CENTERLINE (WINDSOR) LIMITED

Bosch Weld Timers

Mid-Frequency Direct Current
Jeff Mickle
11/15/2019

CENTERLINE REFERENCE
DOCUMENT

This article is intended as an introduction to the Bosch Weld Controller. The integrator should be able to
get online with the timer using the virtual machine and Bosch software to create and edit weld
programs, steppers, and perform current calibration on the relevant electrodes. A Fanuc robot with
Bosch controlled tip dresser example is also provided.
Table of Contents
1 Getting Started ...........................................................................................................................3
1.1 Login to Bosch Software ............................................................................................................... 3
1.2 Timer Reference ............................................................................................................................ 3
1.2.1 Timer Reference – Add/Change Timer.................................................................................. 4
1.3 Establishing Communication with Online Timers ......................................................................... 4
1.4 Power Cycling the Control............................................................................................................. 5
2 Software Navigation Buttons ......................................................................................................5
2.1 Navigation Buttons Descriptions .................................................................................................. 5
3 Schedule ....................................................................................................................................6
3.1 Schedule Tab ................................................................................................................................. 6
3.1.1 Required Setup...................................................................................................................... 6
3.1.2 Optional for Setup ................................................................................................................. 7
4 Seq. Pg.2 Tab ..............................................................................................................................7
4.1 Required for Setup ........................................................................................................................ 7
4.1.1 Mode ..................................................................................................................................... 7
4.2 Optional for Setup......................................................................................................................... 7
5 Stepper Tab ................................................................................................................................8
5.1 Required for Setup ........................................................................................................................ 8
5.2 Optional for Setup......................................................................................................................... 9
6 General Tab ................................................................................................................................9
6.1 Required for Setup ........................................................................................................................ 9
6.1.1 Global Stepper Setup ............................................................................................................ 9
6.1.2 Global Schedule Setup .......................................................................................................... 9
6.1.3 I/O Parameters .................................................................................................................... 10
6.1.4 Current Measure ................................................................................................................. 10
6.2 Optional for Setup....................................................................................................................... 10
6.2.1 I/O Parameters .................................................................................................................... 10
6.2.2 Current Measure ................................................................................................................. 10
7 Electrode Tab ........................................................................................................................... 11
7.1 Required for Setup ...................................................................................................................... 11
7.1.1 Transformer ........................................................................................................................ 11

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 7.1.2 Diodes ................................................................................................................................. 11
7.1.3 Limit .................................................................................................................................... 12
7.2 Optional for Setup....................................................................................................................... 13
8 Current Calibration ................................................................................................................... 13
8.1 Required for Setup ...................................................................................................................... 13
8.1.1 Current Calibration Procedure ............................................................................................ 13
8.1.2 Verification of Current Calibration ...................................................................................... 14
9 Bosch Controlled Tip Dress with Fanuc Robot ............................................................................ 15
9.1 Required for Setup ...................................................................................................................... 15
9.1.1 Communication between Fanuc Robot and Bosch Weld Controller .................................. 15
9.1.2 Fanuc Program to Turn Tip Dress Motor ON ...................................................................... 16
9.1.3 Fanuc Program to Turn Tip Dress Motor OFF ..................................................................... 16
10 Restoring Default Settings/Restoring from a Backup .............................................................. 17
10.1 WARNING .................................................................................................................................... 17
10.2 Getting Started............................................................................................................................ 17
10.2.1 Software .............................................................................................................................. 17
10.2.2 Replacing the Timer ............................................................................................................ 17
10.3 Loading Default Settings ............................................................................................................. 18
10.3.1 Connecting & Loading ......................................................................................................... 18
10.3.2 Copying Schedules .............................................................................................................. 19
10.3.3 Configuration and Electrodes ............................................................................................. 19
10.4 Post Configuration ...................................................................................................................... 19
11 Contact Info .......................................................................................................................... 20
12 Revision History .................................................................................................................... 20

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1 Getting Started
1.1 Login to Bosch Software

• Open the Bosch software on the VM.

• For Username System the password is “Systembos6000”.

1.2 Timer Reference

• This is just a scan list for all the “Added” timers. If connected to the timer the Online button
should be checked and shown with a green background.

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1.2.1 Timer Reference – Add/Change Timer

• Clicking on the “Add” button will prompt the user to enter a timer name and Ethernet I/P for the
new timers. After all timers are added/changed, press “Continue”.

1.3 Establishing Communication with Online Timers

• If Online was checked for all of the weld timers, they should all be unique IP addresses.
• The software will PING the timers and compare the timer data to your computer data
• If PING is green but there is a data mismatch between the computer and the timer, the software
gives a prompt to Upload Data from Timer or Download data to Timer. Unless you are the last
person to get online with the timer, the preferred method should be Upload data from Timer.
• If the PING is red, communication could not be established. Check the IP address inside the VM
of your computer workstation for compatibility.

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1.4 Power Cycling the Control
• ANY and EVERY time you physically power down the controller you should wait for the control
to be completely off before powering back on. (Wait for the capacitors to discharge)
• Check inside the controller on the inverter to see that the LEDS are all off.
• Once off, only then should the control be powered back on.

2 Software Navigation Buttons

2.1 Navigation Buttons Descriptions

• Login – Enter the Username and Password
• Timer Reference – Shows the timers being monitored by the software
• Spot Reference Table – Contains unique ID’s for each weld and a program number
• Pre-warning Table – Tip life (from steppers) and Heat Warn Level (max. phase angle) since last
reset.
• Error Table – Displays all active warnings and errors for the connected online timers
• Plant Layout – Status overview of all online timers for the network. Each timer is represented as
a square with 4 quadrants filled in with different colors to show at a glance if the timer is ready,
faulted, or in a warning state.
• Protocol – Error, weld fault, data change, weld current protocol tabs: Each one provides
information about and event that has occurred. Can be viewed for specific dates and have
between 50 000 and 250 000 entries.

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 • Compare – Detection of differences in program data, electrode data, and timer specific data
between 2 timers or a timer and its backup file or 2 backup files
• Parameter Overview – Display of corrections and invalid parameters in the selected timer
• Rights Administration
• Overview – From the right-side menus you can look at relevant programs for your selection
• Correction- Program based and electrode-based correction for current and pressure
• Set-up – Stepper curves, tip dress curves, fault setup, communication
• Diagnosis (I/O interface) – IO assignment and tracking, timer information, last weld data
• Program Page – Parameters for welding, steppers, electrode information, global setup

3 Schedule

3.1 Schedule Tab

Some of the parameters that are available on the schedule tab are “hidden” until the function state is
changed to “On” then click on the “Data → WT” button. If additional parameters are required for that
function, they will appear once the timer is back online.

3.1.1 Required Setup

• Start inhibit (P) Off
• Weld/Noweld internal On
• Program – Select a number from 0 to 255
• Electrode – select a number from 1 – 31
• SQZ time to allow the isolation contactor to close before passing current

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 • MainWLD – Reg. Mode = PHA

3.1.2 Optional for Setup

• Monitoring – Standard or Mix
• Regulation – Standard or Mix
• Current mon. not required until after current calibration
• Impulse not required until after current calibration

4 Seq. Pg.2 Tab

4.1 Required for Setup

4.1.1 Mode
Mode tip dresser management defines the means of dressing the tips.

• No dresser is used when the Bosch is not the primary control of the dresser motor
• Elec. dresser is used if the Bosch is controlling and electric dresser motor
• Pneu. Dresser is used when the Bosch is controlling a pneumatic dresser motor

4.2 Optional for Setup

Pressure profiles and time monitoring can be defined on the Seq. Pg. 2 tab. There are some additional
features such as the freely programmable output “FPO” shown in the figure above. It has 3 time
intervals for each of the schedule parts “PreWLD”, “MainWLD”, and “PostWLD”.

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5 Stepper Tab

5.1 Required for Setup

Pink shaded areas show the timer actual values for each of the parameters. For Act. Count and Act. Val it
is possible to change these values by clicking on the “Set Counter” button.

• Stepper should be “On” if required

• Count factor can be weighted for different welds but for our purposes is set to 1 for every weld
• Wear/Comp. is set to 1
• Dress new electrode set to “Off” unless Bosch weld timer is driving the tip change dress
functions

When setting up the stepper it is important to note that some parameters are applied to the weld
programs and some are applied to the electrodes. For this reason, it is important to change the
parameters separately to make sure your changes are applied properly.

• Changes to the stepper % boost values are applied to the Programs. Click “Data → WT” once the
values are correct for your application and select the programs you want to have these changes
• The top parameter box in all 3 sections shows the programmed % boost. The bottom parameter
box shows the reference % boost. These 2 values should be the same.
• Counting parameters for welds and tip dresses are applied to the Electrodes. Click “Data → WT”
once the values are correct for your application and select the electrodes you want to have
these changes
• Max. count is the upper limit of the number of welds before dressing is required

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 • Warning-counts is the number of welds before that upper limit is reached that a message is
output that tip dress is required
• Dressings is the upper limit of the number of dresses on a set of caps before they should be
replaced
• Tip dress request is the number of dresses before a warning message is output that tip change is
required

5.2 Optional for Setup

Start portion of the stepper tab can be used to increase or decrease the % boost required for dressed
caps. This might be used if the caps are sticking to the parts until slightly burned in.

Dressing curve

6 General Tab

6.1 Required for Setup

6.1.1 Global Stepper Setup
Stop at end of stepper should be set to “On” if Bosch controls the tip dress and tip change functions. If
the end of stepper is reached and tip change is required, the welding will be inhibited until that change
is performed and acknowledged.

6.1.2 Global Schedule Setup

• Start inhibit (T) “Off” will allow welding on all programs in the timer

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 • Weld/ No weld (T) “On” will allow all welding programs to pass current
• Max. weld time sets the upper limit of the weld program time to prevent abnormally long weld
schedules which could cause damage to parts or equipment.

6.1.3 I/O Parameters

• Contactor delay time will keep the contactor pulled in for consecutive welds until no activity for
programmed time, in this case 60 seconds. This prevents unnecessary cycling of the contactor
mechanism causing premature wear or failure.

6.1.4 Current Measure

• Current measurement should be set to “primary” for initial setup of the electrodes and toroid
sensitivity.

6.2 Optional for Setup

6.2.1 I/O Parameters
• WC period is the length of time for the weld complete signal output to the parent controller
(robot or PLC)
• WC start time can be set to send the weld complete signal early but must be set to a value
smaller than the shortest program hold time

6.2.2 Current Measure

• If voltage sensing leads for secondary current measurement are installed Current measurement
can be set to “secondary” with Meas. Loop check “On” to help detect anomalies in the
secondary loop circuit.

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7 Electrode Tab

7.1 Required for Setup

7.1.1 Transformer
• Type is Sonst. Transform. (Other) unless using a Bosch transformer from pull down menu
• Number indicates how many transformers are connected in the circuit, if greater than 1 it will
bring up another box for how they are connected (series or parallel)
• Turns Ratio should be entered from the manufacturer label
• Nominal current can be calculated from transformer characteristics using the equation:

𝐾𝑉𝐴
𝐼𝑁𝑜𝑚𝑖𝑛𝑎𝑙 = × 𝑇𝑢𝑟𝑛𝑠 𝑅𝑎𝑡𝑖𝑜
𝑉𝑃𝑟𝑖𝑚𝑎𝑟𝑦

7.1.2 Diodes
• Monitoring is set to “On”
• Type is “D4457N” for most commonly used Roman transformers. Roman has suggested that the
D4457N is the closest representation of the Diodes they use in the construction of their
transformers.
• No. parallel can be obtained from the transformer manufacturer and refers to the number of
diodes per leg, usually 2, 3, or 4 depending on the size and rated output of the transformer
• Refer to the Table below for some of the commonly used Roman Transformer models.

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 #
Diodes
Comparable per Turns Sec
Transformer Diode Leg Ratio kVA Voltage
480
A1 TDC-6441 2 72:1 100 9.0
V D4457N
A2 TDC-7890 D4457N 2 61:1 100 10.6
B TDC-6442 D4457N 3 72:1 135 9.0
C TDC-6443 D4457N 3 50:1 185 13.0
D1 TDC-5998 D4457N 3 72:1 160 9.0
D2 TDC-5998 D4457N 3 50:1 160 13.0
E1 TDC-1078 D4457N 4 68:1 170 9.0
E2 TDC-1078 D4457N 4 50:1 170 13.0
TDC-5610 D4457N 3 650 72 135
TDC-1064 D4457N 2 650 72 100
TDC-5583 D4457N 2 650 72 100

600
A TDC-6459 D4457N 2 88:1 100 9.0
V
B TDC-6460 D4457N 3 88:1 135 9.0
C TDC-6461 D4457N 3 61:1 185 13.0
D1 TDC-5999 D4457N 3 88:1 160 9.0
D2 TDC-5999 D4457N 3 61:1 160 13.0
E1 TDC-5620 D4457N 4 84:1 170 9.0
E2 TDC-5620 D4457N 4 61:1 170 13.0

7.1.3 Limit

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 • For most of our welding applications the “Current measurement range” = 14, giving us a current
window from 4.0 kA to 40.0 kA

7.2 Optional for Setup

• %I Limitation will restrict the amount of available current to the threshold in this window
• %I Warning will output a message when the threshold in this window is exceeded
• Lower %I Warning will output a message when the threshold in this window is not achieved
• Upper Curr. Limit can be set if using “KSR mode”
• Toroid sensitivity can be adjusted using “Current calibration” button so that requested current
form the welding programs will match the measured output current at the electrodes

8 Current Calibration

8.1 Required for Setup

8.1.1 Current Calibration Procedure
Every weld gun should have an individual electrode setup and calibration. Once the data for
Electrode 1 (Gun1) is populated on this "Electrode" tab and the timer is “Online", click on the
"Current calibration" button in the lower left corner.

1. Connect the current meter, close the secondary circuit with weld force, or weld with the selected
program.

2. Make sure the timer is set to "Weld mode" and pull in the isolation contactor.

3. Selected weld program should be set to PHA for the relevant electrode to pass current during
calibration procedure.

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4. Click on the "Store values" box to record the weld current data from the weld checker, then press
OK.

5. Acknowledge the Calibration safety message "Possibility of uncontrolled gun movement! Are you
sure?" Click "Yes" to continue "Current calibration".

6. Click on "Start Wld" button with the initial current request set to 50% PHA angle.

• Record the 1st value from weld checker in the top "Measured Current (kA)" space provided. Click
"Enter" to send it to the timer. The number 1 should appear next to this space.

• Click on "Start weld" button with the initial current request set to 50% PHA angle again to get a
second reading.

• Record the 2nd value from weld checker in the top "Measured Current (kA)" space provided. Click
"Enter" to send it to the timer. The number 2 should appear next to this space.

• After 2 values are recorded, press the "Continue" button to switch to the lower current test.

• Click on "Start weld" button with the second current request set to 30% PHA angle.

• Record the 1st value from weld checker in the bottom "Measured Current (kA)" space provided.
Click "Enter" to send it to the timer. The number 1 should appear next to this space.

• Click on "Start weld" button with the second current request set to 30% PHA angle again to get a
second reading.

• Record the 2nd value from weld checker in the bottom "Measured Current (kA)" space
provided. Click "Enter" to send it to the timer. The number 2 should appear next to this
space.
• After 2 values are recorded in both "Measured Current (kA)" spaces, press the "Continue"
button to calculate the "Toroid sensitivity" value for this electrode.
• For multiple electrode applications, select the next electrode number and perform the
"Current calibration" again.

8.1.2 Verification of Current Calibration

1. Select a weld program (set to KSR) for the relevant electrode to pass a known current value
(9.00 kA) to test the accuracy of the new value.
2. If the current on the weld checker is higher than the requested 9.00 kA, the toroid sens. value
can be adjusted lower.
3. If the current on the weld checker is lower than the requested 9.00 kA, the toroid sens. value
can be adjusted higher.
• Once the requested current and the actual current are the same on the weld checker no
further adjustments are necessary. The toroid sensitivity for that electrode should be
documented on the check sheets.
• For multiple electrode applications, select the next electrode number and perform
verification again. Remember to choose/create a weld program with the proper electrode
number for testing.

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9 Bosch Controlled Tip Dress with Fanuc Robot

9.1 Required for Setup

9.1.1 Communication between Fanuc Robot and Bosch Weld Controller
• Must have a valid schedule selected when sending and receiving I/O signals in the Bosch
• Mode tip dresser management must be set to the type of tip dress motor (Elec. Dresser in this
case)
• Short time delays may be required to allow I/O update for the motor to start or stop turning.
• "Tip dresser management" error is a pretty good indicator that the timing is not quite right on
the I/O signals.
• With "Mode tip dresser management" = “Off”, the cutter turning time is not monitored with
corresponding error message.

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9.1.2 Fanuc Program to Turn Tip Dress Motor ON

9.1.3 Fanuc Program to Turn Tip Dress Motor OFF

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10 Restoring Default Settings/Restoring from a Backup
This section will assist in guiding you through restoring the factory default settings into your Bosch
weld controller.

10.1 WARNING
You should not have to restore backup when commissioning or at the OEM. Backups should only be
used by the end user in case of a failure and/or replacement of a controller. Utilizing DB→Timer when
connecting can cause parameters that will not work with the specific timer you are using to be sent to
the unit. This can cause undesired effects, such as, contactor not pulling in or timing out inconsistently.

10.2 Getting Started

10.2.1 Software
You will be using the Bosch BOS6000 software to reset the weld
controller to its default settings. This document was written using
revision 1.47.1. If the software was already open when beginning
this exercise you will need to close it down and relaunch.

• Start Menu → BOS6000

10.2.2 Replacing the Timer

10.2.2.1 Modifying Timer

Once the software has re-opened you will have to locate the timer you
wish to set to default. The Timer Reference pop-up window will appear
after launch, you must:

• Double Click on the timer and another window will pop-

up
• Add “_OLD” to the timer name and change the IP
address to one that is not being utilized on the network;
as depicted in the image on the right.

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10.2.2.2 Creating a New Timer
After modifying the selected offline version of the timer (now labelled
with “_OLD”) you will add a new timer by clicking the ADD button in
the bottom right-hand corner of the Timer Reference window.

• The Add/Change Timer window will pop-up and

here you will enter the original name of the timer
without the “_OLD” attached as well as the original
IP address.
• Ensure you are set to Query under the direction
selection and when the pop-ups occur when
connecting ensure you read them carefully.

10.3 Loading Default Settings

The following portion should happen automatically once you attempt to connect to the timer. The
following instructions will direct you as to which selections to make to ensure the default settings
get installed properly.

10.3.1 Connecting & Loading

This is done by pressing the Continue button in the bottom right-hand corner after you have
ensured the correct name and IP address were used when making the new timer in the previous
steps.

• Another pop-up window will appear

showing that it is attempting to make
a connection to the new timer you
created.
• It should register that the names are
the same but if it doesn’t a pop-up
will appear informing you that the names are not the same and then ask if you want to go
Timer→DB or DB→Timer. In this instance we want to go Timer→DB.
• Next the software will compare the data in the timer to the database saved in your
computer. Because you just created the timer in your list it will contain the default settings
and will prompt you to go Timer→DB or DB→Timer. In this instance we want to go
DB→Timer.
• The software will now update the Timer with the default parameters.

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10.3.2 Copying Schedules
Once the software has configured the default settings it will boot up the way it normally does.

• You have several options at this point based

on why you had to reset to the defaults in the
first place.
• If it was because you had the wrong firmware,
then you will have to re-enter each weld
schedule by hand as you cannot ensure that
the proper values will go to the proper
positions. This can cause any number of issues
such as the hold time not functioning.
• If you were changing back to defaults for any
issue that did not require altering the
firmware revision, then when the software
loads you can go to EDIT in the menu bar and
select COPY
• This will allow you to copy all the programs
from the old Timer to the new Timer.

10.3.3 Configuration and Electrodes

After you bring in all your schedules from
the previous Timer you will have to go
through the calibration and setup process
for each electrode that was attached to
the original which will be covered in
another article. The General and Electrode
tabs contain all the topics we generally
deal with to complete this task.

10.4 Post Configuration

Once you have recalibrated your Timer and setup all the electrodes and weld schedules required
for your system if you continue to have issues it may require the Timer to be flashed. This can only
be done by Bosch however in some circumstances they can assist us in flashing the timer over the
phone.

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11 Contact Info
Gerry Wrobel can be reached at gerry.wrobel@boschrexroth.ca or at 519-965-0818

12 Revision History
2019-12-03 Jeffrey Mickle Added revision history

2020-04-14 Chris Sartor Added Restoring Default Settings

2020-04-14 Chris Sartor Added Contact Info

2021-02-26 Antony Aquino Added Equation to calculate Nominal Current

2022-05-02 Shawn Mcphedran Added 1.4 Power Cycling the Control

2022-05-19 Pranav Chandras Modified and added Diodes Selection based on Transformer

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