TI-PSS 2000/PSP2000 Welding-controlsPSS2000 with

TI- PSS 2000/PSP 2000

.Welding-controls PSS2000 withProgramming Modul PSP 2000

T/- PSS 2000/PSP 2000

Welding-controls PSS 2000 withProgramming Modul PSP 2000Technical Information1070078061·106 (09.89) GB

Reg. Nr. 16149-03

© 1989

Alle Rechte bei Robert Bosch GmbH,auch für den Fall von Schutzrechtsanmeldungen.

Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

Schutzgebühr 5.- DM

<§) BOSCHFlexible Automation

Table of contents

TimerModulType PSS 2000

1. Overview of the PSS 2000

TechnicallnformationP.No.3903/E

1

1. PS 2000 brochure

2. Technical informationPSS including PSP 2000

2. Front panel views of the PSS 2000

2.1 A-module

2.2 B-module

3. Technical data of the PSS 2000

4. PSP 2000

4.1 Technical data

4.2 Mechanical dimensions PSP 2000

5. Installation

5.1 Mechanical dimensions PSS 2000

6. Connect ions

6.1 Connection diagram for the A-module

6.2 Connection diagram for the B-module

6.3 Explanation of connections

6.3.1 Inputs

6.3.2 Outputs

6.3.3 Using a 24 V DC EX! power supply

6.4 Wiring suggestions

6.5 RFI suppression

6.5.1 Interference suppression

7. Maintenance

8. Extensions

The following documentation is available for extensiveinformation on the PS 2000 series:

Explanation of the system, construction, dimensions,functions and colour illustrations.P-No. 3901

Construction, dimensions, installation and connection.P-No. 3903

2

2

3

4

5

5

5

6

7

9

9

10

11

11

13

13

14

16

16

17

17

<§) BOSCHFlexible Automation



3. Technical information PSL 2000

4. Operating and programminginstructions PSP 2000

© 1986 by ROBERT BOSCH GMBH,Erbach.All rights reserved, includingthe right to submit patentapplications. We reserve allrights of use, including copyingand theright to pass on thisdocument.

Errors and technical modificationsreserved.

Construction, dimension, technical data , installation andiconnection.P-No. 3904

Handling the programming module and programming the weldingdata in accordance with the action chart.P-No. 3902

§ BOSCHFlexible Automation

1. Overview of the PSS 2000

Ihe welding ·timer. modulecontains a modern,powerful C-MOS microprocessor which performsall control tasks.

Two vers ions of the. timermodule are available.


TechnicallnformationP. No. 3903/E

Version AFor standard tJ.merswith 8 inputs, 6outputs and 8 programs.

VersionBFor timers performi ngcomplex tasks andadditional optionssuch as:

automatie heat steppingto compensate for electrode wear

- constant current regulation (KSR)to measure, regulate and monitorthe weId current

- pressure control

This module ,has 16 inputs. 10 outputs and 16 programs

1

C@ BaSCHFlexible Automation



2. Front panel views of the PSS 2000

2.1 A-module

1 Screening earth(for PSP matching plug)

2 Fuse for outputsAO; A20,medium slow-blow 1.25 A; 5 x 20 mm

3 Fuse for outputsAl; A21,medium slow-blow 1.25 A; 5 x 20 mm

4 Fuse for outputsA2; A3,medium slow-blow 1.25 A; 5 x 20 mm

5 Plug-in terminal inputs

6 Plug-in terminal outputs

7 Plug-in terminals, 4-pole,"external"

8 Knurled screw for locking themodule

9 2S-pole connector (D-connector)for the programming modulePSP 2000.Maximum cable length 5 m.

10 Green LED "mains"; onwhenmains voltage is present.

11 Green UED "ready"; indicatesoperating status.

12 Yellow LED "ignition" ignitionpulses are output to the powerunit (weId time)

13 Error reset pushbutton

14 Plug-in terminal, 10-pole,for connecting the power supplymodule PSL

15 Plug-in terminals, 6-pole,"internai"

16 Jumper fitted at the works for+ 24 V internal power supply

2

@ BOSCHFlexible Automation

2.2 B-module



1 Screening earth(for PSP mating plug)

2 Green LED "mains"; on whenmains voltage is present

3 Green LED "ready;indic~tes operatLng status

4 Yellow LED "ignition"; ignitionpulses ,are output to the powerunit (weId time)

5 Fuse for outputsAO; A20,medium slow-blow 1.25 A; 5 x 20 mm

6 Fuse for outputs Al; A21,medium slow-blow 1.25 A; 5 x 20 mm

7 Fuse for outputs A2-A7,medium slow-blow 1.6 A; 5 x 20 mm

8 Plug-in terminal inputs

9 Plug-in terminal outputs

10 Plug-in terminals, 4-pole,"external"

11 Knurled screw for locking themodule

12 Jumper fit ted at the works for+ 24 V internal power supply

13 Plug-in terminals, 6-pole,iiinternai ii

14 opening fer optional modules

15 Prepared for plug connection kSfJ..

16 25-pole conriector (D-connector)for programming modulePSP 2000.Maximum cable length 5 m.

17 Plug-in termi!"als, 1O-pole,for connecting the powersupply module PSL

18 Error reset pushbutton

19 Additional connector forfuture extensions

81---

9)---

l~W'

liI'lliflI.rfitllif1.'ur -1..."",,"' ".

ur" ..lW~ ..Iit" VI

3


3. !echnical data of the PSS 2000

4


protection standard

Operating voltage

Ambient temperature

Humidity

8/16 inputs AlB module

6/10 outputs AlB module

Indicators

- Mains

- Ready

- Ignition pulses

Pushbuttons

Connectors to programmingmodule PSP 2000

Other connectors

Data protecti on

Qptional Modules onlyfor the B-module


IP 20, suitable forinstallation in switchcabinets or housings toat least IP 54 standard

27 V AC, + lS %1 - 20 %provided by the powersupply module PSL 2000

No condensation on thecontrol is permitted (dew)

24 V DCInput signal "1" + 24 V !. 15 %

Input signal "0" - 1 V•••+ 2 Vor open

+ 24 V load carrying capacityin accordance with theconnection diagram details.RFI suppression must beinstalled when controllingrelays or contactors (see 6.S)

LED

Green *Green tYellow ~

Error reset #

2S-pole D-connectorMax. cable length S m

Push-lock terminals

!he program data are batterybuffered. Buffering timeapprox. 2 years. !he. batteryvoltage is monitored.

B-memoryBAB-2 interfaceKSRlstepperPressure control valvecontrol module

§) BOSCHRexible Automation

4. PSP 2000

4.1 Technical data

4.2 Mechanical dimensions


Protection standard

Max. ambient temperature

Humidity

Operating voltage

7-segment displays

Input keys

Connector

Program card

Weight

PSP 2000


Front panel when installed 1P 54Rear panel 1P 20

oaC ••• +60° C

Not to exceed 90%

1s supplied by timer module PSS 2000

2 decades for programm No.2 decades for parameter No.4 decades for parameter data2 decades for diagnostic1 decade for unit No.(withaut functian) .1 decade far na weId/weId

o - 9, C+ -Cursor movementData inputna weId/weIdReset keyF1 - F4 special functions

2S-pole D-connectorto the control module PSS 2000

Action chart withfunctional diagram

1.12 kg i.

265240 :1:0.1

72

r--" _~_\l~$ ~i L .J

IBOSCH @ liIil r(J7:

rf· .-F=~

t~~l!C~

·rr

t:U...~J291

305

D-sub-connector, 25-pole ~

"

bracket:

"As ~elivered" conditiori

Brackets can be shifted

5




5. Installation

The control system PS 2000 consists of the followingstandardized modules: .

1. Programming module PSP 20002. Timer module PSS 20003. Powerand. supply module PSL 2000

8I-e lI[lI WlfIPrrr-.- ].<,"--.-

li:. r ,...,..,..

PSP 2000 PSS 2000 PSL 2000

The individual modules can be installed separately ortogether in switch cabinets, control consoles or weldingmachines etc. as required.

PSP!PSS installationinstalled together Required accessories

Installation element

Cable-PSV 006

PSM-XA

PSP PSS

Installation of the PSP together with the PSS in a cabinetdoor or control panel etc.

A connecting cable (to be provided by the client) is neededfor connection to the power supply module. Maximumdistarice 7S m.

6




PSP/PSS installationInstalled separately

.. ..or

Required accessories

D- ==={]

PSV 150 (1.5 m long)

PSV 500 (5 m long)

.. ...

PSM-SAPSM-SB

PSSPSL

-ellDl

rt IIJII" r- r--

mlt._.-

r;.;,..

PSP

The programming module is installed in a maehine controlpanel or in cabinet doors ete.

The timer: module with the power unit is installed ina switch cabinet, housing ormachine body ete.

The PSP is connected to the PSS by means of a prefabricatedconneeting cable with a length of 1.5 m or a maximum lengthof 5 m. !his cable must not be installed close to interference sourc~s (eontactors, valves or motors). Avoidinstalling this cable together with high power lines.

5.1 Meehanieal dimensions

r1t

'"

- .. ~~H4

=====~

'"::::=====

~ + +

66.

SABAccessory k~t PSM

_._._~

~ 175 J_~67 ...L .~

I~SCH @. .

~-

l .0

'" '" 8'" '0

l'" '"

~ .

10-

~. .liF--- Cle~rance for .~I .J

ventilation .~I 7..... . ._-_.-

PSS 2000 A-Module

Front view

. 052115 -

Side viewRear view withoutmounting plate

Weight: 1,8 kg 7

25

o BOSCHFlexible Automation

PSS 2000 8 - module

Front view

Timer ModulType PSS 2000

IS,_+-+__~17S~__~

Ii.."l--------l,,-...l.

II·II

I·jJ"'J-..:....- .:...-l!!..--.,-

L· Clearance forventilation

---Accessor kit PSM - SA

052355 -Side view


91.5",'

-t-H4

= == == == == == =f'"'"'" = == == == == == =

+ ..-127

Rea;- view \'Tithoutmounting plate

weight including KSR - module: app. 2.9 kg

8

@> BOSCHFlexible Automation



6. Connection

6.1 Connection diagram for the A-module

6

7

4

10

1.0

1.5r o

-,-,-

IIII

I

I.IIII

L._._.jFloating contactLoad: 24 V =/ 3 A

Applicable only to operationwith internal powersupply unit

111

yy

electronic output

relay output

-valve 1 IROllA- A20 ~

~valve 2 IRQ) lA- A21 ~-

EO

RO

~ Protective earth '

+ 24 V120 mA inputs . rp'SS 2-tiS:-o' Ä1 Connecting cable to the

~--~~.~stt;ar~t~r1::::::::~~EO I power supply unit PSL must

---Start 2---------<0-1 El • be provided by the client.

--program selection ! Up to 10 m ~-program selection I Up to 75 rn ~

-Ignition on! external-prograrnrning enable-Pr.essure contact·

- Retract -------------_1+ 24 V/ 20 mA outputs

r- -~~M?!!"--- ---""valve 1 (EOllA- AOr--, _valve 2 lEOI lA- Al

~-- -Retract valve (RO) lA- A21-- -Machine contact IEOlO.1A- A3 YL __

Ir--IIIII _+ 24 V for inputsI . . .... - - Reference potential for outputs- 4

I .'.-- ... - - .. - ... ---'

* OPERATION WITH INTERNAL POWER SUPPLY UNIT: JUMPERFROM TERMINAL "SINT" TO TERMINAL "5 EXT"

AND TERMINAL "6 INT" TO TERMINAL "6 EXT"

*111 OPERATION WITH EXTERNAL POWER SUPPLY UNIT: NO

~ FROM "INT'~ TO "EXT"

External $upply of 24 V De; max. load 2 AI max.

10 % residual ripple

+ at terminal "5 Ext."

o V at terminal "6 Ext."

Note: Relays and contactors must have RFI suppression.e.g.: Free wheeling diode for small DC voltage relays

and contactors.

9




6.2. Connection diagram for the B-module

Applicable oniy to operationwi t.h internetl pÖwersupply unit

r:-',~ ~ i3 '" ,

54 .... I'§

]--.,......,...-"-1 ~ j' i8 w ,

1-""'- -1 190 l !L,_,~

+ 24 V I 20 mA

-Ignition on, external

-Pressure contact-External error reset

counter reset externa-Programminq enabled

-proqram selection-proqram selection

-program sp.lect.ion

-program selection

.-.- max. electrode life 1

_ ~BS • reqüest~'Machine contact.fEO)O,lA

-Control unit ready IEOIO,IA_----- valve 1 IROI1A

II

IIIII EO • electronic output

I RO - relay output I INT

I I 1 Floating contact

I EXT 2 P~==:;J Load, 24 V -/ 3 A

I - + 24 V for inputs 3L-Reference' potential for outputs 4 4

~'20~ ** ~ ~~l--=--=- ~

'--·T·-·~L* OPERATION WITH~ POWER SUPPLY UNIT,

,FROH TERMINAL ·5 INT' TO TERMINAL "5 EXT"

'AND TERMINAL "6 INT" TO TERMINAL "6 EXT"** OFERATION WITH~ POWER SUPPLY UNIT, !!Q~ FROH "INT" TO "EXT"

@ ... Protective earth

r;:::-;: ,.L.--::J, PSS 2037.. 81

--Start 1 ------,OItE_"OJ ,

EIlE2

~~ iE6 I'E7

E8 '

E9 IEl0 ,EIl IConnectinq cable to theE12 power Bupply ~it. PSL must

E13 . lbe provided by the client.

E14 lup tolom.0.75-NBS relea$e:----toIE15 , Up to 75 m • 1.5+24Voutputs I

OV~'V 1 Y PSlr- --- '-r' __.valve liED1 A AO

l>'<I~back pressure valve Al Y 1-_=;----,_I A2.-

A3 YA4 y'fA5

A6 YA7 YA20 -A21

External supply of 24 V oe, maxo load 2 AI maxo

10 , residual ripple

+ at te,rminal 115 Exto n

o V at terminal "6 Ext 0 "

Note: Relays and contactors must have RFI suppression.e.g.: Free Wheeling diode for small DC voltage relays

and contactors.

The connection diagrams depicted here are standard connectiondiagrams. The relevant diagrams are included with the PSS 2000contro!.

Please note: Perform connection only in accordance with theconnection diagram supplied with the control!

10


Tirner ModulType PSS 2000

TechnicallnforrnationP. No. 3903/E

6.3 General notes on connectionA-module only

6.3.1 Inputs

The notes given here describe standard connections. Pleaserefer to the relevant connection diagram of the control forits specific connections.The timer voltage is generally 24 V De.

Either a voltage of 24 V is wired from terminal Ext/3 to thecorresponding input via a contact (or electronically) or a24 V external voltage source is used, in which case the 0reference potential of this external voltage source must belinked to terminal Ext/6.

~- start 1 Start 1 always activates solenoid valve 1 (MV 1) and program0-3 depending on the selection.

[]I]+[]l:]external program selection The binary-coded program numbers are selected via inputs ofdiffering significance. The combination for each respectiveprogram number is generated on the basis of the variousinputs' significances.

Input E2 corresponds to significance 1

Input E3 corresponds to significance 2

Programs 0-3 with start 1 Input E2 Input E3

Program No. Significance 1 Significance 2

0

1 + 24 V

2 + 24 V

3 + 24 V + 24 V

Programs 4-7 with start 2 Input E2 Input E3

Program No. Significance 1 Significance 2

4

5 + 24 V

6 + 24 V

7 + 24 V + 24 V

Program selection with B-module Rere, 16 programs are selected in binary code via the inputs

LID to I EU I Program selection 1Program selection 2Program selection 4Program selec~ion 8

Important note: The program must be selected before starting!

11




Internal programselection

CID- external ignition

Cill- progrannning enable

~ - pl'essul'e contact

With timer modules PSS 2012 ••. A, PSS 2025••. A, PSS 2034••• A,PSS 2036...A, PSS 2037 ...B it is possible to select programsinternally. See Operating and Programming Instructions PSP 2000,P.-No. 3902.

Through this input, it is possible to switch the controlto "setting up" (without ignition) 01' "operation" (withignition).

Input E4 must be permanently linked to 24 V DC when not in use.

+ 24 V +[jD= with ignitionopen ~= without ignition01' 0 V(- 1 to + 2 V)

Welding data can be entered 01' altered when

• a + 24 V voltage is applied t~• no start is active 01' even during welding, in which case

new welding data become effective along with the nextsqueeze time.

The machine pressure contact acknowledges that the electrodesare closed. The squeeze time is then started.

Input E6 must be permanently linked to + 24 V DC when working

without a machine pressure contact.

r~-~: : Air valveI II , I

: : IAir--.c=:l=c><J:::;::::=~

pss

.------.1 E pe tÜKI

p Pressurecontact

IÜKJ1.-----.1.~3~.'1 .24,11=

Pressure cylin der

[E- Retract

12

This is a valve control which moves the welding gun out ofoperating position into an enlarged setting (for bulky components~

All starts are locked in this control mode.

Connect further inputs in accordance with the connectiondiagram for the respective control module.

@ BOSCHRexible Automation



[EID - NBS - release In order to start the timer it is absolutlynecessary to connect terminal E15 with +24 V=even if there is no NBS system connected.

6.3.2 Outputs These generally supply 24 V DC to the reference potential.o from terminal Ext/6.

Their load carrying capacity is 100 !DA or 1 A (refer to theconnection diagram for the load carrying capacity.

[![]- valve 1

andULJ- valve 2

Electronic output with a + 24 V DC signal during startactuation ~p to the end of the hold time.

Max. load carrying capacity 1 A.

CA2:J- retract ' Relay output24 V DC is applied for as long as input E7 is activated.Maximum load carrying capacity 1 A.

CAIJ- Machine contact (FK) The machine contact is a potential-free operatingcontact, which is meant as an ,acknowledgement toperipheral devices and which indicates the completionof the welding operation. The output has 24 V andcloses when the hold time has elapsed, and remains

, closed until the start contact is opened (onlyeffective iq single spot operation)-

In series and seam mode, + 24 V is applied for 20 msafter expiry of the hold time.

Important note: Maximum load carrying capacity 24 V;0.1 A

CA2QJ - valve 1and

CA2IJ - valve 2

Same as output Al )) but intrinsically safe relay output.

Same as output A2 )

Connect further outputs in accordance with the connectiondiagram for the respective control module.

6.3.3 EXT power supply If it is preferred to make use of an'external +24 V DC supply.the 2 bridges between terminal INT(internal) 5 + 6 to EXT (external) 5 + 6 !are to be removed (see connection diagramms 6.1 and 6.2)'

External supply: +24 V to terminal EXT 5o V to terminal EXT 6

L-._._.--i

voltage variation from20 to 28 V ripple ~ 5%

INT

The contacts 1.1 u. 1.2are potentialfree load: 24 V=/3 A

1.2.,EMERGENC1

23

4

56

Supply qualification:

I, I

I - + 7.4 V for inputsL-ReferAnce potential for outputs

+ 24V ' .1.EXT' ov----.,------J

When using an emergencyswitch to cut off all output-.ready- and firing circuitsignals- the emergency switchmust provide 2 normally closedcontacts free of potential.Contact 1 switches the +24 Vsupply, contact 2 theconnection 'INT 1/2' (seediagrarrrn) .

13


6.4 Wiring suggestions


gun:with 4 programs


PSS ...

l4

II

IIIL ..:. . .I

All diodes = type 1 N 50 60

BOSCH order No. 054/903707. . .

l.O Start l Program 0l.l Start l Program 1l.2 Start 1 Program 2l.3 Start 1 Program 3

START

PROGR.,,1 "

PROGR.,,2 "

+ 24V=

(ij) BOSeHFlexible Automation



2-gun operation with 4 programs each

START

PROGR.,,1 "

PROGR."Z"

PSS...

11I

+-24V='

GUN 1

~-------1~O- -:r - - - - - - - ---,I ----"'9------1.>1---t---9---1IIIIIIIIII'----------- .J I

IIIIIIIII

r---------- .. II + 24 V=I iII 'II I1 ""'"'---rQ--+--t--I----+-! ::>1---.J GUN 2 : II ~_+Iö_I--I--t--4-iI")l-~

II, I

~ ~_---l<JQ-t-..e____---1;>t-----o--~ START Ir

!- J [T] +- 24 V=

All diodes = type 1 N 50 60 :BoseH order No. 054/903707 '

1.0 Start 1 Program 01.1 Start 1 Program 11.2 Start 1 Program 21.3 Start 1 Program 3

2.0 Start 2 Program 42.1 Start 2 Program 52.2 Start 2 Program 62.3 Start 2 Program 7

15

@ BaSCHFlexible Automation

Timer ModulType PSS 2000


6.5 RFI suppression RFI suppression of external sources is necessary.Interference is caused by switching spikes straying into thecontrol through the eonnecting cables. The followingsuppression measures must be used to minimize commissioningtime and to optimize operational reliability:

All relay coils, miscellaneous inductances, block valves,sWitching elements and special interference sources in eloseproximity must be interferenee-suppressed.

The interference suppression element must be fitted directlyon the sotirce. If this is not possible, the suppressionelement must be installed in a connection housing as eloseas possible to the unit to be suppressed, and the connectingwires must be twisted tightly. Suppression elements,resistors, capacitors and diodes must be mechanicallyweIl supported to prevent breakage due to vibration.

6.5.1 Interference suppressionexamples

OlOOE

-"+----VI--+---i GNO

Diode, suitable for /ow-DC vo/tage re/ays

OIOC€ u. ZENEROIOOe:

+-------\,!-------I GNO

Re ·GLIEJ

-----y'I------1 Mp

R-C network for AC voltage re/ays andAC vo/tage motors

Re·GLIEO

16

DI-ZD attenuatlon network for high DC RC network for are quenehlng in thevo/tage contactors and defined de-ener- ease of inductive loadgizatlon tlmes

Interference ReBistor Capacitor Diodesource

24V 1 N 5060/ZL 12/ZL 2248 V 1 N 5060/ZL 2260 V 1 N 5060/ZL 66

125 V 229Q 5W 2.0jJF 400/600V 1 N 2069250 V 220 5W 0.5jJF 1000V 1 N 1695110 V 220Q lW 0.5jJF 400/600V220 V 220Q 5W O.ljJF 1000V440 V 220Q 5W O.ljJF 2000V

This table is given only as an example. Valve of eomponentsdepends on the load eonditions.

Note:An equivalent type can also be used instead of the diode1 N 5060 (I = 1 A, U = 100 V).

Use of a zenerdiode depends on the application, wherebythe relay' s de-energization time is defined by the zenervoltage when U + ZD = U • A higher zener-voltage producesDI opa shorter de-energization time.

~ BOSCHFlexible Automation



7. Maintenance

8. Options

The control module contains a battery to safeguard its data.This battery buHers the random access memories when the unitis switched off. It has a maximum buffering time of 2 years.

An error message showing code No. 84 (battery exhausted) isissued automatically if the buffering voltage becomes toolow.

To replace the battery, undo the knurled screws and takeout the control module.

The battery is located on the top right-hand side. Rep~ace

a defective battery by a new one.

Bosch order No. for battery: 04~ 445.

(B-modules only)

The following options are-available

B-memoryAll welding data can be additionally stored in anE-EPROM.

BAB-2 interfaceFor centralization and serial data exchange with a higherranking programming unit.Decentrally located controls can thus be included in onecommon central system.

KSR - constant cUP;;ent regulationThe KSR function allows the measuring, regulating and monitoring of theweid current in a spot welding cycle. The required current is specifled inkA. The current is measured and regulated for each current cycle of a weidtime. The regulating is achieved by changing the firing angle, and takeseffect from the 2nd cycle of a weid time onwards.Pressure control valve unitFor controlling the set pressure for servo valves.Programmable setpoints can be preset for each weldingprogram.

Separate descriptions are available for further technicalinformation.

17

1070 078 061·106 (89.09) GB . TI . ATN'NS . Printed in Germany

Documents

TI-PSS 2000/PSP2000 Welding-controlsPSS2000 with