� Action for averting danger.

WARNING




CAUTION




NOTICE




Danger levels?



1.3.2 Icons

The following icons are used to mark text passages specifically.

Table�5: Icons used

Icon Meaning

This icon indicates a tip or an information. It helps useand operate the product optimally or understand thecontext better.

� This icon indicates the need to observe/perform certainthings.

• This icon indicates an (unsorted) list.

1.2.3.

This icon indicates a (sorted) list or specific proceduresteps where a certain sequence has to be observed.

1.3.3 Designations

The following designations may appear in our documentation:

Table�6: Designations

Designation Meaning

BOS Welding user interface

PE Protective Earth. PE conductor.

PG Programming terminal/welding computer.

PLC Programmable Logic Controller.

PSG Transformer-rectifier unit for PSI types.Medium-frequency welding transformer 1000 Hz

PSI Programmable weld timer with inverter.

PSQ 6000XQR

Plug-in module for PSI with UI controller functionality.Is not needed for PSI 6xCx types.

PST Programmable weld timer with thyristor power unit.

WT Weld timer. Also referred to as timer, module or resistance weld timer.

1.3.4 Abbreviations

Refer to Section 19 from page 131.


Safety instructions

2 Safety instructions

� Please note the section with the identical name in the operating instructions "PSI 6xxx: Weld timer with medium-frequency inverter"(for doc. no. refer to table on page 5).


Safety instructions

Notes:


General information on damage to property and products

3 General information on damage to property andproducts



General information on damage to property and products

Notes:


Scope of delivery

4 Scope of delivery



Scope of delivery

Notes:


General information on the „UI regulation“ option

5 General information on the „UI regulation“ option

5.1 Functions and options

What does the UI controller do?

It ensures

• in the sequence modes ”Single spot” (robot) and ”Repeat” (manualguns)

• during the 2nd current block

• that the required amount of heat is supplied to the spot weld.

PreWLD and PstWLD are frequently used for „special tasks“.Whereas a PstWLD used is always executed as programmed even ifthe UI controller is active, a programmed PreWLD influences thecontrol process of the weld. For more information, please refer to thesection „Instructions on welds with preliminary impulse (PreWLD) onpage 28.

How does this work?

1. Based on a faultless welding in KSR mode, the system determinesthe curve of the process variables voltage and current as a functionof time to calculate the resistance characteristic.

For basic information on the resistance characteristic during a weld,please refer to Section 6 from page 25.

2. Ideally on the basis of several resistance characteristics obtained inthis manner, a mean curve (reference curve) is created for a spotweld.

3. Based on the reference curve, the UI controller is able to change theamount of current and weld time of the 2nd current block so that thelearned amount of heat will be supplied to the spot weld securelyeven if different interfering variables occur.

NOTICE

Simultaneous welds at the same component

Voltages and currents which are coupled into the measuring process from outside may simulate a disturbed welding process. Thismay lead to unnecessary controller interventions.

� Always avoid situations where several spots are welded within ashort distance on the same component simultaneously.

What interfering variables can be compensated?

• Electrode wear

• Bad caps

• Different sheet thicknesses / additional sheet

• Different coatings



• Force changes

• Mains voltage changes

• Shunt circuits

• Bad contacts• Glue

• Bad fit

Benefits / advantages of the „UI regulation“ option?

• Very broad range of interfering variables can be compensated

• Considerably fewer user interventions necessary when interferingvariables occur

• Better and more precise monitoring of your welding process by alarge variety of monitored parameters (refer to Section 8 frompage 63).

• Simple and rapid parametrization of the monitoring functions bygraphic representation of the actual value distribution over time (histogram display. Refer to page 71).

• Additional functions building on the options provided by UI regulation and monitoring help improve your welding quality (e.g. adhesivefunction, thin sheet function, gun resistance compensation, Q stoplogic, force monitoring)

5.2 Requirements

• For PSI 6x00:UI controller module (PSQ 6000 XQR).

Information on the required slot, displays and connections of themodule is provided in the operating instructions „ PSI 6xxx: Weldtimer with medium-frequency inverter“ (doc. no. � 1070080028; alsorefer to page 5).

• For PSI 6xCx: Licence Memory Card (Micro SD memory card) with the corresponding option.

Information on the installation/removal of the Licence Memory Cardis provided in the operating instructions „PSI 6xxx: Weld timer withmedium-frequency inverter“ (doc. no. 1070080028; also refer topage 5).

Information on all options stored in the License Memory Card can bedisplayed via BOS in the „Diagnosis“ topic „License“ tab.

• Primary or secondary current measurement with functioning sensortechnology.

• Correctly wired voltage tapping at the gun arms (refer to Section5.3.3 from page 20).

• Matching XQR firmware version.If required, we will provide firmware updates to optimize, improve orexpand the product's mode of functioning. Therefore, the presentdocumentation may describe functions, which require an update ofthe XQR firmware. For details, refer to Section 5.4 page 22.

• Use of the BOS user interface for parametrization and visualization.



Information on the BOS 6000 user interface is provided in the„BOS 6000 online help“ (doc. no.�1070086446; also refer to page 5).



5.3 Information on assembly and connection

5.3.1 ... for PSI 6x00

When a new weld timer is delivered, the matching timer firmware hasalready been integrated and the UI controller module (PSQ 6000 XQR)built in as ordered option.

Please note in this case:

Information on displays and connections are provided in the operating instructions „PSI 6xxx: Weld timer with medium-frequency inverter“ (doc. no. 1070080028; also refer to page 5).

1. If you wish to use secondary current measurement, a matching current sensor has to be installed in the secondary circuit and wired correctly.

2. A voltage tapping has to be installed at the gun arms and wired correctly (refer to Section 5.3.3 from page 20).

3. Use BOS to set the „Current measurement“ parameter correctly under the „Programming“ topic „General“ tab.

4. Check whether, after selection of the relevant weld timer, the „PSQ“tab is displayed under the „Programming“ and „Diagnosis“ topic, the„UIR setup“ tab is displayed under the „Settings“ topic and the „UIRmode“ option group is displayed under the „Overview“ topic.

If that is the case, the UI controller module was detected by the timerfirmware and can now be parametrized using the BOS.

If that is not the case, please write down the software edition of your• BOS (via BOS 6000 title bar) and contact our Service.

Proceed as follows to retrofit a weld timer:1. Switch off the 24 VDC logic supply of the weld timer.2. Remove blanking plate at the corresponding slot.3. Insert the UI controller and tighten it.

Information on the required slot, displays and connections of themodule is provided in the operating instructions „PSI 6xxx: Weldtimer with medium-frequency inverter“ (doc. no. 1070080028; alsorefer to page 5).

4. If you wish to use secondary current measurement, a matching current sensor has to be installed in the secondary circuit and wired correctly.

5. A voltage tap has to be installed at the gun arms and wired correctly(refer to Section 5.3.3 from page 20).

6. Switch on the 24 VDC logic supply of the WT.The weld timer now has to start up without any errors.

7. Use BOS to set the „Current measurement“ parameter correctly under the „Programming“ topic, „General“ tab.


When a new weld timer is delivered

When the WT is retrofitted



If that is the case, the UI controller module was detected by the weldtimer firmware and can now be parametrized using the BOS.

If that is not the case, please write down the software edition of your• weld timer (via BOS 6000, „Diagnosis“ topic, „WT information“

tab) and• BOS (via BOS 6000 title bar) and contact our Service.

5.3.2 ... for PSI 6xCx

When a new weld timer is delivered, the matching timer firmware andthe necessary License Memory Card has already been integrated.

Please note in this case:1. If you wish to use secondary current measurement, a matching cur

rent sensor has to be installed in the secondary circuit and wired correctly.


3. Use BOS to set the „Current measurement“parameter correctly under the „Programming“ topic, „General“ tab.

4. Check whether, after selection of the relevant weld timer, the „PSQ“tab is displayed under the „Programming “ and „Diagnosis“ topic, the„UIR setup“ tab is displayed under the „Settings“ topic and the „UIRmode“ option group is displayed under the „Overview“ topic.

If that is the case, the Option „UI regulation“ option was detected bythe timer firmware and can now be parametrized using the BOS.

If that is not the case, please write down the software edition of your• BOS (via BOS 6000 title bar) and contact our Service.

Proceed as follows to retrofit a weld timer:1. Switch off the 24 VDC logic supply of the weld timer.2. Remove the operating unit of the diagnosis module.3. Slide the License Memory Card with the activated option into the

Micro SD slot.

Information on the installation/removal of the Licence Memory Cardis provided in the operating instructions „PSI 6xxx: Weld timer withmedium-frequency inverter“ (doc. no. 1070080028; also refer topage 5).

Information on all options stored in the License Memory Card can bedisplayed via BOS in the „Diagnosis“ topic „License“ tab.

4. Plug the operating unit of the diagnosis module on again.5. If you wish to use secondary current measurement, a matching cur

rent sensor has to be installed in the secondary circuit and wired correctly.


7. Switch on the 24 VDC logic supply of the weld timer.The weld timer now has to start up without any errors.

When a new weld timer is delivered

When the WT is retrofitted



8. Use the BOS to set the „Current measurement“ parameter correctlyunder the „Programming“ topic, „General“ tab.


If that is the case, the Option „UI regulation“ option was detected bythe timer firmware and can now be parametrized using the BOS.

If that is not the case, please write down the software edition of your

• weld timer (via BOS 6000, „Diagnosis“ topic, „WT information“tab) and

• BOS (via BOS 6000 title bar)

and contact our Service.

5.3.3 Voltage tapping

The voltage signal measured is influenced by the properties of thetransformer, the temperature rise in the secondary cables and flexiblelinks and their wear due to movement. Since these interfering variables hardly exist on the gun arms, it is recommendable to connect the voltage measuring cables there.

The closer the voltage tap is positioned to the electrodes/shafts, thesmaller the influence of the gun resistance on control and monitoringprocesses.In this context, using the „Gun resistance compensation “functionality is also useful (see from page 99).

Basic information concerning compliant designs is provided instandard EN 60204-1: (Safety of machinery - Electrical equipment ofmachines - part 1: „General requirements“ - Section 13.4.3: Connection to moving elements of the machine).

Shielded cable (max. 100 m)

Welding transformer

Highly flexible cable(max. 1 m)

Fig.�1: Voltage tapping

� Always install the voltage tapping behind the secondary cable orflexible links (looking toward the electrodes).

� Please note that if the UI controller module PSQ 6000 XQR is used inconnection with PSI 6x00, the polarity of the voltage tapping line isnot random.Therefore determine the polarity for all guns uniformly!



� Connect voltage measuring cables on the gun arm permanently andwith low impedance by clamping a suitable cable lug under an existing screwed connection.

� Where the voltage measuring cables are moved by the gun, usehighly flexible cable with 0.5 to 1.5 mm2 cross-section. As only onecore is connected to each gun arm, the cable may be unshielded inthis area over a length of approx. 1 m. From there, and before the voltage cable is routed together withother cables, shielded cables must be used for further routing.

� The shield of the voltage measuring cable must be routed to the weldtimer - also through further plugged connections - and must be exclusively connected at the entry to the control cabinet/Schweisskoffer or on the weld timer side, respectively, to frame potential using athoroughly conductive, large area connection.

� A plugged or clamped connection is useful at the connection pointbetween unshielded and shielded cables for easy replacement ofvoltage measuring cables.

� Always install the voltage measuring cables so as to ensure that themovement of the gun is not obstructed and the cables are not damaged.

� The cable's permitted bending radius must be observed in the moving points.

� Please ensure sufficient strain relief and fastening of the cable.

Connection of the voltage measuring cables to the WT:for PSI 6x00: X8A (at the UI controller module „PSQ 6000 XQR“) for PSI 6xCx: X3

Information on the corresponding terminal assignments is providedin the operating instructions „PSI 6xxx: Weld timer with medium-frequency inverter“ (doc. no. 1070080028; also refer to page 5).

Suitable cables and ring terminals

• For use in the area of the gun or gun arm:

• Unshielded cable, e.g. single leads of the type „Ölflex Heat205 SC“ Messrs. Lapp

• Solistrand ring terminals made from electrolytically tin-plated copper (e.�g. type 34124 Messrs. Tyco Amp)

• For use in the remaining area:

• shielded cable, 2 x 0.75 mm2, twisted pair(corresponding to part no.:1070 913 494:consisting of 2 x 2 x 0.75 mm2, LiYCY; 2 pairs of cores for electrode voltage and current sensor signal)



5.4 Firmware modifications

Update XQR controller version from V411 to V412

• New monitoring with respect to mechanical gun defect

• New monitoring with respect to oscillating current

• New sequence (schedule) abortions and fault messages in the caseof contact monitoring (R > 3 mOhm) and data inconsistency(between programmed KSR sequence and UI reference curve characteristic)

• Reweld now also possible in the UI mode (measured or controlled)

• New start-up function „STC“

• New start-up function „Iterative setup“

• New PSF evaluation for aluminum operating mode

Update XQR controller version V413

• Display of software version in BOS 6000 only for PSI6XCX for example V413.01 (refer to Section 5.5)

• Monitoring function „mechanical gun defect“ and „swinging current“can be parameterized (electrode parameter).

• New Monitoring function „electrode pick up“ only for PSIXCX inmode ALUMINIUM.

• Toleranceband for „Test gun resistance“ (Gun resistance change)can be programmed in absolute values (in μOhm).

• Identification of reference curve is stored in weld current log (STCname)

Update XQR controller version V414

• Spatter detection for Aluminium adapted.

• Adaption coefficients for QFactors (UIP, FQF, PSF) implemented(refer to BOS Help Programming: PSQ: UIR Monitoring Adapt.Q-factor since BOS V1.45.1 ).

• Automatic spot repetition by violation of absolute tolerance bands ofQfactors possible (refer to BOS Help Programming: PSQ: UIRMonitoring Abs. Reweld Act. since BOS V1.45.1).

• Measuring loop check force extended. Check on a force toleranceband.

• Revision of monitoring function „Electrode pick up“ for mode Aluminium.

• Revision of the calculation function for the resistance contact monitoring.

• Mode version "Hot Staking" with stepper.

• New special combination "Thin sheet with stepper" (refer to Section13.3).

• Reference value of PHA is automatically written when gunresistance is scaled by the robot interface.



5.5 Display of software version

The controller version has been extended with index .00 to .99 . Theindex for example .00 signalize the versions step from e.g. 41x to41x+1.

The old controller version could be identified only with the date of therelease. In the new display the Controller version can be recognized.With the description of the Controller version (refer to Section 5.4) thedifferences to the previous version can be detected.

Fig.�2: Controller Software Version



5.6 Update Controller mode ALU/Steel electrode specific

With controller version 414 the mode Aluminiumor / Steel can be selected electrode specific.

This works only for special timer types which have additional the firmware with controller version 414. That are for example the typesPSI6XCX.232, 633 and 732 (refer to fig. 3).

Required is a license for UI controller and a license for Aluminium.

Fig.�3: Mode Aluminium/Steel electrode specific


Basics on resistance characteristic

6 Basics on resistance characteristic

The UI controller uses very different types of information from the welding process to perform its regulation tasks. At various times during thewelding process, it scans different measured quantities to calculate the„current“ and „weld time“ as influencing variables. Thus, it considers notonly the current, but also the energy and the resistance. Furthermore, itconsiders information concerning expulsion and the temporal relationship of the individual quantities for regulation.

For a better understanding of the process of a welding task, it is helpfulto know more about the resistance characteristics.

These characteristics can be visualized using the BOS user interface, e.g. under the "Diagnosis" topic, "PSQ" tab. Detailed information on all available display functions are provided via the BOS onlinehelp.

Current

Voltage

Resistance

Curr

ent

Voltage

/ R

esis

tance

Fig.�4: Example: Current, voltage and resistance characteristic

With constant-current regulation mode (KSR) active, this visualization may be used to monitor process changes after a variation of thewelding parameters and these findings may be used for further optimization.

When the UI controller is active, this visualization can be used to detect controller interventions and changes in the process situation.

PreWLD and PstWLD are frequently used for „special tasks“.Whereas a PstWLD used is always executed as programmed even ifthe UI controller is active, a programmed PreWLD influences thecontrol process of the weld. For more information, please refer to thesection „Instructions on welds with preliminary impulse (PreWLD)“on page 28.



6.1 „Normal“ weld

The resistance drops from relatively high values at the beginning of theweld because the sheets warm up and are therefore closer connected.This phase is referred to as the „coupling or „heating phase“.

After a relative minimum, the resistance rises again to a relative maximum due to the beginning liquefaction of the material in the spot to bewelded.

When the maximum is reached, the material in the spot to be welded isliquid. The resistance value drops continuously until the end of the weldtime. During this phase, the spot to be welded grows to the spot diameter to be reached.

Separate regulation algorithms have been implemented for thecoupling and melting phase.

Coupling /heating phase

Melting phase/spot growth

Maximum

Resistance (in mOhm)

Weld time (in ms)

Fig.�5: Resistance characteristic of an undisturbed weld

Optimally, the current and the weld time as well as the force must bechosen so as to ensure that the relative maximum of the resistancecharacteristic occurs before one-half of the weld time has elapsed. With hot-galvanized material, the coupling phase is longer, thereforethe maximum resistance characteristic may also be in the 2nd thirdof the weld time.�



• After start of the welding schedule, the regulation of the coupling firstbegins at the time „1ms“. In this phase, the current adjustment permitted for the controller islimited to +/- 5%.

• At what point the switch to melting regulation occurs is determinedby the weld timer automatically when the reference curve is loaded,on the basis of the reference curve. The point in time determined can be found via BOS6000 in the „Programming“ topic, „PSQ“ tab, „UIR“ subtab under „Beginning of regulation“ (see Section 7.4.1 from page 54), if the „Regulation (P)“parameter has been set to ON.

With respect to the resistance curve shown in Fig. 5:, the „Beginningof regulation“ is always located somewhat before the relative maximum for internal optimization reasons.

The automatic system for determination of the time for changingbetween coupling and melting regulation can be adjusted, if needed,using the „Start manual regulation“ parameter. For more informationon this topic, please refer to the „Start manual regulation“ parameterdescription on page 56.

• During the melting phase, the current adjustment permitted for thecontroller is limited to the settings of the „max. current increase“ and„max. current reduction“ parameters (refer to page 56).

• The melting regulation ends at the end of MainWLD - except when adown slope time is used (refer to page 29).

• If a weld time prolongation is permitted, the weld timer calculates theweld time prolongation at the end of melting regulation and executesthis time with the last current value of the melting regulation.

It must be pointed out here that the characteristic shown in Fig. 5: represents an ideal curve for interpretation. Such dynamic resistance characteristics (i.e. resistance changes of approx. 100 μOhm) are usuallyobtained with thick sheet combinations.

There may certainly be some sheet combinations where minimums andmaximums are not too distinct, therefore, the curve has a very flat characteristic. This is the case, e.�g. for very thin sheet combinations or precision-spot welding.

It is even possible that the resistance characteristic - starting with a highinitial value - simply declines without any detectable extremes until theend of the weld time. This phenomenon can be observed with thin electrogalvanized sheets. The controller can work with these characteristics, however, they are more difficult to interpret.

The "Thin-sheet" function is available for thin sheets (less 1�mm persheet). Refer to section 13 from page 111.

Important information in connection with the regulation

phases

No maximum or only a weakmaximum visible?



Instructions on welds with a preliminary impulse (PreWLD)

If the PreWLD has been programmed, it is used for regulation of thecoupling phase. This prolongs the time available for regulation of themelting phase and gives the controller more leeway for the compensation of interfering variables.

� Therefore, make sure that no melting takes place during thePreWLD. During this preliminary impulse, the resistance characteristic must not yet reach its maximum.

This is achieved by the corresponding amount of current (1. %I) and impulse duration (PreWLD) and a possible cool time (1.CT). The maximum and the falling edge of the resistance curve must be completelywithin the main impulse (MainWLD).

PreWLD MainWLD1.CT


Weld time (in ms)

Fig.�6: Correct weld with preliminary impulse

Notes on multiple impulse welds

If several impulses are used within MainWLD, this has no effect on thetime ranges of the regulation phases.

However a special feature occurs when the regulation continues after a2nd Cool time: since this part of the process can be interpreted as a new couplingphase, the system executes the welding process without adaptive regulation for 30� ms initially, before the regulation sets in again.The entire regulation time available is thus reduced the larger the number of impulses and the smaller the weld time of the impulses (MainWLD!).

� In case of multiple impulse welding, make sure that the resistancemaximum is already reached in the first impulse of MainWLD.



� Make sure that the programmed impulse time (MainWLD) is not tooshort. Sufficient time must remain for melting.A maximum resistance building up via two consecutive impulses isnot optimal.

Notes on welds with upslope (UST)

The regulation for the melting phase begins no earlier than after theUST. This

• prolongs the coupling phase by the UST,

• reduces the regulation time for the melting phase,

• influences the weld time prolongation (if permitted).

Notes on welds with down slope (DST)

The regulation for the melting phase already ends with the beginning ofthe DST. This

• reduces the regulation time for the melting phase by the DST,

• does not influence the regulation time for the coupling phase,

• influences the weld time prolongation (if permitted).



6.2 Welds with insulating materials

Especially when using adhesives, insulating layers are encounteredbetween the sheets to be welded. When used properly, these materialsdo not present an obstruction to the weld. However, their insulating effect first has to be overcome before welding can start.

At the beginning of the weld time, resistance remains high until the insulating layer is driven out or has been burnt off. The duration of this phasedepends on the material used and the electrode gun force, among others.

When the insulation has been removed, the weld will be executed asnormal, and the resistance characteristics will be determined by thesheet combination.

Delayed beginning of the heating phase due to adhesive


Weld time (in ms)

Normal characteristic

Fig.�7: Resistance characteristic of welds with an adhesive

The "Adhesive function" is available for welded joints using an adhesive between the sheets involved. Refer to section 11 frompage 95.



6.3 Welds with expulsion

Expulsion can be detected by a sudden change towards lower resistance values in the resistance characteristic.

Expulsion


Weld time (in ms)

Fig.�8: Resistance characteristic with expulsion at 105 ms

When the system should interpret this kind of change as expulsioncan be parametrized in the "Programming" topic, "PSQ" tab, "UIR"subtab via the "Detection of expulsions" and "Expulsion decay time"parameters.When the system detects an expulsion, it displays the expulsionsymbol incl. the time the expulsion occurred if UI measurement hasbeen activated for the respective weld:

Although the UI controller compensates many interferences, expulsions can nevertheless occur during active UI regulation. The causemay be the occurrence of a single very strong interference as well as theinteraction of several interference variables.

The controller's response to expulsions can be set with regard to current in the "Programming" topic, "PSQ" tab, "UIR" subtab via the "Expulsion current control" parameter. With regard to time an active UI regulation automatically extends theweld time to a certain extent in order to make up for the energy lost inthe material.

Expulsion symbolwith time expulsion occurred



The active UI controller furthermore offers the possibility of varyingthe energy input through %I correction. A spot-weld-related loweringthe heat may thus also be used for the temporary "manual" elimination of expulsion.

For the optimization of welds with expulsion, it is helpful to know the timethe expulsion occurred. Several options to avoid expulsion can be derived:

� Avoid edge welds. Spot position has to be optimized, if necessary.

� In case of unresolvable fitting problems, use an upslope. This improves coupling.

� Check whether the programmed ratio of current to force is correct.

� If force is within the correct range, reduce the current.

� Check whether the repositioning behavior of the welding system isok.

� If the expulsion occurs just before the end of the weld time - especially with hot galvanized material - reduce the weld time slightly.

Expulsionin the 1st and 2nd third of the

weld time

Expulsionin the last third

of the weld time


Commissioning of UI regulation

7 Commissioning of UI regulation

7.1 Basic requirements

• A properly completed basic commissioning of the system. Information on this topic is provided in the operating instructions„PSI 6xxx: Weld timer with medium-frequency inverter“ (no.1080080028) under Section „Commissioning“.

• The information provided in Section 5.2 and 5.3 (see from page 16).

• Appropriately set transformer, current and force calibration parameters.

• Perfect condition of gun and electrode shafts.

• Correct cooling conditions at the gun (water tubes, cooling waterquantity, supply temperature).

• The gun forces generated are in accordance with the command valueinputs and are reproducible.

• Correctly positioned electrode tips.

• Electrode tips dressed to fit.If tip dressing is not possible for a gun, the necessary working surfaceof the tip must be ensured by filing or grinding. Thus, the gun's pushing movement can be minimized especially if tips are lowered at anangle.If a pushing of the gun is still detected after dressing, the electrodeshafts have to be adjusted.Irregularities on the contact surface (e.g. chatter marks) and deviating orientations of contact surface and joining plane must be avoided.

• The electrode tips have been worked in without being excessivelyworn. Recommendation: tip wear ranges between 15 and 100 welds.

• Welding equipment and parts to be joined must be suitable for thewelding task (forces, positioning, cooling, flange width, etc.).

• Interferences are eliminated or at least reduced to a minimum.

• Matching (KSR) basic parametrization of the respective weld. Formore information on this topic, refer to Section 7.2.How to generate reference curves is described in Section 7.3 frompage 41.

... especially at the weld timer

... especially at the gun

... generally at the plant

... and additionally for generation of a reference curve



7.2 Determining the basic welding parameters

We recommend to use a separate program for each combination ofdifferent sheet thicknesses and to determine separate referencecurves.Advantage: when using separate programs, all welding parameterscan be optimally set for the welding task in question and later in the UIcontrol mode, the weld time will not become longer than necessarybased on the different sheet thicknesses.

In connection with manual guns, a single welding program often hasto cover a fairly wide range of sheet thicknesses and material combinations. Recommendation:• in the case of total sheet thickness differences of up to 3 mm:

Determine the (KSR) basic parametrization for the thinnest sheetcombination involved.

• in the case of total sheet thickness differences of more than 3 mm: Determine the (KSR) basic parametrization for the medium sheetcombination involved.

In the case of sheet combinations with extreme differences (thin/softand thick/higher-strength), we recommend the use of separate welding programs.

The basic welding parameters of a spot weld to be configured can be obtained from various sources:

• Accepting the welding parameters from a system with the same welding task that operates reliably

• Results of lab examinations• DVS tables• Manufacturer-specific, internal standard• Calculation programs• Database of welding parameters

• Simulation programs

The approach chosen in this context is dependent on the existing circumstances, options and the time frame available.

How basic parameters are determined may have considerable influence on the later process stability and the scope of possibly required follow-up optimization.

We distinguish between 3 variations in this context:

1. Determination using original component at the production plant.+ Optimally suited for subsequent generation of reference curves.+ Special features typical of component/production have little im

pact on subsequent UI regulation/monitoring (shunt circuit, robotpositioning). This reduces optimization requirements, if any, afterconversion to UI regulation.

+ Very good basis for the UI monitored parameters process stability(PSF) and process quality (UIP).

+ Influence of dress cycles is taken into account.This is important should it be necessary later to switch off the UIregulation (return to KSR mode) temporarily.



+ Suitable if sufficient components for determination of the basicparameters are available.

- High costs due to scrap rate during tests (components).

- Production on the relevant lines is not possible or only with restrictions during determination of the basic parameters.

2. Determination using sheet strips on the production plant.

+ Low costs due to scrap during tests.

+ Well-suited if no/few components are available for determining thebasic parameters (e.�g. for new sheet thickness/material combinations).

+ Suitable for subsequent generation of reference curves.

- Special features typical of component/production may have agreat impact on subsequent UI regulation/monitoring (shunt circuit, robot positioning, wear). This increases optimization requirements, if any, after conversion to UI regulation.

- The basis for the UI monitored parameters process stability (PSF)and process quality (UIP) is not as good compared to the option1.

- Production on the relevant lines is not possible or only with restrictions during determination of the basic parameters.

3. Determination using sheet strips in the lab

+ The ongoing production on the relevant lines is not influenced during determination of the basic parameters.

+ Low costs due to scrap during tests.

+ Well-suited if no/few components are available for determining thebasic parameters (e.�g. for new sheet thickness/material combinations).

+ Suitable for subsequent generation of reference curves.

- Special features typical of component/production may have agreat impact on subsequent UI regulation/monitoring (shunt circuit, robot positioning, wear, gun resistance). This increases optimization requirements, if any, after conversion to UI regulation.

- The basis for the UI monitored variables process stability (PSF)and process quality (UIP) is not as good compared to the option 2.,if the „Gun resistance compensation“ functionality (refer to Section 12 from page 99) is not used.

The objective is, in any case, the optimal (KSR) basic parametrization ofthe respective weld.



Procedure

1. Make sure that neither the program-related nor the electrode-relatedI% and pressure correction for the spot weld is active.

2. Make sure that a possibly necessary I% stepping for compensation ofthe effects of electrode wear is parametrized correctly.

3. Make sure that KSR mode is active for the respective weld.

4. Make sure that automatic reweld is switched off for the respectiveweld.

5. Make sure that UI measurement is active for the respective weld(„Programming“ topic, „PSQ“ tab, „UIR“ subtab: „Measurement (S)“and „Measurement (P)“ parameters).

6. Make sure that UI regulation and monitoring is deactivated for the respective weld.

7. Determine the required SQZ squeeze time.

It must be chosen so that the programmed force has been completelybuilt up when the weld time starts. Otherwise, the clear reproducibilityof the resulting resistance characteristic is reduced.

In the example in the figure below, it is clearly shown that the programmed force is only built up after about 300 ms:

Force (in N)

Time (in ms)

Fig.�9: Example: Force build-up during the squeeze time

For manual guns, a squeeze time of at least 500 ms is generally appropriate.

The squeeze time should be individually verified and adjusted (if necessary) for each type of gun. Especially if large guns and higherforces are involved, a longer squeeze time can improve the quality ofthe weld.

Squeeze time (SQZ)



Resistance (in μOhm)

Time (in ms)

Resistance characteristic forForce: 3.0 kNSQZ: 300 ms

Resistance characteristic forForce: 3.0 kNSQZ: 150 ms

Fig.�10: Example: Resistance characteristic with appropriate and insufficient SQZ

8. Determine the HLD Hold time.

The length of the HLD is dependent on the sheet combination. Tests have shown that an HLD of 100-200�ms is generally appropriate. In the case of higher-strength materials, a longer HLD may be appropriate in order to cool the spot weld in a more defined manner.

9. Determine the force, weld time and amount of current (e.g. based ona table). The following table is suited for• soft deep-drawn steel• organic coating• the use of F16 electrode caps in pairs.

Table�7: Basic welding parameters

Total sheet

thickness (mm)

UST

Upslope

(ms)

MainWLD

Main weld

time (ms)

Amount of

current (kA)

Force

(kN)

1.2 - 200 9.0 2.01.3 - 200 9.0 2.11.4 - 200 8.9 2.11.5 - 210 8.8 2.11.6 - 230 8.7 2.21.7 - 240 8.7 2.21.8 - 250 8.6 2.21.9 - 270 8.6 2.32.0 100 350 8.5 2.32.1 100 360 8.5 2.42.2 100 380 8.4 2.42.3 100 390 8.4 2.52.4 100 400 8.3 2.52.5 100 410 8.3 2.62.6 100 430 8.2 2.6

Hold time (HLD)



Total sheet

thickness (mm)

Force

(kN)

Amount of

current (kA)

MainWLD

Main weld

time (ms)

UST

Upslope

(ms)

2.7 100 440 8.2 2.72.8 100 450 8.2 2.82.9 100 470 8.1 2.93.0 120 500 8.1 3.03.1 120 510 8.1 3.13.2 120 530 8.0 3.23.3 120 540 8.0 3.33.4 120 550 8.0 3.43.5 120 560 7.9 3.53.6 120 580 7.9 3.63.7 120 590 7.9 3.63.8 120 600 7.8 3.73.9 120 620 7.8 3.74.0 120 630 7.8 3.84.1 120 640 7.8 3.94.2 120 660 7.8 4.04.3 120 670 7.8 4.14.4 120 680 7.8 4.24.5 150 710 7.8 4.34.6 150 730 7.8 4.44.7 150 740 7.8 4.54.8 150 750 7.8 4.64.9 150 770 7.8 4.65.0 150 780 7.8 4.75.1 150 790 7.8 4.85.2 150 800 7.8 4.85.3 150 820 7.8 4.05.4 150 830 7.8 5.05.5 150 850 7.8 5.15.6 150 860 7.8 5.25.7 150 870 7.8 5.35.8 150 880 7.8 5.45.9 150 900 7.8 5.56.0 150 910 7.8 5.5

• Notes on Force:

• If several sheet thickness and material combinations have to becovered by a single welding program (e.�g. for manual guns),the force for thickest combination to be welded (taking into account the strength of the sheets) should be used.

• Recommended force increase in relation to the table above:• for 3-sheet-combinations in dependence on the component

geometry (fitting problems): 10%• for high-strength steels: 15%• for ultra-high-strength steels: 20%

• Sometimes, manual guns are only able to build up forces of3 kN. The force should be set to approx. 95 % of the maximumgun force in this case (in order to reduce the wear of the gun).

Force



• Notes on Weld time:

• If several sheet thickness and material combinations have to becovered by a single welding program (e.�g. for manual guns),you should use the value for the thinnest sheet stack as weldtime, at least however 250 ms.

• An Upslope from 50 ms to 100 ms is recommended especiallyin the event of fitting problems, thick sheet stacks (also for3-sheet welds) and adhesives.For manual guns, the upslope values in the table above shouldbe reduced by half.

For welds with adhesive, the „Adhesive (Glue) function“ is available (refer to Section 11 from page 95). Important information onthe necessary basic parametrization is provided in Section 11.1from page 97.

• Notes on Amount of current:

• First optimize the amount of current after correct parametrization of the required force.

• The welding current should range in the upper third of the welding range of the selected sheet combination.

• Determine the amount of current so that a maximum resistance, if applicable, occurs in the 1st third of the weld time.

• Take into account the rigidity and coating of the welding material.• For higher-strength steel (especially Usibor), a current re

duction of up to 1.0�kA from the table value is necessary.• For electrocoating and hot-dip galvanizing, a current in

crease of 0.5 to 1.5 kA of the table value is recommended.

• The resulting current density is reduced due to the larger contactsurface. Unless the basic parametrization is already close to theexpulsion limit, the recommended %I (in the table above) shouldbe increased by 10-20%.

• The current reduction for high-strength steels recommendedabove does not apply or has to be distinctly lower.

• For electrocoating and hot-dip galvanizing, a current increase of1.5 kA of the table value is recommended for total sheet thicknesses of up to 2 mm.

10.Perform a test weld with the parameters set and visualize their resistance characteristic.Information on the resistance characteristic and its visualization isprovided in Section 6 from page 25.

11.Verify the required quality of the welding result by means of destructive test and ultrasonic measurement, if necessary.The objective is, in any case, an optimal (KSR) basic parametrizationof the respective weld with the following main properties:

• The welding result ranges above the minimum requirements.

• The resulting spot diameter is slightly larger than the nominal diameter.

MainWeld (MainWLD)

Slope

2. %I (2.Heat) (amount ofcurrent)

Special features of8 mm tip-dress cutters



• Dynamic resistance characteristic with the greatest possible resistance changes. Curves of this kind can be observed well and indicate a stable process situation.Information on the resistance curve and its visualization isprovided in Section 6 from page 25.

Welding quality cannot be assessed by interpreting the curvecharacteristic but only by means of the spot diameter and possiblyby ultrasonic measurements! Controlling the curve characteristicsmust be limited to assessment

• of the resistance characteristic: It should drop sharply at the beginning (contact) and, followinga temporary maximum, fall continuously towards the end of theweld.

• of the voltage signal: It should be similar to the resistance characteristic.

• Expulsion-free schedule.Also refer to Section 6.3 from page 31.

• Settings of a possibly necessary PreWLD and PstWLD are correct. With regard to PreWLD (preliminary impulse), also refer topage 28.

12.If the current parameter configuration generates an optimal andstable weld, generation of the related reference curve (refer to Section 7.3 from page 41) is permitted.Otherwise, first optimize the parameters and then move to step 10.



7.3 Generating reference curves

To generate a reference curve, it is necessary to record the resistancecharacteristic during one or several faultless welds.

The following options are available for this purpose:

• Defining the resistance characteristic as reference curve.Manual selection of a program-specific resistance characteristicwhich is then loaded into the controller as program-specific referencecurve.

For procedure, refer to Section 7.3.2 from page 43

• Recording by recorder.Automatic recording of resistance characteristics with subsequent filtering and mean value definition. The resulting program-specificmean value curves can then be loaded into the controller as program-specific reference curves.

For procedure, refer to Section 7.3.3 from page 45

The weld timer checks the validity of reference curves while loadingthe reference curves into the controller. The criteria for validity are described on page 81.

In addition to generating program-specific reference curves (as described in Section 7.3.3 from page 45), the STC (Sheet ThicknessCombination) functionality can also be used to generate sheet-thickness-related reference curves. Refer to Section 16 from page 125.

7.3.1 Requirements

� If you wish to use the „Gun resistance compensation“ functionality,the function has to be activated. For information on activation, refer to Section 12.1 from page 100.

� Make sure that the optimal (KSR) basic parameters have alreadybeen defined and programmed for the respective welds (refer to Section 7.2 from page 34).

%I compensation should be set to 0%, if possible, in order to be ableto use all compensation features later in UI control mode.

� Make sure that the electrode tips have been dressed and worked in.

The tip wear condition should be between 15 and 100 welds.

� Make sure that the UI measurement is active for the respective welds(„Programming“ topic, „PSQ“ tab, „UIR“ subtab: „Measurement (S)“and „Measurement (P)“ parameters).

� Make sure that UI regulation and monitoring have been deactivatedfor the respective welds.

� If the resistance characteristics are not generated on a componentbut a sheet strip, the following applies:• The resistance characteristic of the first spot on a sheet must not

be used to define or determine a reference curve.

• Leave a clearance of at least approx. 20 mm between the spotwelds.



� Do not use welds with expulsion to define a reference curve.



7.3.2 Defining the resistance characteristic as reference curve

1. Observe the requirements referred to in Section 7.3.1 on page 41.

2. Choose which BOS window is best suited to define the referencecurve for your project.

• „Programming“ topic, „PSQ“ tab, „UIR reference“ subtabBasic options:

• After selection of spot name (1a) or weld timer and programnumber (1b), the corresponding last measured resistancecharacteristic can be loaded into the display (2), saved as *.ruifile (3), or defined as new reference curve of the respective program (4).

• A saved resistance characteristic can be loaded into the display(5), saved under a different name as *.rui file (3), or defined asnew reference curve (4) of the currently selected program (1b).

1a

1b

2

3

4

5Current

Voltage

Resistance

The weld timer checks the validity of reference curves while loadingthe reference curves into the controller. For validity criteria refer topage 81.



• „Diagnosis“ topic, „PSQ“ tabBasic options:• After selection of the relevant weld timer (1) and stopping the

window update (3), the last 64 measured resistance characteristics are loaded into the display via scroll bar (2) and defined asnew reference curve of the corresponding program (7). Please note: The curve shown here is merely an example andcannot be used as reference curve!

• A currently shown resistance characteristic can be examinedon the basis of the following functions:• Display of the data (6) at the current position (4a, 4b) of the

selected cursor (4)• Display of min., max. or mean value (5) between the two

cursor lines (4a, 4b).

1

3

2

7

4a

6

5

4

4b

3. If you use the BOS window in the „Diagnosis“ topic, „PSQ“ tab, (seeabove), choose the „Program“ option in the „Filter“ area (3) and indicate the program to be used for recording the data in the furthercourse.

4. Perform the test weld(s).5. Check the weld quality by means of the spot diameter and ultrasonic

measurements, if necessary. In the further course, you should onlyuse resistance characteristics of faultless welds.

6. Load the corresponding resistance characteristic into the display anddefine it as new reference curve.

The weld timer checks the validity of reference curves while loadingthe reference curves into the controller. For validity criteria refer topage 81.



UI regulation can then be activated for the respective weld. For information on this topic, refer to Section 7.4 from page 53.

7.3.3 Recording by recorder

1. Please note the requirements referred to in Section 7.3.1 on page 41.2. Choose the „Settings“ topic, „UIR setup“ tab, „Recording mode“ com

mand button (1).The „UI setup“ application (2) is started.

After starting the „UI setup“ application, the command button text (1)changes from „Recording mode“ to „Exit BOS_UI_Setup“.The „UI setup“ application can only be closed again using this command button.

1

2

3 4 5 6 7

9

8

Fig.�11: “UI setup” window: Recording by recorder

3. Use the left checkbox (Fig. 11: Position 3) to determine the weldtimers for which the recorder function is to be activated.

4. Use the checkbox in the „New recording“ columns (Fig. 11: Position7) to determine whether available recorded resistance characteristics (Fig. 11: Position 4) are to be deleted before the recording of further curves is started.

In the status area for recording (Fig. 11: position 8), the system showsyou the current program-related number of all available recordingsfor the weld timer selected on the left (blue line).



5. If needed, limit the recording to- selectable programs (Fig. 11: Position 5)- programs without active UI regulation (Fig. 11: Position 6).

6. Start recording using the „Start recording“ command button (Fig. 11:Position 9).In the status area for recording (Fig. 11: Position 8), you can observethe recording progress.

After the start of recording, the command button text (Fig. 11: Position 9) changes from „Start recording“ to „Stop recording“.

7. When the scope of recording meets your requirements, stop the current recording using the „Stop recording“ command button (Fig. 11:Position 9).

8. Close the „UI setup“ application.To do this, bring the BOS window to the foreground again and selectthe „Exit BOS_UI_Setup“ command button in the „Settings“ topic,„UIR setup“ tab.The „UI setup“ application is exited.

The system then shows you the curves recorded for a program as“pencil of curves ” (see Fig. 12:).

9. Check the weld quality by means of the spot diameter and ultrasonicmeasurements, if necessary. In the further course, you should onlyuse resistance characteristics of faultless welds.

10.Delete all curves which are not suitable to create the reference curveand then define the mean value curve (reference curve).

� Delete the welds with expulsion. For detailed information on weldswith expulsion, refer to Section 6.3 from page 31.

� Delete the curves recorded immediately after dressing. Thesecurves stand out due to their low resistance.

� Delete curves of welds, if needed, where (too high) %I correctionwas active. Please note that %I correction can be caused by active%I stepping (stepper; only relevant for KSR mode) as well as byparameter setting in the „Corrections“ topic, „Correction“ tab.

%I stepping and wear of selected (Fig. 12: Position 1) actualcurves are displayed by the system (Fig. 12: Position 5).

This work can be performed both manually and automatically:

• Manually:

Select the relevant program and the actual curve to be deleted(red) (Fig. 12: Position 1) and activate the „Delete this curve“ command button (Fig. 12: Position 2).

Having deleted all the curves not needed, use the remainingcurves to create the mean value curve (Fig. 12: Position 3). Themean value curve is displayed in red color. The black curves showthe minimal and maximal resistance characteristics.� The result isshown in Fig. 13:



1

2

3

5

4

6

Fig.�12: Deleting superfluous resistance characteristics

Fig.�13: Display of the mean value curve (reference curve)



• Automatically:

Press the „Delete + avg. curves“ command button (Fig. 12: Position 4). The „Delete + avg. curves “ window appears:

1 2

3

4

Fig.�14: „Delete and average curves“ window

Use the left checkboxes (Fig. 14: Position 1) to determine the weldtimers for which the automatic procedure is to be activated.Limit the automatic procedure to selectable programs (Fig. 14: Position 2) and/or certain criteria (Fig. 14: Position 3).

Effect of activated checkboxes:

• „Expulsion“:Deleting welds with detected expulsion.

• „Current correction factor“:Deleting welds with %I corrections greater than the specifiedlimit value.

• „Count“:Deleting welds with electrode wear exceeding the specified limits.

• „Create avg. curve“:Define the corresponding program-specific mean value curves(reference curves) from the remaining curves.

Click on the „Continue“ command button to start the automaticprocedure. If „Create avg. curve“ is active, the reference curves generated aresaved in the standard path for UI setup (can be set using the configuration tool) under the „Reference_Curves“ directory sorted as*.rui files according to weld timer designations.

The system saves information on deleted curves and generatedmean value curves in a log file which you can view using the „Detailinfo“ command button (Fig. 14: Position 4).



11.Transfer the mean value curve (reference curve) to the weld timer.This action can also be performed manually or automatically.

NOTICE

Transfer of an unsuitable resistance characteristic

If an unsuitable resistance characteristic is declared as referencecurve, this may lead to frequent/major interference or even to unsatisfactory welding results.

� Make sure before you start the transfer that a suitable curve hasbeen selected. A selected curve is displayed in red color.

� Never trigger the transfer without reason.

• Manually:

Select the relevant program (Fig. 15: Position 1) or the relevantprogram and the required actual curve (Fig. 12: Position 1) andpress the „Reference schedule --> Timer“ (Fig. 15: Position 2)command button.

1

2

3

Fig.�15: Transferring the mean value curve to the WT

� Please note the subsequent completion message.The transferred curve can only be used as reference curve if declared as „valid“ by the weld timer:



The weld timer checks the validity of reference curves while loading the reference curves into the controller. For validity criteriarefer to page 81.

When the transferred curve has been declared as valid, you mayactivate the UI regulation for this weld.How to activate the UI regulation is described in Section 7.4 frompage 53.

Programs with valid reference curves are easily recognized in the„Overview“ topic using the „Curve valid“ option button. Refer to Section 9.1.1 from page 81.

• Automatically:Press the „Ref. curves (PC) -> SST“ command button (Fig. 15: Position 3 or Fig. 12: Position 6). The „Ref. curves (PC) -> SST“ appears:

1 2

3 4 5 6

Fig.�16: „Ref. curves (PC) -> SST“ window

Use the left checkboxes (Fig. 16: Position 1) to determine the WTsfor which the automatic procedure is to be activated.Limit the automatic procedure to selectable programs (Fig. 16: Position 2), if necessary.

Press the „Ref. curves (PC) -> SST“ command button (Fig. 16: Position 5) to make a variety of settings for writing of the curves („Settings for writing curves“ window is opened automatically) and thenstart the automatic procedure.

If you want to open the „Settings for writing curves“ window only,press the „Settings“ command button (Fig. 16: Position 3).



1

2

3

Fig.�17: „Settings for writing curves“ window

Effect of activated checkboxes (Fig. 17: Area 1):

• „Special programs (excluded)“:Transfer of mean value curves (reference curves) of certainprograms can be prevented here.This is useful e.�g. for dressing and calibration programs.

• „Regulation on“:If activated, the system switches on the program-specific UIregulation („Programming“ topic, „PSQ“ tab, „UIR“ subtab,„Regulation (P)“ parameter) after transfer of a valid referencecurve.

• „Monitoring on“:If activated, the system switches on the UI specific monitoring(„Programming“ topic, „PSQ“ tab, „UIR“ subtab „Monitoring (P)“parameter) after transfer of a valid reference curve.

• „Reference values for UIR monitoring“:If activated, the system determines reference values for theprogram-specific UI monitoring from the mean value curve (reference curve) generated and also writes the values into theweld timer after transfer of a valid reference curve.The values are provided under the „Programming“ topic, „PSQ“tab, „UIR monitoring“ subtab in the „Reference“ input fields.

• „Reference value UIP=100“:If activated, the system writes the reference value „100“ for the„UIR“ monitoring variable into the weld timer in case of programs where the reference curve is generated on the basis ofmean value calculation.

• „Tolerance“:If activated, the system displays additional input options



(Fig. 17: Area 2) for definition of tolerances and to switch therespective UI monitoring variables on/off (Fig. 17: Position 3).The settings made here are written into the weld timer as program-specific UI monitoring data after transfer of a valid reference curve.The values are provided under the „Programming“ topic, „PSQ“tab, „UIR monitoring“ subtab in the corresponding input fields.

For detailed information on UI monitoring, please refer to Section 8from page 63.

� Please note the completion message after transfer.Transferred curves can only be used as reference curves if theyhave been declared as „valid“ by the weld timer.Whether that was the case is saved in a log file which you can viewusing the „Detail info“ command button (Fig. 16: Position 4).

The criteria for validity of reference curves are described onpage 81.

When a transferred curve has been declared as valid, UI regulation is possible for the respective weld and already activated automatically depending on the „Regulation on“ checkbox (Fig. 17:Area 1). How to activate UI regulation manually is described in Section 7.4from page 53.

Programs with valid reference curves are easily recognized in the„Overview“ topic using the „Curve valid“ option button. Refer to Section 9.1.1 from page 81.



7.4 Activating UI regulation

If a valid reference curve was generated for a program (refer to Section 7.3 from page 41), activation of UI regulation is possible for this program.

1. Select the „UIR“ subtab in the „Programming“ topic, „PSQ“ tab.

2. Choose the respective spot name (1a) or weld timer and programnumber (1b).

3. Activate the UI regulation.To do this, you must -�in addition to the existence of a valid referencecurve�- set the „Measurement (S)“, „Measurement (P)“, „Regulation(S)“ and „Regulation (P)“ parameters to „On“ (2).

The programs working with active UI regulation are easily recognizable in the „Overview“ topic using the „Regulation active“ option button. Refer to Section 9.1.1 from page 81.

Detailed information on the effects of the available parameters isprovided in the BOS online help.The most important parameters are described in Section 7.4.1 frompage 54.

For information on the PSQ status display (3), refer to Section 9.1.2page 82.

1a

3

1b

2 2

2 2



7.4.1 Description of the most important UI parameters

Detailed information on the effects of the available parameters is alsoprovided in the BOS online help.

Measurement (�S)

OFF: the UI measurement logic is deactivated for all programs of theweld timer - irrespective of the Measurement�(P) parameter.

ON: The UI measurement logic is activated for all programs of the weldtimer and can be switched on/off program-specifically using the Measurement (P) parameter.

Expulsion current control

Determines in combination with Expulsion decay time and Detection ofexpulsions how the controller reacts to a detected expulsion. The controller changes the current at the time of expulsion by the programmedpercentage (+/- values are possible).

Measurement �(P)

OFF: the UI measurement logic is deactivated for the program displayed.

ON: the UI measurement logic is activated for the program displayed -if it has been released via timer-globally Measurement (S). An activemeasurement logic is the requirement for• generating reference curves,



• displaying the current/voltage/resistance characteristic,• UI regulation and• UI monitoring.

Detection of expulsions

It is used in connection with the Expulsion decay time parameter to setthe expulsion detection and defines a resistance deviation (in %). As soon as a resistance value deviates from the previous measuredvalue by this % value, the system checks whether this also applies to allsubsequent resistance values in the "Expulsion decay time". If that is the case, an expulsion event is initiated with a response according to the "Expulsion current control" parameter.

Weld counter

Number of spot welds carried out with the displayed program since thelast ”Delete”.Can be reset to 0 using the ”Delete (P)” command button.

Expulsion counter

Number of expulsions which occurred during the welding process withthe displayed program since the last ”Delete”.Can be reset to 0 using the ”Delete (P)” command button.

The ratio of expulsion counter to weld counter is used to assess theexpulsion-related problems of this spot.

Regulation (S)

OFF: UI regulation is deactivated for all programs of the timer - irrespective of the Regulation�(P) parameter. All spots are welded in PHA or KSR mode depending on the timer programming.

ON: UI regulation is activated for all programs of the timer and can beswitched on/off program-specifically using the Regulation�(P) parameter.

Regulation (P)

OFF: UI regulation is deactivated for the displayed program.The spot is welded in PHA or KSR mode depending on the timer programming.

ON: UI regulation is activated for the program displayed provided thatall of the following conditions are met:• Measurement�(S) and Measurement�(P) must be switched on• Regulation (S) and Regulation (P) must be switched on• the reference curve for the program displayed must be present and

valid (refer to PSQ symbol on page 82).

Beginning of regulation

The value indicated is calculated automatically by the system when itgenerates the reference curve for the current program.It shows when the system changes from coupling regulation to meltingregulation (also refer to Section 6.1).The value should ideally be in the first half of the total weld time. Otherwise the system will have less time for compensation of interfering variables.



Start manual regulation

Influences the mode of functioning of the automatic system for determination of the time for changing between coupling and melting regulation.OFF: The starting time for the search of the time to change

between coupling and melting regulation is the beginning ofMainWLD.

ON: The starting time for the search of the time to changebetween coupling and melting regulation can be determinedmanually via the „Start regulation “parameter.

By activating „Start manual regulation“, a quality improvement can beachieved for certain weld schedules, if it is possible to reduce the duration of the coupling regulation and increase the duration of the meltingregulation. Therefore it makes no sense to move the start time to after the beginningof MainWLD (in the direction end of MainWLD) using the „Start regulation“ parameter. Moving it to an earlier point in time, however, may be useful if the relativeresistance maximum lies within a PreWLD or UST.

Whether the change time between coupling and melting regulationhas shifted as a result of the manual entry of the starting time can bechecked after a new analysis of the reference curve (refer to Startregulation) via „Beginning of regulation“:

• If the relative resistance maximum lies within a PreWLD, the valuein „Beginning of regulation“ is smaller than the starting time ofMainWLD.

• If the relative resistance maximum lies within a UST, the value inthe „Beginning of regulation“ is smaller than the time <Startingtime of MainWLD> + <Duration of UST>.

Start regulation

Defines the starting time for the search of the change time betweencoupling and melting regulation (also refer to „Start manual regulation“). The reference curve is thereby analyzed again, the value for „Beginningof regulation“ is defined again, and the validity is checked.

The criteria for validity of reference curves are described on page 81.

Max. nominal current increase

Limits the maximum permitted current increase during the meltingphase. The value refers to the current component of the program-specific reference curve.

Max. nominal current decrease

Limits the maximum permitted current decrease during the meltingphase.The value refers to the current component of the program-specific reference curve.

Weld time prolongation

OFF: a prolongation of the weld time is not permitted.

ON: the UI controller may prolong the weld time automatically if required. The Max. weld time prolongation parameter acts as limit value.



Max. weld time prolongation

The specified % value refers to the length of the program-specific reference curve. If Weld time prolongation is activated, the fault message "PSQ max.weld time exceeded" is generated when the maximum permitted weldtime is exceeded.

Expulsion decay time

Serves in connection with the Detection of expulsions parameter for setting of expulsion detection. It defines a number of consecutive resistance measurements performed in a 1 ms cycle.As soon as a resistance value deviates from the previous measuredvalue by the % value defined via "Detection of expulsions", the systemchecks whether this also applies to all subsequent resistance values inthe "Expulsion decay time". If that is the case, an expulsion event is initiated with a response according to the Expulsion current control parameter.

Waiting time for contact

Defines the maximum period of time (in ms) in which the contactbetween electrode and sheet must be established.

Measurement L2 mains

If, in the case of timers

• equipped with a separate XQR control card and

• designed for L2 supply networks (500 to 690 VAC),

disturbances influence the voltage measurement logic too strongly, thevoltage measurement logic can be adjusted accordingly.

OFF Standard voltage measurement logic

ON Voltage measurement logic for L2 supply networks

The parameter is only available if the timer supports voltage measurement logic for L2 supply networks and the function "Enablevoltage measurement method for L2 network" has been activated inthe BOS configuration tool under the "General" tab (value: ON).

NOTICE

Arbitrary change-over of the voltage measurement logic for L2 supply networks

New reference curves may have to be created!The voltage measurement logic used influences the voltage measurement signal and thus also the calculated resistance characteristic of the weld. Reference curves, which are created in connection with a voltage measurement logic therefore always have to becreated again when the timer is changed over to a different voltagemeasurement logic. Otherwise the resulting controller interventionscan lead to welding faults and damages to the workpiece.

� Therefore never switch the voltage measurement logic for L2 supply networks over arbitrarily!



Monitoring (S)

OFF: UI monitoring is deactivated for all programs of the timer - irrespective of the Monitoring (P) parameter.

ON: UI monitoring is activated for all programs of the timer and can beswitched on/off program-specifically using the Monitoring (P) parameter.

Monitoring (P)

OFF: UI monitoring is deactivated for the program displayed.

ON: UI monitoring is activated for the program displayed provided thatall of the following conditions are met:

• Measurement�(S) and Measurement�(P) must be switched on

• At least one of the monitoring functions under Programming / PSQ /UIR monitoring must be switched on.



7.4.2 Special features for activated UI regulation

• Basic parametrization not permitted

Changes of program-specific basic parameters influencing performance are not permitted during activated UI regulation. UI regulationmust be deactivated for the relevant weld in order to change the basicparametrization.

How to deactivate the UI functionality for this purpose is described inSection 7.5 from page 61.

• Updating the basic parametrization

The UI controller ensures good welding quality within the scope of itsphysical options even after construction-related changes of the welding task (e.�g. after changes in material or sheet thickness). Intervention by the user is therefore normally not needed in case of merelytemporary changes for test purposes.If construction-related changes of a permanent nature are to be introduced to production, we recommend adjustment of the relevant basicparameters as soon as possible.

How to switch off the UI functionality for this purpose, is described inSection 7.5 from page 61.

• Function „Reweld“

If the „Reweld“ program-specific function is activated („Programming“ topic, „Schedule“ tab, „Reweld“ parameter), the respectivewelding program is repeated automatically exactly once in the programmed regulation mode (KSR or UI regulation), if• the current monitoring is activated and responds with the error

messages „Low current” or “No current”• a UI monitoring is active and responds with the error messages „...

too low" or „No ... available”• the timer detects the error "Termination of weld / no primary cur

rent (99-134)"• the timer detects overstepping of the programmed "max. waiting

time for contact"• the timer detects an error in the voltage measuring circuit.

This way it may be possible that fewer user interventions are requiredin the case of errors which occur sporadically.

� If a weld fault occurs again during the repetition, it is mandatory toacknowledge the fault.

The activation of the function "Reweld" or the measured values resulting from the reweld are shown in the weld current log and (if UImeasurement is active) also in the UIR histogram display. The UIR histogram display also provides the option to highlight rewelds in color.

• Function „%I stepping“ (stepper)

In UI control mode, a possibly programmed %I stepping will be ignored because the UI controller interprets tip wear as interfering variable.After UI regulation is switched off (switching over to KSR mode)however, a matching %I stepping will be necessary in most cases tocompensate the effects of electrode wear!



• %I correction

%I stepping („Correction“ topic, „Correction“ tab) is also effective in UIcontrol mode and can be used to influence the current value.



7.5 Deactivating the UI regulation

In certain cases it may be necessary to deactivate the UI functionality:

• In case of a defect in the voltage measuring leads.In this case, UI measurement, UI regulation and UI monitoring are notpossible anymore because the actual voltage as one of the fundamental calculation variables is not transmitted to the timer anymore.To maintain production of plant for the moment, temporary global deactivation of the whole UI functionality is necessary. The (KSR) basicparametrization becomes effective again.

• For adjustment of the (KSR) basic parametrization after a permanentconstruction-related change in the welding task.

The programs working with active UI regulation are easily recognizable in the „Overview“ topic using the „Regulation active“ option button. Refer to Section 9.1.1 from page 81.

Procedure after a defect in the voltage measuring leads


2. Select the respective Timer (1).

3. Set the „Measurement (S)“, „Regulation (S)“ and „Monitoring (S)“parameters to „Off“ (2).

1

2 2 2OffOff

Now the basic parametrization and programmed %I stepping, if any, areeffective again for all welds of the respective timer.



Procedure for adjustment of the basic parametrization after a permanent, construction-related change


2. Choose the respective spot designation (1a) or timer and programnumber (1b).

3. Set the „Regulation (P)“ parameter to „Off“ (2).

1a

1b

2

Now the basic parametrization and programmed %I stepping, if any, areeffective again for the respective weld.


UI monitoring parameters

8 UI monitoring parameters

8.1 Available parameters

For optimum quality monitoring, the "Programming" topic, "PSQ" tab,"UIR monitoring" subtab, "Monitoring parameters" parameter group (1)can be used to monitor numerous variables (2) of a welding process(multiple selection possible):

The following can be set for each variable:• Monitoring on/off• Reference value (is always 100% for PSF)• Upper/lower tolerance band ("upper" not applicable to PSF)• Conditional tolerance band

(acts in the "upper" or "lower" direction depending on the monitoringvariable)

• Interpretation of the tolerance specifications as absolute or % values

2

2

1

3

Fig.�18: Parametrization of UI monitoring

Parametrization of the UI monitoring (e.g. for initial commissioning)is also possible in the course of commissioning of UI regulation together with the automatic transmission of mean value curves (reference curves) to the timer. Refer to step 11. from page 49.



Depending on the welding task, it may be useful to monitor differentvariables (Fig.18: Position 2). Therefore monitoring can be turned on/off separately program-specifically for each weld and for each parameter to be monitored.

If UIR monitoring is activated for at least one of the variables, theparameters for "normal" current monitoring in the "Programming"topic, "Schedule" tab are ignored. It is nevertheless recommendedto update the "normal" current monitoring values because the system uses the parameter setting for "normal" current monitoring afterdeactivation of the UI monitoring.

If the weld current log was activated in the "Timer reference" window atBOS 6000 start, the system stores all monitoring results in the logmemory where they are available for statistic evaluations.

Parameter "Reference"

Serves as programmed value for monitoring the individual parametersand quantities. The measured/actual value is compared with and interpreted on the basis of this programmed value:

• Based on the tolerance limits "Upper tolerance band" or "Lower tolerance band" as "good" or "bad".

• Based on the "Upper/lower conditional tolerance band" and "Reweldfactor" (Fig.18: Position 3) for "continuous decrease".

Unacceptable actual values result in a warning or fault message if therelevant monitoring function has been activated.

Parameter „Abs. tol. bands“

OFF: Input values for definition of the tolerance limits are interpreted as% values related to the reference value.

ON: Input values for definition of the tolerance limits are interpreted asdeviation of the absolute value from the reference value.

Whether the input fields are displayed is dependent on the firmwareversion of the respective weld timer and the settings of the user administration.

Parameter „Upper tolerance band“

Specifies the maximum permitted upper tolerance (according to the„Abs. tol. bands“ parameter). Actual values above this tolerance limitgenerate the message type ”… too large”.

The parameter value must be greater than/equal to the "Upper conditional tolerance band".

As a result of the process, the monitoring parameters PSF, UIP andFQF may be clearly lower after dressing for the first welds than in normal production conditions.„Dynamic tolerance band adjustment“ is available so that the tolerance bands do not have to be increased in these cases (refer to Section 8.5 from page 76).

If the function „Reweld“ has been activated, the respective weldingprogram will be repeated automatically once under certain conditions. Please refer to page 59.



Parameter "Lower tolerance band"

Specifies the maximum permitted lower tolerance (according to the„Abs. tol. bands“ parameter). Actual values below this tolerance limitgenerate the message type ”… too low".

The parameter value must be greater than/equal to the "Lower conditional tolerance band".


If the function „Reweld“ has been activated, the respective weldingprogram will be repeated automatically once under certain conditions. Please refer to page 59.

Parameter "Lower conditional tolerance band"

Defines the upper limit of the lower conditional tolerance range (according to the „Abs. tol. bands“ parameter). The lower limit is defined by the"Lower tolerance band" parameter.This parameter is used in connection with the Reweld factor in order todetermine “creeping” faults of the system that cause a gradual yet continuous decline in actual values.

The parameter must be smaller than/equal to the "Lower toleranceband".


Parameter "Upper conditional tolerance band"

Specifies the lower limit of the upper conditional tolerance range (according to the „Abs. tol. bands“ parameter). The upper limit is defined bythe "Upper tolerance band" parameter.This parameter is used in connection with the Reweld factor in order todetermine “creeping” faults of the system that cause a gradual yet continuous “decline” in actual values.

The parameter value must be smaller than/equal to the "Upper tolerance band".




Parameter "Reweld factor"

The program-specific reweld factor defines how many consecutivewelds of the relevant program are permitted in the conditional toleranceband.If this value is exceeded, the weld timer will output the message type"Repeated error ...".

Example: Lower conditional tolerance band, reweld factor = 3

Upper tol. band (in %)

Lower tol. band (in %)

L. cond. tol. band

: Actual value. x: No. of reweld

Reference

„Repeated error ...”

12 3 41 2 3

0

lower conditionaltolerance band 0

NOK

NOK

OK

The internal program-specific counter for the reweld factor is incremented if a random monitored variable ranges within one of the conditionaltolerance bands.As soon as an actual value is in the ok range and at the same outsidethe conditional tolerance bands, the internal program-specific counteris reset.



8.2 Information on the use of monitoring variables

Current:

• Narrow limit values are not useful because the controller compensates interfering variables e.g. by changes in current.

• Observe the "Max. nominal current decrease" and "increase" (referto page 56).

PHA (pulse width):

• Narrow limit values are not useful because the pulse width must bechangeable (current) to compensate interfering variables.

• The upper tolerance band can be used to achieve plant protectionand prevent high, damaging %I values.

Weld time:

• Narrow lower tolerances possible because the weld time does notfall below the weld time of the reference welding.

• The upper tolerance limit should be defined large enough so that"normal" weld current prolongations (e.g. caused by electrode wear)do not lead to an activation of the monitoring function.

Energy:

As for weld time.

Process stability (PSF):

The process stability indicates that the current weld and the referenceweld coincide (value range of PSF: 0% ... 100%).

• A single deviation from the typical PSF value is often an indication forexpulsion and/or edge welds.

• Constant deviations are an indication for interfering variables (e.g.electrode wear, differing materials, varying sheet quality, etc.).

• The PSF does not serve to detect bad welding quality because theinterfering variables are normally compensated by the controller.

• Welding time prolongations deteriorate the PSF

• Manual guns mostly have a worse PSF because welding differentsheet thicknesses actually also constitutes an interfering variable(deviation from the learned condition).

The process stability can only be calculated/displayed if a valid reference curve exists for the respective weld.

Examples:

PSF = 100% the welding process coincides with the reference weld.

PSF = 70% the welding process has changed by 30% compared tothe reference weld.



Process quality (UIP):

The process quality results from the exact analysis of the resistancecurve. UIP is calculated, inter alia, on the basis of:

• Initial and final resistance

• Minimum and maximum values

• Gradients and trends.

If the dynamics of the resistance curve are only weak, the system compares certain data with the reference curve and includes these results inthe calculation of the UIP.

• By internal weighting of all variables mentioned, the UIP value canbe used to make a statement with regard to the change in weldingquality.

• In case of manual guns, the range of values obtained by the use ofvarying materials and sheet thicknesses is fairly broad and thereforea statement regarding quality is difficult.

The process quality can only be calculated/displayed if a valid reference curve exists for the respective weld.

Force Quality Factor (FQF):

Value for assessment of the welding quality derived from the force characteristic during a weld. For detailed information, refer to Section 14 from page 115.



8.3 Procedure for commissioning

Parametrization of the UI monitoring (e.g. for initial commissioning)is also possible in the course of commissioning of UI regulation together with the automatic transmission of mean value curves (reference curves) to the timer. Refer to step 11. from page 49.

1. Select the subtab "UIR" in the "Programming" topic, "PSQ" tab.

2. Select the corresponding spot name (1a) or timer and program number (1b).

3. Make sure that UI measurement has been activated for the respective weld (2).

4. Parametrize the "Monitoring (S)" and "Monitoring (P)" parameterswith the value "On" (3).

2

2

3

3

4

1a

1b

Based on the PSQ status display (4), the system shows you the program-related current status of UI monitoring.For explanations on the PSQ symbol, refer to page 82.



5. Select the "Programming" topic, "PSQ" tab, "UIR monitoring" subtaband make sure that the "Monitoring" parameter (1) is set to the value"Off" for all monitoring variables to be commissioned.

1

1

6. Make sure that all conditions for subsequent test welds (e.g. type ofregulation) are representative for the welding task monitored. For all test welds, the optimization of the relevant basis parametrization (refer to Section 7.2 from page 34) and generation of the relevant reference curves, if applicable, (refer to section 7.3 frompage 41) must be completed. For commissioning of the monitoring variables PSF and UIP, corresponding valid reference curves are necessary and monitoring variable FQF must be activated (refer to Section 14 from page 115).

7. Make sure that the weld current log has been activated in the "Timerreference" window.This is needed for functioning of the UIR histogram display (instep 9.).

8. Perform several test welds before the actual welding task.

9. Select the "Programming" topic, "PSQ" tab, "UIR histogram" subtab.This display shows the characteristic of the value measured for allmonitored variables of a program.

Detailed information on the operation and display options of the histogram are provided in the BOS online help.



10.Use the option button (below the UIR histogram display) to chooseone of the monitoring variables available.

1

2

2

3

4 56

7

8

Fig.�19: UIR histogram display

• In order to see the number (4), the actual value defined (5) and thetime of expulsion, if applicable, of a certain weld, the cursor line(3) can be moved to the left and right by drag and drop.Parallel to this, the display fields „Com.“ and „Actual“ display thereference value set for this weld, the actual value defined and,above the diagram (6), additional information on the weld.

• Welds without expulsion are displayed by the system as “�“, and welds with expulsion as „x“.

• The values programmed at the time of welding for reference andtolerance limits are displayed by the system as lines (1 and 2).

• The system displays the tolerance bands programmed presentlywith different diagram background colors (7 and 8):

• white OK range (7)

• light grey: conditional tolerance range

• grey: NOK range (8)

11.Move the cursor to a weld which is typical of the selected monitoredvariable.

12.Press the "Act. -> Com." command button. The "Act. -> Com." dialog window appears:

13.In this dialog, use the "UIR monitoring parameters" selection list tochoose which actual value at the cursor position is to be taken overas reference value of the respective UI monitoring variable. If youwish to take over the actual values of all UI monitoring variables asnew reference values, select the "<All>" entry.Press the "OK" command button to take over the values.



14.Select the "Programming" topic, "PSQ" tab, "UIR monitoring" subtaband check the reference values taken over previously, if necessary.

15.If needed, adjust the tolerances of the monitored variables andcheck the effect on the tolerance ranges by means of the UI histogram display.

16.Make sure that normal, production-related fluctuations of the actualvalues do not range outside the tolerance limits.


17.If parametrization of the UI monitoring variables satisfies your requirements, set the "Monitoring" parameters of the respective variables to the value "On".

The PSQ status display in the "Programming" topic, "PSQ" tab, "UIR"subtab now have to display the activated condition of UIR monitoring forthe relevant programs.For explanations on the PSQ symbol, refer to page 82.

The programs with active UI monitoring are easy to see in the "Overview" topic using the "Monitoring active" option button. Refer to Section 9.1.1 from page 81.

8.4 Deactivating UI monitoring

NOTICE

Arbitrary or inadvertent deactivation of the UI regulation

If UI monitoring is deactivated partly or fully, unsatisfactory welding results may no longer be detected or not be detected with thenecessary accuracy.

� Do not deactivate an active UI monitoring without good reason.

In certain cases it may be necessary to deactivate UI monitoring:

In case of a defect in the voltage measuring lines

In this case, UI measurement, UI regulation and UI monitoring are notpossible anymore because the actual voltage as one of the basic calculation variables is no longer signalled to the timer.To keep the system in production at least provisionally, the timer-globaltemporary deactivation of the entire UI functionality is necessary. As aresult, the (KSR) basis parametrization and the "normal" current monitoring in the "Programming" topic, "Schedule" tab become effectiveagain.

The procedure for this case is described on page 61.



For test purposes (alternative 1)

Every currently active UI monitoring of a weld is to be deactivatedjointly.In the following procedures, separate settings for individual UI monitoring variables are not changed. The configuration for a weld active priorto deactivation can thus be restored again quickly later.

Procedure:

1. Select the subtab "UIR" in the "Programming" topic, "PSQ" tab.


3. Set the "Monitoring (P)" parameter to "Off" (2).

1a

1b

2



For test purposes (alternative 2)

Individual UI monitoring of a weld is to be deactivated temporarily orpermanently.

Procedure:

1. Select the "UIR monitoring" subtab in the "Programming" topic,"PSQ" tab.


3. Set the "Monitoring" parameter of the relevant UI monitoring variableto "Off" (2).

1a

1b

2

2



Notes:



8.5 Dynamic tolerance band adjustment

The function

• allows the automatic influencing of the reference value in dependence on the current wear counter status.

• can be activated separately for the variables PSQ, UIR and FQF

• can be switched on/off program-specifically

• only becomes active after being switched on if the UI monitoring ofthe corresponding monitoring variable is active.

After dressing, the PSF, FQF or UIP value may be clearly lower for thefirst welds for process-related reasons than in normal production conditions. This is caused by the smaller electrical resistance of freshlydressed electrode tips. Since narrow static tolerance bands would lead to an error especially inthis production phase, they are frequently enlarged „accordingly“ inpractice. They are then too large for subsequent production phases,however.This problem is solved by the dynamic tolerance band adjustment.

8.5.1 Relevant parameters

The relevant parameters are provided in the „Programming“ topic,„PSQ“ tab, „UIR monitoring“ subtab.

The following can be adjusted for the variables PSF, UIP and FQF(FQF: only in connection with the „Force monitoring“ option) and UIP:

• Dyn. tol. band:Switching on/off dynamic tolerance band adjustment for the corresponding activated monitoring variable.

• Max. tol. red.: Absolute value by which the reference value is reduced in case of awear counter status of „1“.

• Till wear:Wear counter status from which the reference value is no longer influenced by the dynamic tolerance band adjustment.

If the wear counter lies between „1“ and „Till wear“, the system willperform a linear interpolation of the reference value.





8.5.2 Determination of the required parametrization

We recommend to first activate UI monitoring according to Section 8.3 from page 69.

1. Select the „Programming“ topic, „PSQ“ tab, „UIR histogram“ subtab.This display shows the characteristic of the value measured for allmonitored variables of a program.

For basic information on the histogram, refer to page 71. Detailed information on the operation and display options of the histogram are provided in the BOS online help.

2. Select:• the respective spot designation or• weld timer and program numberin order to display the measurements of the desired weld.

3. Use the option button (below the UIR histogram display) to select thedesired parameter from the available monitoring parameters (PSF,UIP, FQF).

4. Move the cursor line (1) using drag and drop to the measured valuewith the smallest wear value (2).Then subtract the actual value (3) from the reference value (4; is always 100% for PSF) and enter the result, with a safety margin, if necessary, i(n this example the safety margin is 2) into the parameterfield „Max. tol. red.“ (5).

1

2

4

5

77



5. Move the cursor line (1) to the right to the first measured value wherethe process band becomes stable again (2).Enter the corresponding wear value (3) into the „Till wear“ parameterfield (4).

3

2

4

1

5

77

Determination of the required parameters is now completed.

The dynamic tolerance band adjustment can then be switched on bysetting the „Dyn. tol. band“ parameter (5) to the value „ON“.

The dynamic tolerance band adjustment will only become activeafter it has been switched on if the UI monitoring of the corresponding monitoring parameter is active.

The influence of an active dynamic tolerance band adjustment on thereference value and the tolerance limits in the histogram will be visibleafter the next tip change, at the latest:




For quick information

9 For quick information

The present section presents various options on how to obtain a quickoverview of conditions or values related to the UI functionality.

9.1 Status of the UI functionality

9.1.1 "Overview" topic, "Overview" tab

1

2

3

The following information is provided:• The programs for which UI measurement is activated/deactivated.• The programs that work in UI regulation.• Which UI monitoring variables are active in which programs.• For which programs do valid reference curves exist.

The weld timer interprets a reference curve as „valid“ if• „Beginning of regulation“ (refer to Section 7.4.1 from page 54) lies

at least 20% before the end of MainWLD and

• the resistance drop of „Beginning of regulation“ until the end ofMainWLD is at least 4 MicroOhm.

• under the „Programming“ topic, „PSQ“ tab, „UIR“ subtab, the„Special combinations“ parameter is set to „Thin sheet“ (refer toSection 13 from page 111).

• under the „Programming“ topic, „PSQ“ tab, „UIR“ subtab, the„Mode“ is set to „Precision-spot welding“.

• The programs for which gun resistance compensation is active.

When are reference curves valid?



1. Select the "Overview" topic, "Overview" tab.

2. Select the desired timer (1) and the corresponding option button (2).Programs where the function is active or the relevant condition is"true", are displayed with red background (3).

9.1.2 PSQ status display

Based on the PSQ status display, the system indicates important program-related statuses related to UI regulation and monitoring.

It is visible in several topics of the BOS and always refers to the status

• of the program displayed ("Programming" topic, "PSQ" tab, "UIR" subtab; "Programming"topic, "Schedule" / "Seq. Pg.2" / "Stepper" tabs;"Correction" topic, "Correction" tab),

• of the curve characteristic shown("Diagnosis" topic, "PSQ" tab),

• of the actual values determined for UI monitoring variables("Diagnosis" topic, "Last weld" tab), or

• the weld marked by the cursor ("Programming" topic, "PSQ" tab, UIR histogram" subtab).

PSQ

yellow: not activegreen: active

yellow: no/invalid reference curvewhite: valid reference curvegrey: no statement on validity of the

reference curve possiblered: function of the UI controller is

blocked because of an abortedcalibrationStatus

UI regulationStatus UI monitoring

Fig.�20: PSQ status display

When calibration has been aborted, the function of the UI controlleris blocked. It can be reset by right-clicking on the red PSQ field.



9.2 Actual values determined for the last welding schedule

1. Select the "Diagnosis" topic, "Last weld" tab.

2. Select the desired timer (1).In the areas 2 and 3 you will find the data for the last weld.

1

2

3

The display will be automatically refreshed by every new sequence.

All values are also stored in the logbook memory and can be trackedlater weld by weld.

Slightly different values displayed for „Mean PHA“, current and weldtime between the indications for MainWLD and PSQ result from thefact that the weld time can be measured with or without trail current.

Display of the PSQ actual values (3) is only possible if UI measurement was active during the schedule of the respective weld ("Programming" topic, "PSQ" tab, "UIR" subtab: "Measurement (S)" and"Measurement (P)" parameters).

Process quality and UIP can only be calculated/displayed if a validreference curve exists for the respective weld.The corresponding active option is needed for FQF (refer to Section 14 from page 115).



9.3 Curve characteristics of the last 64 welds of a timer

1. Select the "Diagnosis" topic, "PSQ" tab.

2. Select the desired timer (1).

3. Stop updating of the display (3).

4. Use the scroll bar (2) to select the curve characteristic of interest.

5. Move both cursors by drag and drop to display the data (6) at the current position (4a, 4b) of the selected cursor (4) or the min., max. oraverage (mean) value AV (5) between the two cursor lines.

1

3

2

7

4a

6

5

4

4b

A display of curve characteristics is only possible if UI measurementwas active during the schedule of the respective weld ("Programming" topic, "PSQ" tab, "UIR" subtab: "Measurement (S)" and"Measurement (P)" parameters).



9.4 Spot/expulsion overview

Informs you about all the expulsions detected in the defined time window (1a, 1b). With the parallel display of expulsion (2) and total welds(3) it is quickly visible which welds require optimization in terms of expulsion reduction.

The display only takes into account the timers for which the weld current log was activated in the period of time under review (in the"Timer reference" window).

1. Select the "Functions" / "Spot/expulsion overview" menu path. The"Spot/expulsion overview" window appears.

2. Define the information-relevant period of time (1a, 1b).

3. Use the "Show all spots including zero expulsion" checkbox to selectthe required scope of display.

4. Press the "Update" command button.

1a 1b

2 3

5. Press the "Cancel" command button to close the window.



9.5 Display of the PSF, UIP and FQF process variables

The „Process stability” (PSF), „UIP” or „FQF“ process values can be selected here in order to make up a list of their current status for all programs of the selected timer. This offers the user a quick overview of the status of quality monitoringof the selected weld timer.

The display only takes into account the programs for which the UImonitoring has been activated for the respective process variableand at least 1 fault was detected.

1. Select the "Overview" topic, "Overview" tab.

2. Select the desired weld timer (1) and the corresponding option button (2).

1

2

Meaning of table columns

Any column can be sorted by clicking on the heading of the desiredcolumn.

Spot Name

If no spot name exists, the text "There is no spot reference !" will be displayed.A spot name on a colored background indicates that correspondingspots exist for this program. By placing the cursor on the spot name inthis case, the corresponding spots will be shown in the tool tip text.



Prg.

Number of the program used for welding the spot.

A click on a program number opens the "Programming" topic, "PSQ"tab, "UIR histogram" subtab with the display of the respective program-specific monitoring variable.

n.i.o. (i.e. not OK, faulty)

Number of welds for this program that are faulty, not OK.

Total

Displays all welds for this program since the „Reset“ button was hit forthe last time.

Display ”Status - max: %

Percentage display of the faulty (n.i.o.) welds in relation to the totalnumber of welds.

green: in the course of the last welds, the "Accepted" repetitionfactor (refer to page 94) was exceeded, and at the sametime the ratio of not OK welds to total welds is smaller thanthe ”Status - max” parameter (refer to next page).

yellow: in the course of the last welds, the "Accepted" repetitionfactor (refer to page 94) was not yet exceeded, and at thesame time the ratio of not OK welds to total welds is smallerthan the ”Status - max” parameter (refer to next page).

red: the ratio of not OK welds to total welds is greater than/equalto "Status - max" parameter (refer to next page).

Examples:

3 out of 70 welds have exceeded a tolerance band. The bar is green because the "Accepted" repetition factor was exceeded in the course of the last welds (refer to page 94) and the ratio ofnot OK welds to total welds is smaller than the "Status - max" parameter(in this example 1%).

4 out of 81 welds have exceeded a tolerance band. The bar is yellow because the "Accepted" repetition factor (refer topage 94) was not yet exceeded in the course of the last welds and theratio of not OK welds to total welds is at the same time smaller than the"Status - max" parameter (in this example 1%).

4 out of 71 welds have exceeded a tolerance band. The bar is red because the ratio of not OK welds to total welds is greaterthan/equal to the "Status - max" parameter (in this example 1%).



”Status max. %” parameter

Defines the ratio of faulty welds (welds that are not OK) to the total number of welds (in %) that turns the “Status - max. %" display red.

"Update” command button

Serves to read the current data and to refresh the display. The displaywill be automatically refreshed when the window is called up.

“Reset" command button

Resets the error display of the process values. Counting the faulty spotsand the total spots is restarted.No sequence errors are reset!



9.6 UIR process overview

Provides an overview of the status of the connected weld timers withrespect to• PSF process stability• UIP• Q Stop• Conditional spot repetition• FQF

The "Q Stop" function does not exist in all weld timers. For a description of the "Q Stop" function refer to Sect. 10 from page 91.

The display has been sorted so that the worst value is displayed first.Double-clicking on a weld timer name will open the "Overview" window containing the respective UIR process variable and provides anoverview of the process status of the individual programs of the weldtimer in question.

Green bar

Percentage display of all valid (= executed with active UI regulation)programs of a weld timer which have not dropped below a "lower conditional tolerance band" and "lower tolerance band" or exceeded an "upper conditional tolerance band" and "upper tolerance band".

Yellow bar

Percentage display of all valid (= executed with active UI regulation)programs of a weld timer which have not dropped below a "lower conditional tolerance band" and "lower tolerance band" or exceeded an "upper conditional tolerance band" and "upper tolerance band" during thelast welds.

Red bar

Percentage display of all valid programs of a weld timer includingQ Stop errors.

“Update” command button

Update is used to refresh the display.

“Reset" command button

Resets the status display of the process values. Counting of the corresponding UI monitoring errors is restarted.No sequence errors are reset!



Notes:


Q Stop (Quality Stop)

10 Q Stop (Quality Stop)

The function requires

• Weld timer firmware version with Q Stop

• With PSI 6x00 only: UI controller hardware (PSQ6000 XQR) withfirmware version -404 or higher

• active voltage measurement (UI measurement switched on)

• active UI monitoring for process stability (PSF), process quality (UIP)or force (FQF).

Using the "Q Stop" function, the weld timer can detect any problems occurring in the PSF, UIP or FQF parameters, which can be signalled tothe operator and/or the PLC.

With the help of a program-specific, configurable supervision, it mustfirst be defined which PSF, UIP and/or FQF values are to be detected asbasically problematic by the weld timer (refer to Fig.„Configuring Q Stop“, page 93). The weld timer generally accounts foractual values within the "conditional tolerance range" of the corresponding monitored value only (refer to example in Fig. on next page). In addition, you have to define the threshold for the weld timer that hasto be exceeded in order to actually signal the problems occurred as anerror.

The following response patterns can be implemented:

• program-specific Q Stop

• component-specific Q Stop

10.1 Program-specific Q Stop

Any problematic events occurring will be considered program-specificand evaluated accordingly.For each welding program, there is a separate internal counter(= Q Stop counter program) which is automatically incremented or reset to "0" by the weld timer, depending on problematic PSF, UIP and/orFQF values.

If the program-specific Q Stop counter exceeds a configurable, program-specific reweld factor, the "Q Stop" signal will be output includingthe "Q Stop consecutive spots" (2107) error message. The "Weldingfault" output will be additionally energized.

The weld timer will reset a program-specific Q Stop counter if the following requirements are met:

• after a configurable, program-specific number of immediately consecutive faultless welds ("Accepted" repetition factor). Thus,sporadic errors do not trigger a Q Stop.

• when a Q Stop error has been reset and the next welds are acceptable. How many faultless welds are necessary for this depends onthe firmware version of the weld timer (for PSI 6xCx) or the firmwareversion of the UI controller module (for PSI 6x00):

• For firmware versions of the UI controller module smaller thanV410:1 acceptable weld



• For firmware versions of the UI controller module from V410 on:Number of acceptable welds, defined via the "Accepted repetitionfactor" parameter (refer to page 94).

If no acceptable weld is performed in the sequence after reset of aQ-stop fault, the Q stop counter will not be reset but rather continuecounting. The weld timer signals another Q-stop fault.

Example: program-specific Q Stop; reweld factor: 3

lower tolerance band

conditional tolerance band

PSF/UIP/FQFreference value

Q Stop error

Q Stop counter0 1 2 3 3 3 3 0 1 2 3 4 0

Reset Q Stop error

10.2 Component-specific Q Stop

Any problematic events occurring will be considered per componentand evaluated accordingly.An internal, non-program-specific counter is automatically incrementedby the weld timer depending on problematic PSF, UIP and/or FQF values.

If the non-program-specific Q Stop counter exceeds a configurable,global limit value, the "Q Stop" signal will be output including the "Q Stopcomponent" (2106) error message. The "Welding fault" output will be additionally energized.

The weld timer will reset the non-program-specific counter to zero if thefollowing requirements are met:

• positive edge at the "component end" input, if the weld timer isequipped with this type of input - or -

• after a definable number of welds if the "Internal end of componentactive" parameter (refer to page 94) has been parametrized withthe value "On".



10.3 Exceptions

If the PSF, UIP and/or FQF value is below the lower tolerance band, noQ Stop error will be output. Instead, an error message will be immediately signaled including the corresponding error text (e.g. "UIP toolow"), and the weld timer will be stopped. Nevertheless, the Q Stopcounter will be incremented because the value was outside the conditional tolerance band.The "Welding fault" output will be energized.

When the upper tolerance band is exceeded (only possible with UIPand FQF), the Q Stop counter will not be incremented, and the corresponding welding fault will be immediately signaled.The "Welding fault" output will be energized.

10.4 Special spots

Special spots are spots which are subject to special quality requirements. For this reason, the (program-specific) reweld factor will be setto "0" in this case. As a result, every spot welded within the conditionaltolerance band will immediately trigger a Q Stop and an error message"Q Stop special spot" (2108).

10.5 Configuration

Fig.�21: Configuring Q Stop



"Q Stop (all programs)" parameter group

Internal end of component active

Activates/deactivates the timer-internal generation of an end of component event.�Normally, it is possible in connection with "Q stop” functionality to transmit an end of component to the timer via input signal. An internal, non-program-specific counter which is incremented automatically by thetimer depending on problematic PSF, UIP and/or PSF values can thusbe reset. If no externally generated signal is available, the timer can generate thisevent itself in dependence on the "Spots in series" timer-global limitvalue.

Spots in series

Acts in connection with the "Internal end of component active" parameter and defines the number of spots after which the timer generatesan internal "End of component event". This event resets the internalcomponent-specific spot counter "Actual" (= processing of a new partbegins).

Limit value

Defines the number of consecutive welds permitted in the upper orlower conditional tolerance band. If this value is exceeded by the component-specific counter "Actual",the timer generates the "Repeated ... error" message.

Actual value

Component-specific Q Stop counter.For counter reset, refer to Sect. 10.2 on page 92

"Q Stop (program-specific)" parameter group

Limit value

Limits program-specifically the number of consecutive welds in the”conditional tolerance band”.If the program-related Q Stop counter exceeds this limit value, a Q Stoperror will occur.

Actual value

Program-specific Q Stop counter.For counter reset, refer to Sect. 10.1 on page 91.

"Accepted” repetition factor

Defines how many consecutive OK welds of a program are necessaryto reset the internal program-related counter "Actual".


Adhesive function

11 Adhesive function

The adhesive function requires• BOS 6000 version 1.30.0 and higher.

• For PSI 6x00: UI controller module (PSQ 6000 XQR) with XQR firmware version greater than/equal to V�404.

• the use of the PreWLD

• an existing shunt circuit, which heats up the material during the current flow and thus drives the adhesive out of the welding spot. Anexception are conductive adhesives, however, this function is alsouseful in connection with such materials.

An adhesive acts as an electrical insulator between the sheets. Theweld current flows off via shunts at the beginning of the welding process, and is not available to the actual spot to be welded. Depending on the kind, thickness and the viscosity of the adhesive, thetime until the adhesive is driven out by the heat generated and the weldcurrent flows through the spot to be welded, may vary to a great extent.

Since the preconfigured weld current is applied during a normal weldingschedule (normally between 7kA and 12kA), the adhesive is veryquickly driven out by the high temperature generated. Sometimes, thistakes place almost explosion-like. As the gun cannot follow this changequickly enough, the process reaction is often very vigorous, resulting insplashes and burnt spots.

Due to the effects described, it is thus not possible to ensure a constantwelding quality.

Several resistance characteristics of welds with adhesive are shownhere:

Resistance (μOhm)

7.0 kA (LV spot)

4.0 kA (adhesive)

4.0 kA (adhesive)

4.0 kA (adhesive)

7.0 kA (LV spot)

4.0 kA (adhesive)

4.0 kA (adhesive)

4.0 kA (adhesive)

4.0 kA (adhesive)

2.0 kA (adhesive)

2.0 kA (adhesive)

2.0 kA (adhesive)

Time (ms)

1

2

3

4

5

7

8

6

9

10

11

12

1112

10

9

1

2

5

6

Fig.�22: Resistance characteristics in connection with adhesive


Adhesive function

The adhesive breakthrough is indicated by the steep resistance drop inthe interval between 20ms and 40ms. This time can even be longer under production conditions.

The high resistance at the beginning of the welding schedule is undefined. When loading such a curve as a reference curve, this resistance is also part of the curve and included into control and monitoring.

Effects of the adhesive function

When the function is active, the controller defines the length of PreWLDrequired to drive the glue out and adapts itself automatically to thebreakthrough time of the adhesive. In this context, it is not importantwhat kind of adhesive (e.�g. sealing adhesive, bonding adhesive) isused. When a defined sheet/sheet contact has been reached, the actualwelding sequence starts with MainWLD. UI regulation and control areonly active in MainWLD.

Ref

Shorter contacttime because noinfluence of adhesive present

Time (ms)

Resistance (μOhm)

Resistancecurve withadhesive influence

Resistancecurve withoutadhesive influence

Contact time extensionuntil influence of adhesiveis no longer present

1

2

3

1

2

3

Fig.�23: Resistance curve with and without the influence of adhesive


Adhesive function

Ref

Shorter contacttime because noinfluence of adhesive present

Contact time extensionuntil influence of adhesiveis no longer present

Time (ms)

Current (in kA)

Current curvewith adhesiveinfluence

Current curvewithout adhesive influence

1

2

3

1 23

Fig.�24: Current curve with and without the influence of adhesive

11.1 Required parameter setting

1. Make sure that the UI measurement is active for the respective weld("Programming" topic, "PSQ" tab, "UIR" subtab: "Measurement (S)"and "Measurement (P)" parameters).

2. Make sure that UI regulation and monitoring are deactivated for therespective weld.

3. Use a prewarming current block (1st block) for the respective weld.For this purpose, program in the KSR mode as follows

• a PreWLD in the range of 50 ... 80 ms.This is to warm up the spot weld and drive out the adhesive. Nowelding should take place at this point! The actual duration of PreWLD should be sufficient to drive outthe adhesive.

• a 1.%I in the range of one-half welding current of the 2.%I.

4. Program a main current block (2nd block with MainWLD and 2.%I)for the respective weld in the KSR mode in which the actual weldingtakes place.

5. Optimize the KSR parameters (no expulsions, sufficient spot diameter, ...).

6. Create the reference curve for the weld and load it into the controller.

If the UI regulation for the respective weld is then activated, the adhesive function can be switched on/off as required (refer to Section 11.2page 98).


Adhesive function

11.2 Activation/deactivation of the adhesive function

� Make sure that all the work mentioned in Section 11.1 on page 97has been performed prior to activating the adhesive function.

NOTICE

Driving out the adhesive quickly with deactivated adhesive function

This may result in fluctuating welding quality, expulsions and burntspots!

� Do not deactivate the adhesive function without good reasonwhen UI regulation is active.

Fig.�25: Activation/deactivation of the adhesive (“Glue”) function


Static gun resistance compensation

12 Static gun resistance compensation

The function is suited for compensation of static resistance deviationsbetween initial gun (gun used to record the reference curve) and thecurrently connected gun.

Dynamic resistance deviations resulting from an electrode gun replacement can be compensated by UI regulation only and thus alsoinfluence the UI monitoring variable PSF (refer to page 67).

Effects of gun resistance compensation

The behavior of the UI controller is influenced by the resistance measured. The controller compares the current resistance curve with the respective reference curve and changes the amount of current and, ifrequired, the weld time as needed. The measured resistance characteristic not only contains contact andmaterial resistances of electrode and workpiece but also an ohmic resistance of of the gun's mechanics which is constant during the weldingschedule (= static gun resistance).

Since even guns of identical construction may have a different staticgun resistance, it is very probable that the resistance characteristic willbe influenced by a gun replacement.

If e.g. the reference curve for a weld was generated with gun 1 (initialgun) and later an identical replacement gun was connected for gun 1(with deviating gun resistance), changes of this kind without static gunresistance compensation result in a controller intervention although no"real" interference variable is present.

t

R

0

Accepted resistance characteristic with initial gunwithout UI regulation.

Accepted resistance characteristic with replacement gun without UI regulation.

Fig.�26: Deviating resistance characteristic between initial and replacementgun

In this manner the weld and the monitoring result are also influenced bythe guns used. This leads to a broader variation of the process stability(PSF) and makes interpretation of the monitoring results more difficultunnecessarily.

The UI controller can use gun resistance compensation in order to determine the difference between the gun resistance at the time the reference curve was generated and the current resistance, and include thisdifference in the control process. Two variables are required:



• "Reference gun resistance".Corresponds to the resistance of the gun which was used to generate the reference curve for a weld. It is needed to calculate the gunresistance from the reference curve of a weld.The value is program-specific because each welding program canbe assigned to any electrode number (=gun).

• „Gun resistance setting“. Resistance of the gun used currently.

To determine the required values, a short-circuit weld with new, start-dressed tips is necessary. We therefore recommend to perform thisshort-circuit weld directly after gun replacement.

Determination/transfer of the required values can be triggered automatically via input signal or manually via the "Gun resistance" window.

t

R

0

Resistance characteristic when creating a reference curve, generated e.g. with the initial gun

Gun resistance determined for the initial gun(Reference gun resistance)

Resistance characteristic when creating a reference curve, "adjusted" by the gun resistance ofthe initial gun

Gun resistance determined for the replacement gun

Resistance characteristic when creating a reference curve, "adjusted" by the gun resistance ofthe initial gun and adjusted to the gun resistanceof the replacement gun

Fig.�27: Principle of gun resistance compensation

12.1 Setting of the gun resistance compensation

1. Make sure that you are logged on to the BOS 6000 as member of theBOS weldmaster group. Otherwise you will not have access to therequired parameters and functions.

2. Make sure that UI measurement is active for the relevant short-circuit welding program of the current gun ("Programming" topic, "PSQ"tab, "UIR" subtab: "Measurement (S)" and "Measurement (P)" parameters).

3. Make sure that UI regulation is deactivated for the relevant short-circuit welding program of the current gun ("Programming" topic, "PSQ"tab, "UIR" subtab: "Regulation (P)" parameter).

4. Make sure that the last weld in the respective timer is a short-circuitweld of the current gun performed with activated UI measurementand with new, start-dressed tips. If that is not the case, perform ashort-circuit weld using the matching short-circuit welding program.



5. Select the "Programming" topic, "PSQ" and "UIR reference" tabs. Select the short-circuit program under "Program" and press the"Actual curve <-- Timer" command button. The resistance characteristic shows that is was a short-circuit weld:

Test system

78

Fig.�28: Resistance characteristic of the short-circuit weld



6. Press the "Gun resistance" command button. The "Gun resistance"window is opened:

• In the example shown, program 1 was used to perform a short-circuit weld which resulted in an actual resistance of 78 μOhm.

• The „Test gun resistance“ is „0“. This means that the gun resistance compensation has not yet been set in connection with thedisplayed gun (electrode).In these cases, the gun resistance compensation is deactivatedautomatically.

• The „Reference gun resistance“ is „0“. This means that no gunresistance compensation is active for the program displayed(here: 1).

7. Press the "Resistance --> Gun resistance" command button andconfirm the following query by pressing "Yes (Ja)".

The resistance value of the short-circuit weld is now copied to the 3fields shown.

78

78

78

• Gun resistance setting:The gun's share in the resistance characteristic valid as of now.The value is electrode-specific.



• Test gun resistance:Resistance value determined when the gun resistance compensation was activated for the first time in connection with the short-circuit weld. This value remains stored electrode-specifically inthe system even after repeated replacement of a gun and, in thecase of values > 0 in connection with the electrode-specific „upper“ and „lower“ test tolerances, it can be used as reference valuefor the plausibility check of the gun resistance of the new gun. Background: in case of identical gun mechanics, the gun resistance of the new gun should only change within certain limits. If thedeviation is too large, you are probably dealing with different guntypes.

If the measured resistance value of a new gun is outside the tolerance, the system refuses to transfer the resistance actual value tothe "Gun resistance setting" parameter (via "Resistance --> Gunresistance" command button), generates the "Resistance of gunnot valid" fault message and sets "Gun resistance setting" to 0.Gun resistance compensation is thus deactivated. The "Test gunresistance" and "Resistance monitoring reference" parametersremain unchanged.

An intended change of the "Test gun resistance", "Upper test tolerance" and "Lower test tolerance" can be transferred to the timervia the "Data --> WT" command button.

• Reference gun resistance:Gun resistance which was valid at the time when the referencecurve of the respective program (input field „program“) was created.In special cases (refer to Section 12.4 from page 107), the valuecan be overwritten with the current resistance values using the"Resistance --> Ref." command button.

• Resistance monitoring reference:The program-specific reference value defined in UI monitoring forthe "Resistance" monitoring variable.

Now the gun resistance of the respective gun (see "Electrode" field) isknown to the system and is entered automatically in the "Reference gunresistance" field for all reference curves defined subsequently when thereference curve is saved.

After setting the gun resistance compensation (refer to Section 12.1)the current gun resistance must be redefined in the following casesaccording to the procedure described in Section 12.3 from page 104:

• after a gun replacement• after replacement of a gun arm• after a position change of the voltage taps• after a pole reversal of the voltage measuring cords, unless the

PSI�6xCx timer is used.



12.2 Activating the gun resistance compensation

The gun resistance compensation becomes active for a program automatically when all the following conditions are met:• "Reference gun resistance" > 0• "Gun resistance setting" > 0

Programs with active gun resistance compensation can be identifiedin the "Overview" topic using the "Gun resistance function active" option. Refer to Section 9.1.1 from page 81.

Active compensation values (difference between „Gun resistancesetting“ and „Reference gun resistance“) are visualized in the „Diagnosis“ topic under the „PSQ“ tab:

Test system

Fig.�29: Visualization of the active gun resistance compensation value

12.3 Procedure after a gun replacement

If a gun is replaced (e.g. for maintenance purposes), the gun resistanceof the new gun (replacement gun) has to be determined.1. Make sure that you are logged on to the BOS 6000 as member of the

BOS weldmaster group. Otherwise you will not have access to therequired parameters and functions.

2. Make sure that UI measurement is active for the relevant short-circuit program of the new gun ("Programming" topic, "PSQ" tab, "UIR"subtab: "Measurement (S)" and "Measurement (P)" parameters).

3. Make sure that UI regulation is deactivated for the relevant short-circuit program of the new gun ("Programming" topic, "PSQ" tab, "UIR"subtab: "Regulation (P)" parameter).



4. Perform a short-circuit weld using the matching short-circuit weldingprogram and new, start-dressed tips.

5. Select the "Programming" topic, "PSQ" and "UIR reference" tabs. Select the short-circuit program under "Program" and press the"Actual curve <-- Timer" command button.

Test system

71

Fig.�30: Resistance characteristic of the short-circuit weld after gun replacement


78

78

78

71

78

• The short-circuit weld with the new gun led to an actual resistanceof 71 μOhm (field „Resistance“).



• The „test gun resistance“ is > 0. This means that the gun resistance compensation has already been set for the gun (electrode)shown.

• The reference gun resistance is 78 μOhm. This means that a reference gun resistance of 78 μOhm was determined when the reference curve of the program displayed (here: 1) was created.



71

78

71

71

78

Now the gun resistance of the replacement gun is known to the systemand the following applies:

• For all subsequent reference curves generated with this gun, theelectrode-specific „Gun resistance setting“ is entered into the program-specific field „Reference gun resistance“.

By taking into account the "Reference gun resistance" and "Gun resistance setting", the use of the new gun (replacement gun) has no influence on the behavior of the UI controller anymore within the scope ofthe functionality described after activation of gun resistance compensation (refer to Section 12.2 page 104).

Active compensation values (difference between „Gun resistancesetting“ and „Reference gun resistance“) are visualized in the „Diagnosis“ topic under the „PSQ“ tab.



12.4 Special cases

In connection with gun resistance compensation, special cases may bepossible:

• Reference curves are being used which were generated with UI controller version smaller than V406.

• Reference curves are being used which were generated prior to activation of gun resistance compensation.

In such cases, the gun resistance of the initial gun (Reference gun resistance) is not known to the system and the gun resistance compensation for the respective reference curves is thus not active.

Provided that the respective initial gun is still being used and its gun resistance has not changed significantly, the subsequent transfer of the„Gun resistance setting“ into the „Reference gun resistance“ parameteris possible using the „Resistance --> Ref.“ command button.

Proceed as follows:

1. Make sure that you are logged on to the BOS 6000 as member of theBOS weldmaster group. Otherwise you will not have access to therequired parameters and functions.

2. Make sure that UI measurement is active for the relevant short-circuit welding program of the current gun ("Programming" topic, "PSQ"tab, "UIR" subtab: "Measurement (S)" and "Measurement (P)" parameters).

3. Make sure that UI regulation is deactivated for the relevant short-circuit welding program of the current gun ("Programming" topic, "PSQ"tab, "UIR" subtab: "Regulation (P)" parameter).

4. Make sure that the last weld in the respective timer is a short-circuitweld of the current gun (the initial gun) performed with activated UImeasurement and with new, start-dressed tips. If that is not the case,perform a short-circuit weld using the matching short-circuit weldingprogram.

5. Select the "Programming" topic, "PSQ" and "UIR reference" tabs. Select the short-circuit program under "Program" and press the"Actual curve <-- Timer" command button.



Test system

78






78

78

78

8. Press the "Resistance --> Ref." command button.The "Resistance --> Reference curve" window is opened:

78

9. Choose whether the "Gun resistance setting" is to be taken over tothe "Reference gun resistance" parameter for all programs workingwith the gun (electrode) shown or only for the program shown. Acknowledge by pressing the "OK" command button.

78

78

78

78

By taking into account the "Reference gun resistance" and "Gun resistance setting", the later use of a new gun (replacement gun) has no influence on the behavior of the UI controller anymore within the scope ofthe functionality described after activation of gun resistance compensation (refer to Section 12.2 page 104).



Notes:


Thin-sheet function

13 Thin-sheet function

The “thin-sheet“ function optimizes the behavior of the UI controller inconnection with welded joints where each sheet involved is thinner than1 mm.

Welds of this type often have the following properties:

• Low resistance dynamics.Thus it is definitely possible - especially in case of connections withzinc coatings - that there is no or no stable and reproducible resistance reduction in spite of good spot quality.

• Frequent sticking of electrode tips after dressing when the power input is too high.

• Strong variation of current and UIP values.The quality of information about e.g. the UIP monitoring result istherefore considerably impaired.

• Narrow welding window.Spot growth cannot be significantly influenced by time extension.

We recommend the use of the thin-sheet function when

• resistance characteristics within a dressing cycle - in spite of goodspot quality - show very low dynamics or even a resistance increase.

• current and UIP values of corresponding thin joints vary strongly.

Effects of the thin-sheet function

The thin-sheet function activates a regulation algorithm which was optimized specifically for thin-sheet connections and feeds energy to thespot weld as early as possible.

Please pay attention to the following:

• Avoid the "Slope" function as far as possible in connection with thin-sheet welds.

• If a Slope is indispensable, the controller will start its "thin-sheet"strategy only after the Slope.

• Without Slope, the controller starts its thin-sheet strategy at the beginning of MainWLD.

• The weld time prolongation which can be influenced by the controlleris automatically limited to 40% of the total weld time in case of activethin-sheet function. If this is not sufficient for the controller, the schedule is completedwithout fault message.





Thin-sheet function


4. Optimize the KSR parameters (no expulsions, sufficient spot diameter, ...).


13.2 Activating/deactivating the thin-sheet function



3. Set the „Regulation (P)“ parameter (2) to the value „ON“.

4. In the „Special combinations“ parameter (3) select the „Thin sheet“setting in order to activate the function. The thin-sheet functionality can be blocked again setting „Standard“.

The thin-sheet function requires active UI regulation (4) for the respective weld.

1b

1a

2

3

4

Fig.�31: Activating/deactivating the thin-sheet function


Thin-sheet function

If „Thin sheet“ has been set for the „Special combinations“ parameter, the system will always set the status to „valid“ when loading areference curve.

13.3 Thinsheet with stepper

With controller version 414.00 the function „Thin sheet with stepper“ isavailable as setting for the parameter „Special combinations“.

Thin sheet with stepper adapt internal control algorithms specially forwelding of thinsheet (sheet thickness < 1mm) .

If in CCR mode was programmed with stepper function, it will be takenfor UI controlling and UI monitoring too.

Additional the current limitation will be set internal to 0 %.

The parameterized value in the GUI works not (parameter „Max. current reduction“ is not editable).

Fig.�32: Setting Thin sheet with stepper


Thin-sheet function

Notes:


Force monitoring

14 Force monitoring

The force monitoring requires

• weld timers with TriCore-CPU (PSI 6xCx types) and

• alternatively

• a force sensor with analog feedback signal mounted and wired onthe gun arm correctly, or

• an electrode gun control which is able to transmit the force actualvalue with sufficient accuracy and speed to the weld timer as analog or digital signal.

For connection of an analog feedback signal, a timer type with forcefeedback option on X9 (terminals 4 and 5) is necessary.To feed in a digital feedback signal, a timer type with matching inputsin the I/O field or integrated servogun function is necessary.Information on whether your unit supports the respective feedbackoption is provided in the type-specific supplement of the operatinginstructions.

Information on the wiring of an analog feedback signal is provided inthe operating instructions "PSI 6xxx: Weld timer with medium-frequency inverter" (no. 1070080028) in Section "Electrode force feedback".

• "Force monitoring" option on the License Memory Card

• Active UI monitoring to the variable "FQF" (Force Quality Factor) forthe respective weld.

Effects of the "Force monitoring" function

The "Force monitoring" function allows the analysis of the force actingon the electrodes in the course of a weld.

The force characteristic can be visualized using the BOS user interface, e.�g. under the "Diagnosis" topic, "PSQ" tab.

Due to the thermal expansion during the weld time, the material is"pressed" against the electrodes. This leads to an increase of the actualforce measured. You can thus draw conclusions about the thermal and mechanical processes taking place during the welding process and derive an assessment of the welding quality.

F [kN] or I [kA]

t

FQFmonitoring

SQZ WLD HLD

CurrentForce

Fig.�33: Impact of thermal expansion on the actual force


Force monitoring

Interpretation of the force characteristics

The figures below show several force characteristics of welds withoutfaults.

All force characteristics were recorded under ideal conditions. Mostcharacteristics obtained under production conditions are much moredifficult to interpret as a consequence of process disturbances orelectrode gun properties.

All characteristics are based on the same sheet combination where thecurrent was increased in 500�A steps from 4 to 11 kA and the otherparameters have remained identical:

Force [N]

Time [ms]

12345

78

6

910111213

1514

1

2

3

4

5

7

8

6

9

101112

13

1514

13

Fig.�34: Examples of force characteristics

• In case of low currents, the material between the electrodes is notheated sufficiently and therefore expands only little.This results in very flat curve characteristics (see lower diagramcurve; current range 4 to 6 kA).

• As current increases, material heating generates a growing counterforce against the electrodes.This leads to increasingly steep slopes at the beginning of the forcecharacteristic.

• At 9.5 and 10 kA (curves 12 and 13), the resulting force characteristicfirst shows a steep slope, then the force characteristic drops againslowly. This drop is caused by the electrodes sinking in. The bestweld was obtained at 9.5 kA.

• The last two curves at 10.5 and 11 kA (curves 14 and 15) drop abruptly after a very steep slope. These are expulsion welds.


Force monitoring

14.1 Required parameter setting1. Adjust the parameters in the "Programming" topic, "PSQ" tab,

"Force" subtab to the application used.

The tab is only displayed when the "Force monitoring" option (License Memory Card) is activated.

Breite: wie SeiteHöhe: Inhalt

Fig.�35: "Programming" topic, "PSQ" tab, "UIR Electrode" subtab

"Interface force input" parameter:

None:No force feedback. The Force monitoring function is not used.

Analog on:Use of an external force sensor. The force actual value is signalled tothe timer via X9 (terminals 4 and 5) as analog signal (0 - 10 VDC).

Servo gun:The force actual value is signalled to the timer digitally.

"Polarity input signal" parameter:

NEG_POL / POS_POL:Allows a change of the input signal polarity without rewiring.

"Force calibration value" parameter:

Defines how the timer should convert the actual analog voltage intoforce. Example: Input value "1.5" -> 1V is equivalent to a force of 1.5 kN


Force monitoring

"Force offset" parameter:

Allows compensation of a constant offset voltage at the analog input.Example: Input value "200" -> force actual value = measured value +200 N

"Selection reset signal" parameter:

In order to inform a connected force sensor when force measurement should be active, the timer uses the OR function to link

• the status of an enable signal for force measurement generatedinternally (set with Program start and reset after HLD)

• with the status of the digital "Operate force sensor" input (externalenable for force measurement).

The result of linking both signals is reported at the "Operate signal"timer output signal (X9 terminal 1; 0 V or 10 V).

Using the "Selection reset signal" parameter, the logic of the "Operate signal" output signal can be set according to the requirements ofthe used force sensor:

Off:The "Operate signal" output signal is not used.

Pos:10 V at the "Operate signal" output signal shows that force measurement should be active.

Neg:0 V at the "Operate signal" output signal shows that force measurement should be active.


3. Make sure that a valid reference curve exists for the respective weld.

4. Make sure that UI monitoring is active for the respective weld ("Programming" topic, "PSQ" tab, "UIR" subtab: "Monitoring (S)" and"Monitoring (P)" parameters).


Force monitoring

5. Parametrize the required tolerance data of the UI monitoring for the"FQF" variable ("Programming" topic, "PSQ" tab, "UIR" monitoring"subtab.)

The parameter block is only displayed when the "Force monitoring"option (License Memory Card) is active.

Fig.�36: Parametrization of the tolerance data for force monitoring


Force monitoring

14.2 Activation/deactivation of the force monitoring

� Make sure that all the work mentioned in Section 14.1 from page 117has been performed prior to activating Force monitoring.

Activating:Set the "Monitoring" parameter of the FQF variable to the "On" value.

Deactivating:Set the "Monitoring" parameter of the FQF variable to the "Off" value.

Fig.�37: Activation/deactivation of the force monitoring


Force monitoring

14.3 Force monitoring in measuring loop check (with UIR V414)

With active force monitoring the system check, if the programmed forceis in the range between Meas. loop force treshold above and below.Refer to BOS Programming PSQ -> UIR ( with BOS Version 1.45.1).

The parameter are only with active license „Force monitoring“ andonly for timer with „function Force Meas. loop check“ available.

Fig.�38: Parameter Force monitoring in measuring loop check

The force monitoring in measuring loop check provide the following error messages for undercutting or exceeding of the force treshold:


Force monitoring

Fig.�39: Message electrode force not reached

Fig.�40: Message electrode force exceeded


The „hot-staking“ mode

15 The „hot-staking“ mode

The functionality of this operating mode optimizes the behavior of the UIcontroller in the case of hot staking.

Hot staking is used for welding tasks in connection with e.�g. collectorsand electronic components. E.�g. the ends of varnish-insulated wiresare placed in a copper link which is then bent around the wire or severalwires during the welding sequence.

The welding process during hot staking is characterized by the following features:

• The delicacy of the workpiece results in very short welding periods.

• The welding electrodes have direct contact to the copper link but notto the wire.

• The varnish insulation of the wire has to be removed sufficiently wellduring the welding process to ensure fault-free contact between thecopper link and the end of the wire.

Effect of the „hot-staking“ mode

• The internal monitoring for the reporting of problematic resistancecharacteristics (triggered e.�g. by electrode contact errors) and necessary abortion of a weld is adapted specifically to the hot-stakingsituation.

• The controller interconnection for current adjustment is adaptedspecifically to the hot-staking situation.

• The melting phase (refer to page 26) is started early after the start ofMainWLD for reasons related to the process. Its starting time is dependent on the programmed welding profile - if the „Start manualregulation“ parameter is set to OFF („Programming“ topic, „PSQ“tab, „UIR“ subtab, „Regulation“ parameter group). The following applies:

• MainWLD without slope: 10 ms after the start of MainWLD

• MainWLD with slope: 5 ms after the end of UST


1. Make sure that UI measurement is active for the respective weld(„Programming“ topic, „PSQ“ tab, „UIR“ subtab: „Measurement (S)“and „Measurement (P)“ parameters).



4. Optimize the KSR parameters (sufficient rigidity, ...).



The „hot-staking“ mode

15.2 Switching the „hot-staking“ mode on/off



3. Set the „Mode“ parameter (2) to the value „Fine spot“.

4. In the „Mode version“ parameter (3) choose the „Hot staking“ settingin order to activate hot staking.The hot-staking functionality is blocked again using the „Steel“ setting.

„Hot staking“ requires active UI regulation (4) to become active forthe respective weld.

1a

1b

2 3

4

Fig.�41: Switching the „hot-staking“ mode on/off

If the „Mode version“ parameter is set to „Hot staking“, the system willalways set its status to „valid“ when a reference curve is loaded.


Sheet Thickness Combination (STC)

16 Sheet Thickness Combination (STC)

The STC functionality (Sheet Thickness Combination) allows - in contrast to the "program-related" reference curve calculation (for procedure, refer to Section 7.3.3 from page 45) - a "sheet-thickness related"reference curve calculation.

For this purpose, the timer collects curve characteristics of welds in adirectory configured using the configuration tool and structured according to timer and STC identification, where the common feature is not aprogram number but a sheet-thickness identification (STC identification).

Thus from the curve group recorded for a defined STC identification onecurve can be selected which serves as reference curve for the corresponding STC identification.Advantage: a sheet-thickness-related reference curve can be used forall programs used to weld the same material/thickness combination.

16.1 Using the STC function

1. Please note all instructions given in section 7.3.1 on page 41.

2. Make sure that the "STC teach mode" parameter is set to "Yes" in theBOS configuration tool under "General attributes". It activates the STC functionality.

3. Make sure that the subsequent "Comment column for STC value" isparametrized correctly.It defines which column in the BOS spot reference table contains theSTC identification (sheet thickness identification) which is mandatory for the STC function.

4. Make sure that the "STC Setup path" in the BOS configuration toolunder "Export / Import" is parametrized according to your requirements. The system stores *.stc files generated in the course of the STCfunctionality in this path in a structured manner.

5. Extend the information in the BOS spot reference table by correctSTC identifications (column "STC").Welds to be performed on the same material with the same sheetthickness are given the same STC identification. Also transmit a changed spot reference to the timers involved, if necessary.

6. In the "Setup" (Attributes) topic open the "STC Setup" tab and activate the "Recording mode..." command button. The "STC Setup" window is opened.

7. Select the relevant timer using the checkbox. If you do not wish to continue to use curves already recorded, activate the "New recoding" checkbox in the relevant line. Then activate the "Start recording" command button and weld thedesired sheet thickness combinations. In the right-hand part of the window, the system will show you thenumber of curves recorded for the timer selected on the left-handside, sorted according to program numbers (if the "Show details ..."checkbox is active).

Ensuring prerequisites

Teach curves


Sheet Thickness Combination (STC)

8. When all necessary welds have been executed, stop the recording.

9. Activate the "Exit STC teach" command button in the BOS main window. The "STC Setup" window is closed.

10.Choose the "Actual" STC curve mode. The recorded curves are displayed.

11.Select the desired STC identification.

12.Choose the curve desired for the current STC identification via the"Program" and "Actual curve" input fields and activate the "-->PC"command button.The current curve is sorted accordingly in the preset directory andstored as "reference curve candidate" (*.stc). If you wish to collect several "reference curve candidates", repeatthe present step.

13.Repeat the actions from step 10. for all further required STC identifications.

Selection and loading procedure are possible both manually and automatically. Use the automated option if many reference curves need tobe generated and copied to the controller.

14.Choose the "Reference" STC curve mode. The declared "reference curve candidates" are displayed.

15.Select the desired STC identification.

16.Use the "Program" and "Reference curves" input fields to select the"reference curve candidate" wanted for the current STC curve.

Manual loading to the controller:

17.Activate the "Active Ref. Curve ->SST" command button. The currently selected "reference curve candidate" can now betaken over into the timer as reference curve for the correspondingprograms.

Automatic loading to the controller:

18.Activate the "Select start reference" command button. The currently selected "reference curve candidate" is stored in the„STC_Reference“ directory sorted according to STC identification as*.stc file with the "SETUP_" name prefix.

19.Activate the "Ref. Curves (PC) --> SST" command button. All stc files with the prefix "SETUP_" sorted according to the STCidentification in the „STC_Reference“ directory can now be takenover into the selected timers as reference curve for the corresponding programs.

Create „reference curve candidates”

Select „reference curve candidates“ and copy them to the

timer


List of tables

17 List of tables

Table�1: Necessary and supplementary documents 5. . . . . . . . . . . . . . . . . . . . . . . . . . Table�2: Example for the structure of a safety instruction 6. . . . . . . . . . . . . . . . . . . . . Table�3: Danger classes according to ANSI Z535.6 7. . . . . . . . . . . . . . . . . . . . . . . . . . Table�4: Examples for classification of safety instructions 7. . . . . . . . . . . . . . . . . . . . . Table�5: Icons used 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table�6: Designations 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table�7: Basic welding parameters 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table�8: Abbreviations and definitions 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Notes:


List of figures

18 List of figures

Fig.�1: Voltage tapping 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�2: Controller Software Version 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�3: Mode Aluminium/Steel electrode specific 24. . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�4: Example: Current, voltage and resistance characteristic 25. . . . . . . . . . . . . . Fig.�5: Resistance characteristic of an undisturbed weld 26. . . . . . . . . . . . . . . . . . . . Fig.�6: Correct weld with preliminary impulse 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�7: Resistance characteristic of welds with an adhesive 30. . . . . . . . . . . . . . . . . . Fig.�8: Resistance characteristic with expulsion at 105 ms 31. . . . . . . . . . . . . . . . . . Fig.�9: Example: Force build-up during the squeeze time 36. . . . . . . . . . . . . . . . . . . . Fig.�10: Example: Resistance characteristic with appropriate and insufficient SQZ 37Fig.�11: “UI setup” window: Recording by recorder 45. . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�12: Deleting superfluous resistance characteristics 47. . . . . . . . . . . . . . . . . . . . . . Fig.�13: Display of the mean value curve (reference curve) 47. . . . . . . . . . . . . . . . . . . Fig.�14: „Delete and average curves“ window 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�15: Transferring the mean value curve to the WT 49. . . . . . . . . . . . . . . . . . . . . . . Fig.�16: „Ref. curves (PC) -> SST“ window 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�17: „Settings for writing curves“ window 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�18: Parametrization of UI monitoring 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�19: UIR histogram display 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�20: PSQ status display 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�21: Configuring Q Stop 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�22: Resistance characteristics in connection with adhesive 95. . . . . . . . . . . . . . . Fig.�23: Resistance curve with and without the influence of adhesive 96. . . . . . . . . . Fig.�24: Current curve with and without the influence of adhesive 97. . . . . . . . . . . . . Fig.�25: Activation/deactivation of the adhesive (“Glue”) function 98. . . . . . . . . . . . . . Fig.�26: Deviating resistance characteristic between initial and replacement gun 99Fig.�27: Principle of gun resistance compensation 100. . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�28: Resistance characteristic of the short-circuit weld 101. . . . . . . . . . . . . . . . . . . . Fig.�29: Visualization of the active gun resistance compensation value 104. . . . . . . . Fig.�30: Resistance characteristic of the short-circuit weld after gun replacement 105Fig.�31: Activating/deactivating the thin-sheet function 112. . . . . . . . . . . . . . . . . . . . . . . Fig.�32: Setting Thin sheet with stepper 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�33: Impact of thermal expansion on the actual force 115. . . . . . . . . . . . . . . . . . . . . Fig.�34: Examples of force characteristics 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�35: "Programming" topic, "PSQ" tab, "UIR Electrode" subtab 117. . . . . . . . . . . . . Fig.�36: Parametrization of the tolerance data for force monitoring 119. . . . . . . . . . . . Fig.�37: Activation/deactivation of the force monitoring 120. . . . . . . . . . . . . . . . . . . . . . . Fig.�38: Parameter Force monitoring in measuring loop check 121. . . . . . . . . . . . . . . . Fig.�39: Message electrode force not reached 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�40: Message electrode force exceeded 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig.�41: Switching the „hot-staking“ mode on/off 124. . . . . . . . . . . . . . . . . . . . . . . . . . . .


Notes:


Abbreviations

19 Abbreviations

Table�8: Abbreviations and definitions

Abbreviation Meaning

%I General abbreviation for heat. May be specified in %I (scale values) or kAScale values (%I) With thyristor power units: Measure for the electrical phasevalue.For MF inverters: Measure for the pulse width.

AC Alternating current.

BOS Bedienoberfläche Schweissen (Graphical User Interface(GUI) for welding)

BQR User interface for U/I controller

CAN Controller Area Network; data bus

CT Cool time Time between the current impulses/blocks (1., 2., 3. CT)

Cyc Cycles. Refer to P.

daN Dekanewton. 1 daN = 10 N

DC Direct current.

dimmed The relevant object or its text is shown in grey color. In thiscondition, the relevant functionality is inhibited, or cannotbe activated for reasons of the very system.

DST Downslope time. Time in which the %I decreases until the end of theMainWLD.

ELMO Electromotive.

EMC Electromagnetic compatibility

EOS End of Sequence. Refer to WC.

ESD Electrostatic discharge. Abbreviation for all names that are related to electrostaticdischarge. e.g. ESD protection, ESD hazards, ESD-sensitive components.

FPO Freely programmable output. Is not offered for all timers.

FQF Force Quality Factor.Value for the welding quality, derived from the characteristic of the counterforce to the electrodes during a weld.

HLD Hold time. Time after the last weld time in which the parts to be welded can cool down.

HSA Main switch trip.

Ignition Ignition: Firing pulses for triggering the power unit are switched onand off

IMP Number of impulses. Impulses forming the MainWLD.

IP Internet Protocol

kA Kiloampere (amount of current)


Abbreviations

MeaningAbbreviation

kN Kilonewton (force)

KSR Constant-current regulation. Keeps the current in the welding circuit constant.

KUR Constant-voltage regulation Compensates line voltage fluctuations.

LT Power unit (thyristor or inverter)

MF Medium Frequency

ms Milliseconds.

NBS Mains load limitation control Monitors and influences the mains load.

NWI Post-warming pulse.

OFF Off Time. Time between two spot welds in which the solenoid valveis not driven. Relevant for Repeat mode only.

Option button Round object on the user interface for toggling a functionon/off.

P Cycles (mains cycles)With a line frequency of 50 Hz: 1 P -> 20 ms.With a line frequency of 60 Hz: 1 P -> 16.6 ms

PE Protective Earth. PE conductor.

PG Programming terminal/welding computer

PHA Phase angle

PLC Programmable Logic Controller

Post-heat Post-heating time, also referred to as PstWLD or 3.WLD

Pre-heat Pre-heating time, also referred to as PreWLD or 1.WLD

PreWLD Refer to Pre-heat.

PSF Process stability.Value for the consistency between the current resistancecharacteristic and the resistance characteristic of the reference curve.

PSG Transformer-rectifier unit for PSI types.Medium-frequency transformer 1000 Hz

PSI Programmable weld timer with inverter.

PST Programmable weld timer with thyristor power unit.

PstWLD Refer to Post-heat.

Radio button

Refer to "Option button".

REPEAT Repeat mode. Operating mode for manually operated systems.

RO Relay output

SINGLE Single spot operating mode. For automatic and manual systems

Slope Current increase. Current increases/decreases from an initial to a final heatvalue.

Solenoid Solenoid valve. Drives the gun cylinders for closing the electrodes


Abbreviations

MeaningAbbreviation

SQZ Squeeze time. Time that runs before the weld time. The electrodessqueeze the parts to be welded together.

STC Sheet Thickness Combination.Function which can be used to generate sheetthicknessrelated reference curves instead of programrelatedreference curves.

Stepper %I stepping in order to compensate for electrode wear

TCP Transmission Control Protocol.TCP controls the way in which data is exchanged betweencomputers. It is a link-oriented, packet-switching transportprotocol and belongs to the range of Internet protocols(IP).

Temp. Temperature.

Tool tip Explanatory text. Appears when the mouse pointer remains on an inputfield/object for a moment.

ÜK Monitoring contact e.g. for monitoring the pressure inside the cylinder (thatcloses the electrodes) or monitoring of the electrode position (e.g. “gun closed”)

UIP Process quality.Value for the welding quality, derived from the resistancecharacteristic of the current weld.

UIR UI control

UST Upslope time Time in which the %I increases from the beginning of theMainWLD.

WC Weld complete contact. This signal is output when the schedule has been completed.

WLD Weld time A distinction is made between PreWLD (pre-heating timeor 1.WLD), MainWLD (main weld time or 2.WLD), andPstWLD (post-heating time or 3.WLD). All 3 weld times can be programmed separately in terms ofduration and %I.Impulses and slope values can only be programmed forthe MainWLD.

WT Weld timer. Weld timer, also referred to as resistance weld timer orsimply as timer.


Abbreviations

Notes:


Index

20 Index

%%I correction, 60%I stepping, 59

AAbbreviations, 131Abs. tol. bands, 64AC, 131Adhesive, 30Adhesive function, 95

BBeginning of regulation, 55BOS, 8

CCable for voltage measurement, 21Characteristic of a resistance curve, 26Commissioning, 33Compensation of the gun resistance, 99Conditional tolerance band, 65Coupling phase, 26

DDamage to products, 11Damage to property, 11DC, 131Designations, 8Detection of expulsions, 55Down slope (DST), 29Dyn. tol. band, 76Dynamic tolerance band adjustment, 76

EELMO, 131EMC, 131EOS, 131ESD, 131Expulsion, 31Expulsion counter, 55Expulsion current control, 54Expulsion decay time, 57Expulsion overview, 85Expulsion symbol, 31

FFirmware modifications, 22Force monitoring, 115Force Quality Factor (FQF), 68FQF, 68, 115

GGun resistance compensation, 99Gun resistance setting, 102

HHeating phase, 26Histogram display, 71

Hot staking, 123HSA (main switch trip), 131

IIcons, 8Insulating materials, 30

KKSR, 132KUR, 132

LL2 Mains (measurement), 57Lower conditional tolerance band, 65Lower tolerance band, 65

MMax. nominal current decrease, 56Max. nominal current increase, 56Max. tol. red., 76Max. weld time prolongation, 57Measurement (P), 54Measurement (S), 54Measurement L2 mains, 57MF, 132Micro SD memory card, 16Monitoring (P), 58Monitoring (S), 58Multiple impulse welds, 28

NNBS, 132

OOFF, 132

PPG, 8, 132PLC, 8, 132Preliminary impulse, welds with a, 28Process overview UIR, 89Process quality (UIP), 68Process stability (PSF), 67PSF, 67, 132PSG, 8, 132PSI, 8, 132PSQ 6000 XQR, 16, 18PSQ 6000XQR, 20PSQ status display, 82PST, 8, 132

QQ Stop

component-specific, 92program-specific, 91

RReference (UI monitoring), 64Reference curves, definition "validity", 81


Index

Reference gun resistance, 103Regulation (P), 55Regulation (S), 55Resistance characteristics, 25Resistance monitoring reference, 103Reweld, 59Reweld factor, 66

SScope of delivery, 13Sensor cable, 21Setting UI monitoring, 63Sheet Thickness Combination, 125Slope, 132Solenoid, 132Special spots, 93Spot/expulsion overview, 85Start manual regulation, 56Start regulation, 56STC, 125Stepper, 133

TTest gun resistance, 103Test tolerances, „upper“ and „lower", 103

Thin-sheet, 111Till wear, 76Time expulsion occurred, 31Tolerance band, 64Tolerance band adjustment, dynamic, 76

UUI controller module, 16, 18UI monitoring, 63UIP, 68, 133UIR, 133UIR histogram display, 71UIR process overview, 89Updating the basic parametrization, 59Upper conditional tolerance band, 65Upper tolerance band, 64Upslope (UST), welds with, 29

VValid reference curves, 81

WWaiting time for contact, 57Weld counter, 55Weld time prolongation, 56WT, 8, 133


Notes:

The Drive & Control Company

Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Tel. +49 9352 18 0 Fax +49 9352 18 8400 www.boschrexroth.com/electrics

DOK-PS6000-UIR********-AP07-EN-P

Rexroth PSI 6xxx

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