TI PSS 2081 .. .

8; PSP 2000; PR81

Timer Moduls PSS 2081 ... 8 including programming

Module PSP 2000/programming unit PR 81

Au.g.~

105

TI PSS 2081 .. .8; PSP 2000; PR81

Timer Moduls PSS 2081 ... 8 including programming

Module PSP 2000/programming unit PR 81

Technicallnformation
1070078078-105 (02.92) GB

Reg. Nr. 16149-03

1992

Alle Rechte bei Robert Bosch GmbH,

auch fr den Fall von Schutzrechtsanmeldungen.
Jede Verfgungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
Schutzgebhr

5.- DM

@> BOSCH
Flexible Automation

Timer module
Type PSS 2081 .. B

Technical information
P.-No. 3944/E

Table of contents
Survey of further Technical Information:
Page
1.

Survey PSS 2081 ... B

2.

Front panel view PSS 2081 ... B

3.

Technical data PSS 2081 .. B

3.1.

Functiona1 description PSS 2081 ... B

3.1.1.

Programmable functions

3.1.2.

Control sequence

3.1.3.

Stepper function

10

3.1.4.

Diagnostics

12

PSP 2000 Sequence display

13

4.1.

Technical data

13

4.2.

Mechanical dimensions

13

4.3.

List of all functions of the PSP 2000

15

Manual programming unit PR 81

18

Technica1 data PR 81

19

Installation of the entire system

21

Mechanical dimensions PSS 2081 ... B

23

Connection

24

7.1.

Connection diagram

24

7.2.

General connection instructions

25

7.2.1.

Inputs

25

7.2.2.

Outputs

28

7.3.

Connection and installation of adapter "PSA"

30

7.4.

Interference suppression

32

7.4.1.

Interference elimination examples

32

Maintenance

33

4.

5.
5.1.
6.

6.1.

7.

8.

(ij) BOSCH
Flexible Automation

9.

9.1.
9.1.1.
9.1.2.
9.1.3.
9.2.
9.2.1.
9.3.
9.4.

Timer module
Type PSS 2081 ... B

Technical information
P.-No. 3944/E

Options (special modules)

KSR (constant current regulation)
Current tolerance
Example of a KSR function application
Control loop for the KSR function
Pressure control
Mode of functioning
B-memory module
BAB2 interface for data bus

33
33

34
35

36
36
36
37

39

Timer module
Type PSS 208l ... B

BOSCH

Flexible Automation

Technical information
P.-No. 3944/E

The following manual~ are available for more comprehen~ive

information about the con~truction ~erie~ PS 2000:
1. PS 2000 brochure

Explanation of the ~ystem, con~truction,

functions and colour
illustration. P.-No. 3901

dimension~,

2. Technical information
PSS including PSP 2000
(Timer module with
Programming module)
3.

Techni~al

information
PSL 2000
(Power ~upply module)

Construction, dimen~ion~, installation

and connection.
P.-No. 3903
Construction, dimen~ion~, technical
data, installation and connection.
P.-No. 3904

4. Operating and programrning

in~truction~ PSP 2000

Handling the programming module

and programming the welding data in
accordance with the action chart for
standard weld module.
P.-No. 3902

5. Technical information
PSS2081 ... B including
PSP and PR 81

Construction, dimension~, technical

data, installation, connection and
options
P.-No. 3944

1988 by ROBERT BOSCH GMBH, Erbach

All right~ reserved incl.
patent rights. No part of
this publication may be
reproduced or transmitted
in any form or by any
means without the prior
permi~~ion of the
Copyright owner.
Errors and technical
modifications excepted.
c

(l

BOSCH

Aexible Automation

Timer module
Type PSS 2081 ... B

1. Survey PSS 2081 ... B

The welding timer module
contains a modern,
powerful C-MOS microprocessor which performs
all control tasks.
Type designation:
PSS 2081.0B (as shown in
figure)
It contains: 16 programs,
stepper operation. The
module has 16 inputs,
10 outputs
The designation:
PSS 2081.1B
means that the option
KSR (KSR = constant
current regulation) is
built-in in this
module.

Technical information
P.-No. 3944/E

Technical information
P.-No. 3944/E

Timer module
Type PSS 2081 ... B

(@ BOSCH
Rexible Automation

2. Front panel view PSS 208l.0B

1 Screening earth
(for PSP maeching plug)
2 Green LED "mllins" ; on wohen
mains volt.age is present.
3 Green LED "ready": indicates
operating status

YelloW' LED "iO'oitioo" ; ignition

pulses are output co the power
unit. (weId timel

5 Fusit tor out.puts AO; A20

medium slow-blow 1. 25 A; 5 x 20 mm
tor outputs Al; A21
slow-blow 1. 25 A; 5 x 20 mm

Fuse
" medium
7

FUSEl

tor outputs A2

A7,

medium slow-blow 1." A; 5 x 20 mm

8 Plug-in ter::dnal inputs

,,..

10 Flug-in terminals 4-pole. '"external"

11 Knurled screw tor lockinq the

module

'r

12 Jumper fitted at ehe works for

+

24V internal power supply

'~-

13 Plug-in terminals, 6-p01e. "internal"

14 Openinq for optiooal modules
e. Cl. B-module or BAS
15 Prepared for pluq

connec~ion

...'...

'.
'.
'. ..

9 Pluq-in eerminal outputs

9
KSR

16 25-po1e connector {D-connec~orl

tor pro9ramminq module
PSP 2000, max. cable length 5 m
17 Pluq-in ~erminals. la-pole. for
connectinq ~he power supply module PSL
18

Faul~

reset pushbutton

19 Additional connector tor

future extensions

(ij) BOSCH
Flexible Automation

Timer module
Type PSS 2081 ... B

Technical information
P.-No. 3944/E

The series PSS 2081 ... B offers the following

new features:
o 16 programs with
12 parameters each (modes of functioning or
operation)
o Programmable via portable programming unit
PR 81
o Automatie heat adjustment (stepping) for
compensation of electrode wear
o Diagnostics of operating and fault conditions
o Switching technology in microprocessor
technique
As options:
o Constant current regulation (KSR) for
measuring, regulating and monitoring the weld
current
o Press ure control module
As accessories:
oB-memory module for data protection
o BAB2 interface module for data transfer to a
centralized programming and diagnostics
station with VDU, printer or tape recorder

Timer module
Type PSS 2081 ... B

BoseH

Rexible Automation

Technical information
P.-No. 3944/E

3. Technical data PSS 2081.0B

Protection standard

IP 20, suitable to be mounted in

switch cabinets or housings to at
least IP 54 standard

Operating voltage

27 V AC, + 15%/-20% provided by the

power supply module PSL 2000

Ambient temperature

OOC + 600C

Humidity

No condensation on the control is

permitted (dew)

16 inputs/B-module

24 V OC
Input signal "1" +24 V 15%
Input signal "0" - 1 V ... + 2 V
or open

10 outputs/B-module

+24 V load carrying capacity in

accordance with the connection
diagram details. RFI suppression must
be installed when controlling relays
or contactors (see 7.4.)

Indicators

LEO

- Mains

green

- Ready

green

- Ignition pulses

yellow ~

Pushbuttons

Error reset

Connectors to programming
module

25-pole O-connector

Cable length for PSP 2000

Cable length for PR 81

max. 5 m
max. 1. 25 m

*t

can be connected at the same time

via adapter PSA 125 (see 7.3.)
Other connectors

Push-lock terminals

Oata protection

The program data are batterybuffered. Buffering time approx. 2

years. The battery voltage is
monitored.

Accessories

B-memory
BAB2-interface

Options (cannot be
retrofitted by the user)

KSR
Pressure regulator control

Weight

2.8 kg
5

Technical information
P.-No. 3944/E

Timer module
Type PSS 2081 .. B

@l BOSCH
Flexible Automation

3.1. Functional description PSS 2081. .. B

Timer modules of the PSS 2081 series

are a new generation of welding
controls which are particularly
designed for fulfilling the
functional and technical requirements
of flexible automation.
Today, welding robots and other semior fully automatie welding devices
require more sophisticated
programming possibilities, functional
sequences and monitoring tasks than
conventional single- anddoubleprogram controls courd offer.
Therefore, we supplemented our
extensive variety of controls of the
AYD-DYF series by developing the new
type PS 2000.
In the following, the timer module
type PSS 2081.B will be described.

PSS 2081 .. [18,

.===='

Type version

Type version

Timer module

"'--r-J "-t-J

Special module

Type function

Module design

Special customer design

(software option)

@ BOSCH
Aexible Automation

Timer module
Type PSS 2081 B

Technical information
P.-No. 3944/E

3.1.1. Programmable functions

The following parameters or data can be input via the programming
unH PR 81

o-

15

Pause time

o-

99 cycles

Hold time

1 - 99 cycles

Off time

o-

1st half-wave after pause time

40 - 99 scale divisions

Operating mode
Stepper function

single spot, repeat, seam

10 x heat values
10 x number of spots
prewarning point
spots per workpiece (part)
electrode number
reset counter

Proaram number
Pre-squeeze time
Squeeze time
1st weId time
1st heat
1st pause time
Pulsation
WeId time
Heat

99 cycles

Further da ta possible depending on the options.

<> BOSeH
Flexible Automation

Timer module
Type PSS 2081 .. B

3.1.2. Contro1 sequence

Technica1 information
P.-No. 3944/E

Prior to actuating the start contact, the

externa1 program se1ection (0 through 15
via 4 1inesl must have been effected. The
program se1ection is indicated by 0-15 at
the disp1ayof thePSP 2000.
Upon start actuation the va1ve vo1tage
(24 V d.c.) is re1eased and the presqueeze time is started. With OK
(overpressure contactl the squeeze time
starts to run. With NBS a110w the we1d
time is initiated.
In order to make sure that we1ding current
is also present in the fo110wing we1d
times, the input "we1d" must be made at
the PSP 2000 module and +24V must be
app1ied to the externa1 contact we1d-no
we1d.
When the system is operated without the
PSP 2000 module. the DIP switch 3 on the
CPU printed circuit of the PSS 2081 ...
must be switched from Sl to ON.

CPU board

Timer module
Type PSS 2081 ... B

I) BOSCH
Flexible Automation

Technical information
P.-No. 3944/E

The number of weId times corresponds to

the programmed pulse number. WeId time 1
(heat 1) and weId time 2-9 (heat 2-9) can
be programmed separately. The last weId
time is followed by the hold time.
In the case of single-spot welding the
hold time elapses.
The following shows a possible flow
diagram for a welding program with pulse
operation.

Flow Diagram

K=PRESSURE CONTACT
I
I
I
I

S1

I'\;

-HEAT

[J-1. HEAT

I
01

iUUUUUUU

saz SOZ
I

I
I.
I

nnnnnnnn

I
I

FK= MACHINE .
CONTACT

PAUS WE LD P.tl.IS WE LD

1. WELD
1

eSl

PULS

PULS

3.

:I:

PULS

WELD
4.

PULS

I
I
I

I
I

ALTERNATIVLY

I
I
I

I
1

~SQZ

nnnnnnn

I
I
I
I
I

~E

I
1

UUUUUUU

saz

1. WELD
1.

WELD

PULS

2. PULS

WE LD
3. PULS

';E

WELD
4.

HOLD

PULS

UP SLOPE
SETTING PAUS TIME 1 TO ZERO

Please note: In the case of pulse or seam

welding, the 1st pause time can be dropped in
order to increase the heat directly (current
steps) .
9

@) BOSCH
Rexible Automation

Timer module
Type PSS 2081 . B

3.1.3. Stepper function

Technical information
P.-No. 3944/E

This function serves to provide heat

stepping in order to compensate the wear
of electrodes depending on the number of
welds performed.
In order to activate this function a
number of parameter da ta must be
programmed using the portable programming
unit PR 81.
The life of an electrode is to be divided
into maximum 10, minimum 2 sections called
steps. To each step one has to allocate a
certain number of welds performed, called
spots. The maximum number of spots is
65,500.
Into each step one has to enter the
required heat scale values both for 1st
heat and successive heat in pulse
operation.
Furthermore, the number of spots or welds
per workpiece or part is programmed (see
figure) .
A prewarning point of 1 - 99 is

programmed. When this point is reached,

the output "prewarning" is set.
A display on the PR 81 shows how many

parts can yet be welded be fore the

electrodes should be replaced, i.e. before
the maximum number of welds has been
performed.
When the maximumnumber of welds has been
performed, the "prewarning" setting is
cleared and another output "max. number of
welds" is set.
The restart of the timer is inhibited. The
inhibition can be released by resetting
the counter to zero (after having changed
the electrodes) by selecting the input
"reset counter", or the inhibition can be
released via the PSP 2000 module "exceed
maximum number of welds". With this
feature it is possible to weld another 250
spots (electrode change delayed). This
function can be repeated without any
limitation.

10

BOSCH

Flexible Automation

Timer module
Type PSS 2081 . B

Technical information
P.-No. 3944/8

It is possible to program the number of the

welding electrode which is to be used by the
stepper program.
The stepper function must also be activated and
deactivated via a program.

Graduation diagram
of the stepper function

---e>U
END

7L

. ':-r

>.

73i+----...,..-,....,r:
1
72+--"T"--'+
71

70

+-....,..,.,..,,-:1,
2DD

1600

18002000

,:
"

SPOTS

PREWARNING
'., POINT "

Example of a graduation diagram for the stepper

function.

11

Timer module
Type PSS 2081 ... B

BaSCH

Flexible Automation

3.1.4. Diagnostics

Technical information
P.-No. 3944/E

The diagnostics field "D" of the PSP 2000 module and

the diagnostics field of the portable programming
unit PR 81 eontain the automatie displays of the
most important operating conditions and fault
messages of the weld timer module. The display
appears in 2-digit codes.

Diagnostics coding: (Extraet from the plug-in card in the PSP

module)

o
o

DiagnoSuc
20
21
30
31
32
39

80

No weid internat
No weid external
Override
Max. e1ectrode Iife
Prewaming
No programming enable .

Emergency stop/No 24 V D.C.

83 Over Temperature
84
85
86

87
99

Battery back-up low

Parity check
DamagedRAM
No weid program
Special Code (see reverse side)

Diagnostics coding with KSR operation (reverse side of the plug-in eard)

Special Code 99

@)
0

I
01 Meesuring
02 Loop
11
12

1. Heat
Heat

21
22

open

No weid inl
No weid ext

Nocurrent

13 N current
14 0

1. Heat
Heat

Under current

31
32

1. Heat

23
24

1. Heat
Heat

Over cumll1l

33

1. Heat
Heat

Power llmit

25

1. Heat
Heal

Repeat under current

1. Heal

Mal. phase shift

26

1 .,

CF@]

34

41
42

Heat

Heal

min. Phase shirt

Timer module
Type PSS 2081 B

BOSCH

Flexible Automation

4.
4.1

Technical information
P.-No. 3944/E

Sequence display PSP 2000

Technical data
Do not use for programming the timer module. Only a sequence and
diagnostics display with operator guidance functions.
Protect;ion standard

Front panel when installed IP 54

Rear panel IP 20

Ambient

OOC . +60 o C

tempera~ute

Humidity

No condensation is permitted (dew)

Operating voltage

Is supplied by timer module PSS 2000

7-segment displays

decades for program no.

decades for parameter no.
decades for parameter data
decades for diagnostics
1 decade for timer no.
(without function)
1 decade for no weld/weld

Input keys

2
2
4
2

o-

9. C

+ -

Cursor movement
Data input
no weld/weld
Reset key
Fl - F4 special functions
Connector

25-pole D-sub.
to the timer module PSS 2000

Program card

Action chart with functional diagram

Weight

1.12 kg
PSP 2000
165

4.2. Mechanical dimensions

"

105

D-sub-connector, 2S-pole

"I

J"

"

Securinq bracket:
~As delivered" condition
Brackets can be shifted

Timer module
Type PSS 2081 ... B

BOSCH

Flexible Automation

Technical information
P.-No. 3944/E

Figure of PSP 2000

The programming field is divided into 5 functional fields

BOSCH

1
2
3
4
5

14

Input and display field

Function keys
Input key
Diagnostics
Welding timer selection

I> BOSCH

Flexible Automation

Technical information
P.-No. 3944/E

Timer module
Type PSS 2081. . B

4.3. The PSP 2000 offers the following functions:

o Display of the program number that is
display field "A".
currently executed
o Display of the type number of the timer
module connected and sequence display in
field "CU.

Seqwmce Display

1/.:1d= I
....

~ead

The aequence display can be

"

only dur!ng

the exeoutionof the contral sequence. Param"er

"9'" must se se'ected.

7i'-~

"-1= -j-- .. j-I

la BB BI

durinll at ..queeze end

aqueeze time

[BBt/BI

top: durina: weId

end paUlle

timee
C'_ld")

bottom: u above,
however,

"no weId"

fB BBBI

darina: hold time

DO
uO

- top:

with machine contact

(FK) activatioD (only

durlng single-spot
operation)
- bottOlll:

durinl off time (in

repeat )lade)
When the sequence i.
not rwminlif, the type
of control i.
displayed when thi.
panuaeter i. selected

("98")

Whilest thia display 18

show in fleld A the

presently selected program numbllr 18 shown

o Diagnostics via number code in display field

"DU.
o Display and programming of the no weId/weId
function.
15

BOSCH

Rexible Automation

Timer module
Type PSS 2081 .. B

Technical information
P.-No. 3944/E

o During the prewarning period in stepper

operation:
Display of the remaining parts to be
welded
Display of the electrode no. of the
electrode pair that is in prewarning
condition
o Function keys for
selective reset of spot counter
selective delayed electrode change (exceed
maximum number of spots) for further 250
welded spots
Data protection B-memory
(data transfer to the EEPROM)
Can also pe operated at the front panel of
the B-memory and at the PR 81
o Heat correction
Heat correction for all heats by max. 5%
in steps of 1% each in all 16 programs.
o Display of the electrode number that was
allocated to a program (cannot be modified
via PSP).

() BOSCH
Flexible Automation

Timer module
Type PSS 2081 ... B

Technical information
P.-No. 3944/E

The following program card serves as operator

help. It is inserted into the opening at the left
side of the PSP 2000 module.

PSS 2081.1 []
A

,--- ...

1001

"---"

A.l].
,-,
,-,

(30)

@J (31)
D

EJ
A

Q No.

lXX'
,---",

CF

xxIRest parts
~

w.'=9Q
Q'=9Q

Oventdo

( .p

(32)

-....-

.l].

,,

(CH5)

@E1ecbodeNo.
B

,--- ...

C Sequenca disI>loY

TI

I ~TlPei (81.Ll

TI
~
B

@J::;'

~ """"" ~

[%]

xl

ProgrmnmInsi of weIcIplnrnetw wfth PR 81

--_

D~~

.32_ ...
20
21

31

31

:i:..-

....
.

NoWlld ........

BQ

No programmtng _b&e.

Ernergencyslop/No 24 V D.C.

83 Ov.-Tempirature
Bett8ry
b8ck-up Iow
_
.....k
_ _ RAM

NoMlld .......

rt

)
BOSCH

No_~
(see reverae skIe)-

Specbli

-sofoly -.-nory
05666...

Scale 1:1

17

BOSCH

Flexible Automation

Timer module
Type PSS 2081 ... B

Technical information
P.-No. 3944/E

5. Manual programming unit PR 81

For the numerous programming possibilities
which include welding data for 16 programs,
stepper operation data up to 10 steps, KSR
data (with option) for 16 programs, pressure
control da ta (with option), the manual
programming unit PR 81 is required for da ta
input into the timer module PSS 2081.B.
The individual parameters are selected with
the help of a flashing field (cursor), da ta
input is performed via the keyboard.
The cover of the programming unit holds the
code explanation for detailed diagnostics.
When these code numbers are selected, the
input and output conditions of the control
can be displayed.

18

@ BOSCH
Flexible Automation

Timer module
Type PSS 2081 B

Technical information
P.-No. 3944/B

5.1. Technical data PR 81

Construction

Manual programming unit with 1.20 meter

connecting cable for weld timer module
PSS 2081 B. plastics casing
Overall dimensions:
width
130 mm
depth
200 mm
height
45 mm

Input possibilities
for the following
standard functions
and display

Program number
Diagnostics
Pre-squeeze time
Squeeze time
1st weld time
1st pause time
Weld time
Pause time
Hold time
Off time
Pulsation
Operating mode
1st commanded heat value
1st half-wave after pause time
Commanded heat value
Prewarning point
Parts
Stepping
Electrode no.
Step no.
1st heat for stepping
Heat for stepping
Number of spots
Welds per part
Counter

Display only

Prewarning

Input keys

o-

movement

Data keys
Reset key
B-mem. -) A-mem.
A-mem. -) B-mem.
Read B-mem.

digits
digits
digits
digits
digits
digits
digits
digits
digits
digits
digit
digit
digits
digits
digits
digits
digits
digit
digits
digit
digits
digits
digits
digits
digits

2 signs
"**11
(flashing)
stars

9; Ci +i -;

= cursor

2
4
2
2
2
2
2
2
2
2
1
1
2
2
2
2
2
1
2
1
2
2
5
2
5

colour black
colour orange
colour green
colour yellow
colour grey

19

@ BOSeH
Flexible Automation

Technical information
P.-No. 3944/E

Timer module
Type PSS 2081 ... B

Diagnostics display

Table 01 dlagnostics

Mode 01 operation: single spot

repeat

seam
Timer ready

NolVes

Code

Mode of operation

20
21

22

no weid Internal
no weid external
"0 valve intern@-l

00 /01
00 /01
00 /01

Stage 01 operation Timerready

eleclrode change delayed/override
rnax. electrode Iifa reached
prewaming

NolVes

30
31
32

Timer ready
Input signal
programmlng enable
start retracl
start

47

Interface adress

NolVes
/01
/01
/01102
/01
Prog.-No.
00 /01
00 /01
00 /01
No

46

operating Irequence

50/60

39

40
41
42

43

44
45
46

pressure switch
program selecnon
NBS clear signal
eleclrode replaced
fault acknowledgement

. Output signal

60
61
62

60
81
82

83
84
85
86
87
88
89

90
00
99
NOTE:

nmerreedy

valve on
machine contact on
NBS request signal
Not ready
Fault message
emergency stop/misslng 24 V OC
weid wlthout comrnand
earth fault
over temperature
battery back up low
parity check
damaged RAM
no weid program
+ 24 V external
no pressure contact
no current
program mask
special funclion (see program mask.)

I1

1
2

00
00
00
00

NolVes
00 /01/02
00 /01
00 /01
NolVes

00 /01
00 /01
00 /01
00 /01
Prog.-No.
00 /01

No.
00-99

Please reter to front panel of timet or lnstructlon manoal of speclflc

tlmerfar further details of fault messages.

044877-..

programming unit only works in connection with a timer module

PSS 2081. ..

20

Writing currently in

German. Also available in English and Spanish

Weight

840 g (incl. cable)

BOSCH

Aexible Automation

6.

Technical information
P.-No. 3944/E

TiJer module
Type PSS 2081 B

Installation of the entire system

The control system PS 2081. . B comprises the
following standardized function modules:
1. Sequence and display module PSP 2000
2. Programming unit PR 81
3. Timer module PSS 2081.B
4. Power supply module PSL 2000

41...

PR

~1.

.fijr-

...

'-"""it----.,-

1.:0:." .. . v

I
J
r
fr
-- ~
r ,I
E

c - '1

tJllr" r- r--

rt
Ij,

"rr

r I () I ~11
oll ~

:-_'1L-~1Ll

PSP 2000

PSS 2081

PSL 2000

The individual modules can be installed

separately or together in switch cabinets,
operating panels, welding machines etc., as
needed.
Connection between PSS 2081 ... B and power
supply module PSL .. , via connecting cable.
Distance max. 75 m (to be provided by the
customer! )
21

Technical information
P.-No. 3944/E

Timer module
Typ~ PSS 2081 ... B

BOSCH

Aexible Automation

Separate installation of PSP/PSS

Required accessori~si

PR'

Adapter PSA 12S:

r--:;;- -"'!'i'- ~

1.'0:..

_"-

.;; 0:

_ e ..

"
l*-

PSP

IIIrr.- ,...-

r"

i~

rn

,Q

li IrrF'

J[
c

~
PSL

d!

,.,

.....

~ ""':'"

c-"1t

Lg.Nr. 054729

"+

I"

Connect1nq cable

,.,

..

...

...."':""'-- J

Lg.Nr. 052355!

PSS

PSM-SB

1~25

- ~~
'cable

PSV 006

PSM-SB

= mounting angle for PSS

PSV 500/150

= connecting

PSV 006

= flat

.1ldapter

= device

2081 .. B for
installation at the right side of
the power supply module PSL.

cable between adapter or

PSS and PSP (no standard types)

cable connection between PSP

and adapter
with 3 connectors

x at the front side with hole

in the front panel for
connecting the programming unit

PR 81.(Socket X2)

2 x at the back side

a) Connection to PSP 2000
Standard cable PSV 006.
In exceptional cases
connecting cables PSV 500
(5 m long) and PSV 150 (1.5 m
long) are also available.
(Socket X3)

b) Connection to PSS 2081 ... B

Only possible via connecting
cable 1. 25 m. (Plug Xl)
'il'he scope of delivery of "Adapter PSA 125"
comprises:
Lg. No. Q56691
- Adapter
Lg.No. 052754
- Connecting cable PSV 006
Lg.No. 054605
- Connecting cable 1.25

22

Timer module
Type PSS 208l ... B

lij) BOSCH
Aexible Automation

Technical information
P.-No. 3944/E

6.1. Mechanical dimensions PSS 2081 ... B

PSS 2000 B - module

,.'_t-t-_ _..J1:L;"_ _---j

11'

=
=
=
=
=

15

=
=
=
=

=
=
.=

=
=

..,J-.:.....

-=---"--.-

Clearance for
ventilation

-Accessor

Front view

kit PSM - BA

052355 -

Side view

weight including KSR -

moduh~

; app. 2.9 kg

=
=.
.
=
=
=
=

127

'&
Rear view without
mountinq plate

TiJ\ler module
T~e PSS 2081 .. 8

BOSCH

Flexible Automation

7.

Connection

7.1.

Connection

Technical information
P.-No. 3944/E

dia~ram

@ - Protectiva
+

earth

~.L.--,

24 V 120 mA

P5520 81.10BI

=====~::~: ~ ------I~~

Load'~:' i ;-1I
,

-...:.E.1 I

-Ignition on, external E2

-overP:ressure cQntact E3
---;-'Reset fault
E4

77R eset counter

-:Programminq enabled
-Start retract
-program . selectiQn
-Proqram selectiltm

E8
E9

-Proqram selecti/;m
-Proqram selectiQn "8"

E10
Eil

10

:KSR
)input

I I

I I
I' ,

not
{I)
allocated ...:!.)

ES
E6

..1\--

E7

I!

~~

J4

:': ( ....\
11 D 1

17 ~:c.2-

1-",'511 m.I

I
I

Option Interface BAB2

(with T-piece)

0:0.

5H!BD

\ ..'
--

-..;:

1.

EU
E13

. Connecting cable to power supply

uni t PSL. to be provided by ,the

Ii

customer:
up to 10 m

E14
-NBS allow-------IE15

24 V outputs

r----ov --f1.:..i1Iv
L,J -Va1ve1

AO

t>kJ ---:- Valve 2 CElO) 1:A:

I
_
etrac~ (Rd) lA

A1

A2

-:---

---......;Prewarning (BOI O.lA

l-Max. number of welde (BQ)i O.lA
NBS request (BQ) O.lA

I
I

(~) 1A

Mchine contact (BO) .O.lA

-~ontro1 un~' t read

----...
1.< BO)
O.lA

A3

.r-.. '-.-'.---'I
l '

27V;"'"

Temp. co~tact

- - - - - - - ' , Va1ve 1

(RQ) 1A

A20 - -

+24V

A21 - -

I~~r

Ra

I
I

re1ay output

I
,
I

1------=+-Ir<6l~."
Iqnition. _
0.
7

- - - - - - V e 1 v e 2 (RQ) 1A

I
I

~
.~
~

EO = electronic 9utput

ystem. earth '3

yY
V

0.75

PSL

A4
AS.

A6
A7

Ci:'

up to 75 m 1.5

supplyl

B.

"

1------110

Pol

INT

1 1------., Floatinq contact

EXT
+ - -+ 24 V for inputs

LReference potential

L. _
~RGENC

.-l

Load: 24 V =/ 3 A

On1! when operated with" internal

power supply

~ __-=-;i-=--=-;
I-.-f-. __
.---l

,~~--~

[1fI op~ration with internal power supply:

Bridge betwee:n
term."5 int"->term. "5 ext"
end

term. "6 int"->terrn. "6 axt"

IfIIf1

Operation with external power supply: WITHOUT BRIDGE BETWEEN

"INT"->"EXT"
external supply of 24Vd.c., max.
load 2A.
+ to term. "5 ext" - OV to term.
"6 ext"
see section 7.2.1.

Note: Re!ays and contactors must have RFI suppression. 8.g. free wheeling
diode for small d.c. relays and contactors.
Plaase note: Connection must :always be performed using the connection
diagram supplied with the contro!.

,.

r@

BOSCH

Rexible Automation

7.2.

Tim~r module
Type PSS 208l . B

Technical information
P.-No. 3944/E

General connection hints

Selection is generally performed with
24 V d. c. !

7.2.1. Inputs

Lead +24 V from terminal "ext. 3" directly

via a contact (or electronically) to the
corresponding input.

From internal $upply

From external 2.V d.c.

voltage supply

In many machine installations a +24 d.c.

load voltage is supplied. This voltage
serves for the supply of the inputs and
outputs of CNC, PLC or relay controls.
The inputs and outputs of the PSS 2000 can
also be supplied with thisvoltage.
In case of such an application the two
bridges must be removed from terminals
int. 5 + 6 to ext. 5 + 6. (See connection
diagram PSS 2081.10 B).
External voltage supply
+ 24 V -terminal ext. 5
o V - terminal ext. 6
Requirements to the 24 V voltage supply:
Tolerance:
from 20 to 28 V d.c.
Standing~wave ratio: S 5%

When using an emergen~y I

switch to cut off all: II
output-, ready-and
firing circuit signal~,
the emergency switch
must provide 2
normally closed contacts
free of potential.
.
Contact 1 switches
the +24V supply,
contact 2 the
connection 'INT 1/2'
(see diagram)

E~T
-

~-R.ler~nc.

.24V
EX'

.V

+ 24 V fOJ: input.
potentia;,for outputs

.1.

-'-

~
5

'-I-

QJ

~.

IN'

e!~
~

EMBRGENcYT 1.2.

The contacts 1.1 u. 1.2

are potentialfree load: 24 v=f3 A

.--.J

25

BoseH
0
Rexible Automation

Timer module
Type PSS 2081 B

Technical information
P.-No. 3944/E

IEOI

Start 1

Start 1 always activates the solenoid valve 1

(MV 1) and program 0 - 15 depending on the
selection.

[]

Start 2

Start 2 always activates the solenoid valve 2

(MV 2) and program 8 - 15 depending on the
selection.

Weld external

with the help of this input it is possible to

switch the timer to "no weld" or to "weld". When
this function is not used,the input E2 must be
permanently connected to +24 V d.c.
+ 24 V d.c. -)
open
-)
or 0 V
(-1 to +2 V)

Overpressure
contact

= weld

~ =

no weld

The machine overpressure contact acknowledges

that the electrodes are closed. When this input
has been selected the squeeze time and then the
weld time starts to run
When operation is performed without the
overpressure contact, the input E3 must be
permanent1y connected to +24 V d.c. Care must be
taken that the squeeze time is selected long
enough so that the material to be welded is
pressed together optimally before the weld time
starts to run.

Mode of operation
of the overpressure contact

f+;LijJ ,

A;,vo\v.

Al,_

r----1'

C~'J,'~'=~=f=1
: ; I
I

p Pressuro
contact

"~,--

lOK)

L-:....:----j''';r~" ....

Pressure cylin der

~
,

26

pe tKI

<@

BOSCH

Flexible Automation

I Esl

Technical information
P.-No. 3944/E

Timer module
Type PSS 20S1 B

Reset faults
external

There are several possibilities to "reset

faults", which are always necessary when a fault
has inhibited the timer module. When the fault
has been eliminated, it is acknowledged either
via the above-mentioned input "E4" or via the
"data and reset key" on the programming unit
PR Sl, or via the green key 6 at the front
panel of the timer module PSS ... or by actuating
the keys ~ and
111
on the keyboard of the
PSP module.

Reset counter

The counter shows the number of spot welds

performed for each electrode. The maximum count
is 65,500. The counter is reset by applying +24 V
d.c. to the input "E5". Resetting can be
performed for the counters of all programs or
separately (selectively).

Programming
allow

Weld data input or modification is possible only

when +24V d.c. are supplied to "E6".

Start retract

This is a valve control function which puts the

electrode holder from the working position into
an extended form (e.g. in the case of bulky
welding depositor for changing the welding
electrodes). During this selection all types of
start are inhibited.

to lElil
Program iifection

Via the inputs

E S - program selection value "1"
E 9 - program selection value "2"
E10 - program selection value "4"
E11 - program selection value "S"
16 programs are selected externally in binary
code.
In each case, +24 V d.c. is to be applied to the
respective terminal.
Note:

The program must have been selected before

the start.

-.-J Terninal
E8

Proq.

-n1,'/alu.;'
0
1

+24 V

3
4
5
B

+24 V

+24 V

+24 V

+24 V

EID

+24 V

+74 V

+24 V

+24 V

+24 V

+24 V

11

+24 V

"

+24 V

+24 V
+24 V

Eil

+24 V

I
B

B
9
10

13
14
15

ES

+24 V

+24 V
+24 V

+24 V

+24 V
+24 V
+24 V

+24 V

+24 V

+24 V

+24 V

+24 V

...24 V

+24

+24 V

+24 V

27

( BOSCH
Aexible Automation

Timer module
Type PSS 2081 . B

NBS allow

7.2.2. Outputs

Technical information
P.-No. 3944/E

NBS = weld load limitation

The NBS monitors within its scope of functioning
that only that number of welding machines is
working which is permitted by the mains supply.
When no NBS is connected, the input "E1S" must be
permanently connected to +24V d.c.
Generally supply +24V d.c. against the reference
potential "0" of terminal

lI

ex t. 6".

The load carrying capacity is 100 mA or 1 A.

(Please check the connection diagram supplied
together with the respective device for the load
carrying capacity.)
Magnetic valve 1
and

Electronic output with +24V d.c. signal.

While the start is activated until hold time has
elapsed.
Max. load 1 A.

Magnetic valve 2
Start retract
valve

Relay output
24 V d.c. are supplied for as long as input E7
has been selected. Max. load 1 A.

Prewarning

When stepper operation is active, a "prewarning

point" can be programmed, which signals optically
that the maximum number of welds of one electrode
will soon have been performed and that only a
certain number of welds can yet be performed
before the electrode must be changed. To this
output, e.g. a signal lamp can be connected. It
goes off when the "maximum number of welds" has
been reached. Max. load 0.1 A.

Max. number of
welds

Output "A4" has +24V d.c. when the maximum life

of an electrode has been reached. At the same
time the timer is inhibited, Now either the
electrodes must be changed or the counter must be
reset, or a "electrode change delayed" time can
be entered via the keyboard of the PSP module for
further 2S0 weld spots. Max. load 0.1 A.

(!'u- eIedrode rrflt. J

NBS request

NBS = weld load limitation (for explanation of

NBS see information about E1S).
20 ms before the squeeze time is over until the
end of the last weld time, +24V d.c. are applied
to this output. They serve as request of the NBS,
which allows the respective system for the
required per iod of time depending on the mains
load.
If no NBS is used, this output can be neglected.
Max. load 0.1 A.

28

BOSCH

Aexible Automation

Timer module
Type PSS 208l B

Machine"
contact IFK).

Technical information

P.-No. 3944/E

This output serves as acknowledgment to the

peripheral devices. The machine contact indicates
that the welding procedure has been completed.
'A6" has +24V d,c. when:
In Ihe single SpOI mode:
1 Cycle before Ihe end of hold time is reached, and stays aClivated until Ihe
slarl inPUI is opened, (Ifthe Start inpulis opened before Ihere will be noFK)
In Ihe sPOI repitition mode or seam mode:
The FK is activated for 20 ms with in the last cycIe hold time.
Max. load 0,1 A.

Timer ready

~.

Magnetic
valve 1
and
Magnetic
valve 2

Output has +24 V d.c. when the timer module is in

ready state .. (In parallel to green LED"
t "
Ready at the front panel of PSS 2081 ... B). Max.
load 0.1 A.

..

O~<P.'

AO}

but intrinsically safe

relay output.
Max. load 1 A

as output Al
For further output allocations please refer to
the connection diagram supp1ied together with the
system.

Timer module
Type PSS 2081 ... B

BOSCH

Aexible Automation

7.3.

Connection and
installation of
adapter "PSA"

Technical information
P.-No. 3944/E

"The adapter" is a device designed for connecting

theportable programming unit PR ~1 in parallel
to the connection between PSS 2081 Band
PSP 2000. See drawings.

Installation instruction

Installation ap.ning

min. 17 x 72 mm

132

(14,5

60,51

/'11

[.

~. ~-'_I'
r-'-"

$-1

.I

riJ7

.-

~I

T
1

T-

'"(:!
@

--spring band
(part of
PSV 006)

,~rrrr-

.~r

I-

housing front plate

'Connectinqcable 1.25 m long to ti mer module

Art. No. 054605

I
i.
I

Mountinq angle
state when supplled
---- angle. ean be m~unted diff.rently

30

PSV 006
PSV 150
PSV 500

291

t-

or
or

r
r

-+-

~ tor PR8!
_~~;;:~l"1~connectinqliDe

l]l

LWJ

I
adapter PSA

BOSCH

to timer module

1+
I~

,,,,,/./y;

i'$'

Timer module
Type PSS 2081 ... B

BOSCH

Flexible Automation

Technical information
P.-No. 3944/E

Dimension diagram adapter - PSA

Ztt
,'0:;

~I

ZEt

-$

-$

-$-

-$

.~

OZt

+
~

ilP
:z:
u
on
0

ID

:><;

~
"':><;

~.

GI
.-f

Po

I
ltl

'"

.jj

GI

oVI

Technical information
P.-No. 3944/E

Timer module
Type PSS 2081 B

BOleH

Rexible Automation

7.4. Interference Suppression

Measures are necessary for the suppression of interference caused by
external sourees. Interference is caused by switching peaks and is
scattered into the control via the connecting lines. The following
interference suppression measures must be applied in order to achieve a
minimum of commissioning time and an optimum of operating reliability:
Interference suppression measures must be applied to all relay coils,
other inductors, block valves, switching elements, and special
interference sources in the close proximity.
The interference suppression link must be installed directly at the
source of interference. If this is not possible, the interference
suppression link must be installed in a connection housing as close as
possible to the unit causing the interference, and the connecting lines
must be closely twisted. The interference suppression links, resistors,
capacitors and diodes must be mechanically well supported in order to
prevent breakage due to vibration.
7.4.1. Interference
Elimination
Examples
Re -GLIED

DIODE

...

..r--..

r:l

- I ~n '1

GND

Diode, su/lable tor low De va/tage re/ays

M.

R-C nerwork tor AC va/tage re/ays and

AC va/tage motors

OIOe( U. ZENERDIODE

CI-ZD

"

Re-GLIEO

attenuation network tor high oe

voltage contactors and defined de-ener-

Re network for are quenching in the

eBse of Inductive load

gization limes

Inlerference Resistor
ource
24 V-

4BV-

eov125V50 V110V-

OVV-

Capacitor

--

---

2200SW
22005W

2.0 ~F 400/600 V
O.5\lF tOOOV
0.5 IlF 4001600 V
O., ...Fl000V
O.1IlF 2000V

220C1W
22005W

22005W

Diode

1 N 5060/ZL 121Zl, 22
1 N S060/ZL 22
1 N S060/ZL 66
t N 2069
1 N 1695

This table is only an example. The dimensions of the components are

determined by the load conditions.
Please note:
Instead of the diode 1 N 5060 (I-1 A, U-100 V) also an equivalent type
can be used.
The use of a Z-diode depends on the respective case of application
whereby the de-energization time of the relay is determined by the
Zener voltage if UDI.ZD - UB. A larger Zener voltage will result into a
shorter de-energization time.
32

BOSCH

Ae>rible Automation

Timer module
Type PSS 2081 B

8. Maintenanee

The
for
RAH
The

Technieal information
P.-No. 3944/8

timer module PSS contains a buffer battery

da ta protection. This battery buffers the
memories when the timer is switched off.
buffer time is max. 2 years.

When the battery voltage is low a fault message

is displayed automatically by code no. 84 =
battery backup low, and the control inhibits
the next start.
In order to change the battery, please loosen
knurled screw and pull out timer module.
The battery is located at the top right side.
Replace defective battery by a new one.
Bosch order no. for battery: 041445.
9.

Options
(Special modules)

9.1.

KSR - constant
current regulation

Cannot be retrofitted by the customer!

The KSR module has the following
operating modes:
Heat values
= PHA
Weld current monitoring
= SSU
Constant current regulation
= KSR
PHA operation
In this operating mode welding is performed
with the heat values specified in the control.
The KSR module permits display of the weld
current consumed for each weld. Display is made
in kA eff., aecuraey one deeimal plaee, i.e.
100 A. This operating mode ean be seleeted for
transition from heat value operation to KSR or
SSU operation, e.g. when retrofitted. The
eurrent values measured and displayed ean serve
as eommand values for programming of eurrent
values - whieh are needed for SSU or KSR
operation.
Operating mode SSU
In this operating mode welding is performed
with the heat value speeified in the eontrol.
The measuring result of the weld eurrent is
compared with the programmed current - taking
into aecount the admitted toleranee. If the
toleranee is exceeded the FK (machine contact)
is inhibited.

33

@ BOSCH
Flexible Automation

Timer module
Type PSS 2081 . B

Technical information
P.-No. 3944/E

KSR operation
In this operating mode welding is performed
with the current values in kA specified in the
control. Actual current'values are measured
periodically and compared to the commanded
current value. In the case of deviations the
heat values are automatically corrected. Thus
it is possible to control the current to
specified current values within one weId time
which exceeds 3 cycles.
If the measuring results deviate more than the
permitted tolerances the FK lmachine contact)
is inhibited.
9.1.1. Current tolerance

The system permits the specification of

different current tolerances as a basis for
current monitoring.
Two different types of current tolerances can
be programmed:
"current tolerance"
"conditional current tolerance"

Example:
+15%

Tolerance band

15%
.

O'lb

Condilional

-10'lb
-15%

Commanded current

tolerance band
}

from

-10% unlll-15%

In addition it is possible to preselect the

"maximum permitted heat value". The timer may
perform heat stepping up to this value.

34

@ BOSCH
Aexible Automation

Technical information

Timer module
Type PSS 2081 .. B

P.-No. 3944/E

9.1.2. Example for the application of the KSR function

]
VARIABLE FACTORS
CONTAMINATON OF WORK PIECE
SURfACE
CONTAMINATON OF THE ELECTROOE
WEAR OF SE(ONOARY (ABlE IN
SUSPENOEO GUN STATION
CHANGE oF THE INOU(TIVE
RESISTANCE
VOlTAGE

VARIATION

The figure shows the line for all KSR data on the programming mask

r !,5-25lA
' -99.9 lA
1-4.11

OPHA
1.KSR;2.1su..,..l

' ..".... .
....,''.. ..... :',:':':

. ::::' ::':=:
. . .... .
4-,
rl.%;l.lA

.'
.'
.'
.'

-+
PROG.IIa~

MOIlfIKSR1---.J

~J>(%I ~J<

1.11CY

ACl. VAlUE

I
I
%
L
I1
. HEAT STEPPlNG

11

HEAT

MAl(

SPOTS

PIlESS, IDlAGH. r
l ICURRENT
RANGE

i PREW

.ps

SPOT i

hwHc)

AcT COUNTER

COMP

SPECIAL FUNCT. 99

LJ

BOSCH

Aexible Automation

Timer module
Type PSS 2081 . B

Technical information
P.-No. 3944/E

9.1.3. Control loop for the KSR function

Commanded
value in kA

Bosch
firner

Aclual value
in kA

Thyrislor
power unit

9.2.

Pressure control

9.2.1. Hode of functioning

Cannot be retrofitted by the customer, please

specify in new orders.
The regulators can adjust a pneumatic.
pressure (actual value) with the help of a
specified voltage (commanded value).
Depending on their design the pressure
regulators have further control properties,
i.e. they keep initial pressure constant,
thus making up for variations in primary
pressure.
The commanded value (0 - 9.9 V d.c.) is
supplied as initial voltage at the front
plate of the control.
For every selectable program (16 times) one
individual commanded value can be programmed
via the manual programming unit PR 81 .
Programming is performed individually for
every program between 0.1 - 9.9 V in steps of
0.1 V. Therefore a new pressure can be
specified for the respective welding task of
the electrode holder or welding machine when
a new program is selected.

r@ BasCH
Aexible Automation

Timer module
Type PSS 2081 . B

Technical information
P.-No. 3944/E

The figure shows the input field for the pressure control values
for each program.
O.PHA
I.KSR;2.SSU-l

1 ::

I,

PROI,N..
I
MODE IXSRJ----I

PRE
SOl

-'"

lt

SOl

,1-2,5-251.1
-91,91.1

1- \0

,...0.%;1.1.1

,::

L~J>I%J ~J<I%Jt-'

NEAT SlEPPING

1. WELD 1. PS

-,r--...",......-,)

- T " i-,---.,--,..-,

1. HEAT
I

1. NCY
aPS

HEAT
\

SPOTS

~:UOEH'

HEAT STEPP,HG

B-memory module

LPRESS. D1AGH,
ClJRREHT RANGE

i
i
I
waD PAUSE NOt.O OFF

11---.. . . ,. . . . "T,-.,.,
AC!. YAlUE
I

9.3.

HEAT
MAl(

nqr--I---'j

ACT. YAlUE PREW PREW IlAL\HCE

POINT

SPOT

ACT COUNTER

COMP

SPECIAL FUNCT, 99

LJ

All timers PSS 2081 .. B are equipped with a

buffer battery. This battery buffers the data
input by the customer in the RAM memory (Amemory)
This battery has a life of 2 years. Its
function is monitored.
All parameter data can be stored additionally
in an EEPROM memory with 8 Kbyte storage
capacity. This EEPROM is soldered to a small
plug-in type printed circuit called the EEPROM
board. This EEPROM board is plugged into a
module called B-memory module. All operating
and display elements for data transfer are
located on the B-memory module.
The B-memory module is a plug-in type option
and is not contained in the standard design.
Weld-specific da ta can be saved using this
module and an EEPROM board, so that the
important da ta can be rapidly transferred when
the timer is exchan~ed.

BOSCH

Aexible Automatton

Timer module
Type PSS 2081 ... B

Technical information
P.-No. 3944/E

B-memory module

0)--------------,

38

plug-in type EEPROM board

module locking device

pressbutton for da ta
B -) A-memory

yellow LED, on during data transfer

A -) B

pressbutton for data transfer

A -) B-memory

red LED, on in case of fault

in data transfer

red LED, on when the contents

of A-memory is different from contents
of B-memory

pressbutton for check whether contents

of A-memory is the same as contents
of B-memory

transfe~

(>

BOSCH

Rexible Automation

9.4.

Technical information
P.-No. 3944/E

Timer module
Type PSS 2081 ... B

BAB2 interface
for data bus

This option permits serial da ta transfer from

and to a superordinate programming and monitoring
system. The interface serves for the integration
of decentralized controls into a common control
system. (Can be extended to max. 31 control
modules) .
The BAB2 interface can be retrofitted and is
ins er ted instead of the B-memory module.
For more detailed information about the BAB2
interface please refer to our Technical
Information P.-No. 3771.

5}--

__

Module locking

Connection socket for serial bus

(15-pole)

Green LED for

Green LED for "send"

DIP switch
(address coding)

"receive"

39

() BOSCH
Flexible Automation

Timer module
Type PSS 2081 .. B

Technical information
P.-No. 3944/E

Survey sketch of a system network

(centralizationl via BAB2 interfaces

WelctingPC
with Double-BAB--card

BAB2-D-Plug and Case

BAB2-Terminator

PR 81..

Welcting TllIleIS 1YP PSS 2081.xyB

40

BAB2-Jnterface Card
BAB2-T-camecta
BAB2-D-Plug and Case
BAB2-Thrminata:

1070078078-105 (9.) GB

. HB AN ATNSp PrInted In Germany