Bosch BT220 Technical And Operations Manual

Technical Information and Operation 1070 080 037-101 (99.01) GB Reg. No. 16149-03 E 1999 by Robert Bosch GmbH, Erbach / Germany All rights reserved, including applications for protective rights. Reproduction or handing over to third parties are subject to our written permission. Discretionary charge 20.00 DM

Contents I 1070 080 037-101 (99.01) GB Contents Page 1 Safety Instructions 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Explanation of pictographs and symbols 1-1 . . . . . . . . . . . . . . . . . . . . . . . Warning of magnetic fields 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal use 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qualified personnel 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retrofits and modifications by the user 1-5 . . . . . . . . . . . . . . . . . . . . . . . . Maintenance, repair 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation and assembly 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Units without Monitoring Contact ÜK 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . Start Simulation 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Reset 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working safely 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overview 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation and Assembly 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical Connection 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Power Supply (X1) 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Lamp and Ready Outputs (X2) 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 RS232 Interfaces 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 RS485 Interface 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operation 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Display and Acknowledge Events, if necessary 5-2 . . . . . . . . . . . . . . . . . 5.2 Display / Change Internal Time Setting of the BT220 5-3 . . . . . . . . . . . . 5.3 Set System Language 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Displaying / Changing Welding and Process Data 5-4 . . . . . . . . . . . . . . . 5.4.1 Selection of Program and Weld timer 5-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.2 F2: Sequence 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.3 F3: Monitoring 5-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.4 F4: Data of the Last Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.4.5 F5: Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 5.4.6 F6: Pressure Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 5.4.7 F7: Stepper Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5.4.8 F8: FPO_1 (freely programmable analog output) . . . . . . . . . . . . . . . . . . . 5-15 5.4.9 F9: Heat Correction 5-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II 1070 080 037-101 (99.01) GB 5.5 Deleting the Message Memory 5-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 Display Diagnostic Memory 5-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 Printing the Diagnostic Memory 5-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 Deleting the Diagnostic Memory 5-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 Adapting the BT220 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 5.9.1 Setting the Message Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 5.9.2 Setting the Flash Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.9.3 Setting ”Automatic Message Scrolling” . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 5.9.4 Display Parameters 5-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 Testing the BT220 Keyboard 5-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11 Configuring the Printer Interface (X4) 5-29 . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 Inhibiting the Control Function 5-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13 Overview: BT220 Specific Functions and Parameters 5-33 . . . . . . . . . . . 6 Maintenance 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Battery 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Reset 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Software release 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Appendix 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Information on the STK multi-contact interface board 7-1 . . . . . . . . . . . 7.2 List of Figures 7-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Subject index 7-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instructions 1070 080 037-101 (99.01) GB 1-1 1 Safety Instructions The product described hereunde was developed, manufactured and tested in accordance with the basic safety stipulations of the EC Machine Directive. You should nevertheless be aware of residual risks! You should therefore read this manual before mounting, setting up, commis- sioning or programming the system or working with this control system for the first time. Keep the manual in a place where it is easily accessible to all users! Explanation of pictographs and symbols The following warnings and notes may be attached to the individual hard- ware components which are designed to inform the user of certain circum- stances. ’ Warning of dangerous voltages! ’ Components subject to electrostatic induction! ’ Disconnect mains plug before opening! ’ Bolt for connection of the PE (protective earth) conductor only! ’ For shield conductor only!

1070 080 037-101 (99.01) GB 1-2 There is a certain hierarchy of warnings in this manual. The warnings are printed in bold letters and marked by a warning sign at the margin. The hierarchy of the warnings is as follows: 1. WARNING 2. ATTENTION 3. NOTE WARNING! The term WARNING will be used wherever danger is imminent. The possible consequences may be death or severe injury (personal injury). ATTENTION! The term ATTENTION will be used wherever a dangerous situation is possible. The possible consequences include death, severe or light injury (personal injury) damage to property or environmental hazards. NOTE The term NOTE will be used for making recommendations on the use. Non-compliance with these recommendations may result in damage to property, e.g. to the machine or the workpiece. !

Safety Instructions 1070 080 037-101 (99.01) GB 1-3 Warning of magnetic fields In the environment of resistance welding systems magnetic field strengths have to be expected which usually are below the limits specified in VDE 0848 Part 4; in cases of doubt, the field strength must be measured. WARNING! When using manual welding guns, the limit values may be exceeded for the extremities. In this case, additional work protection measures must be taken. WARNING for persons with cardiac pacemakers! Warning signs should be posted for protecting persons with cardiac pace- makers because the function of these devices may be disturbed (impulse failure, total failure) and a negative influence on the pacemaker program- ming or even a total program destruction may occur !!! We recommend posting a warning of the type shown below at all entrances to factory halls containing resistance welding equipment: No entry for persons with cardiac pacemakers! Danger! DIN 40023 ! !

1070 080 037-101 (99.01) GB 1-4 Normal use In conjunction with the connected PS 5000 weld timer the Operating terminal serves for the ‘ Display and change of parameters ‘ Display of faults, warnings and signals It is only suitable for ‘ industrial applications in accordance with DIN EN 50082-2 of Electromagnetic Compatibility (EMC). It is not intended for any other use! ATTENTION! The use for purposes other than the intended use may result in personal damage to the user or third persons or damage to the equipment, the work- piece to be welded or other hazards. Therefore, our products should only be used for their intended purpose! Qualified personnel This manual is designed for welding technicians and engineers with special training and specific knowledge of the welding technology. They require pro- found knowledge of the hardware components, the functions and the pro- gramming of the welding equipment. The term qualified personnel refers to - engineering personnel familiar with the safety standards of the electrical and automation technology. - commissioning personnel entitled to commission, earth and label electri- cal circuits and equipment/systems in compliance with the standards of safety technology. - operating personnel who have been instructed in operating installations in resistance welding technology and who know the contents of the pres- ent documentation as far as operation is concerned. WARNING! An exception are persons with cardiac pacemakers! Due to the strong magnetic fields arising from resistance welding, the func- tion of cardiac pacemakers may be disturbed. This may cause the death or considerable health damages to persons with cardiac pacemakers! Therefore, these persons should avoid the welding system. Please note our comprehensive range of training courses. More information is available from our training center (Phone: ++49 (0)6062 / 78258). !

Safety Instructions 1070 080 037-101 (99.01) GB 1-5 Retrofits and modifications by the user Our equipment has been designed and manufactured by us as a safe unit. WARNING! Retrofits or modifications may have negative effects on the safety of the unit! The possible consequences include death, severe or light injury (personal injury) damage to property or environmental hazards. Therefore, please contact us prior to retrofits or modifications to the welding system using third-party equipment. This is the only way to determine whether these parts are suitable for use with our product. Maintenance, repair WARNING! - Danger of life through electrical voltage! Prior to any maintenance work - unless described otherwise - the sys- tem must always be switched off! In the event of necessary measure- ment or test procedures on the active system, the applicable safety and accident prevention regulations must be strictly observed. In any case, suitable insulated tools must be used! - Danger of life through inappropriate EMERGENCY-OFF devices! EMERGENCY-OFF devices must be operative in all modes of the sys- tem. Releasing the EMERGENCY-OFF facility must by no means result in an uncontrolled restart of the system! ATTENTION! - The right to perform repair/maintenance work on the timer compenents is reserved to the BOSCH service department or to repair/maintenance units authorized by BOSCH! - Only use spare parts/replacement parts approved by BOSCH! − If handled improperly, batteries may cause cauterization or explode! Therefore: Batteries must not be opened forcefully, recharged, soldered at the cell body or thrown into fire! - Only use original replacement batteries! Spent batteries or accumulators must be disposed of as hazardous waste. ! !

1070 080 037-101 (99.01) GB 1-6 Installation and assembly ATTENTION! - Please observe all applicable safety and accident prevention regula- tions! - Danger of damage to property through short-circuits! When drilling or sawing out openings, metal burr may get inside modules or plant sections that have already been installed. Possible consequences include short-circuits and a destruction of the equipment. Therefore, all equipment should be well partitioned prior to any additional work! - The units, and especially the operating elements, must be installed so as to be sufficiently protected against unintentional operation or contact. - Connection and signal leads should be run so as to avoid disturbance of any equipment functions by capacitive or inductive interference. - Equipment designed for installation in housings or switch cabinets must be installed in such enclosures before they may be used or operated!

Safety Instructions 1070 080 037-101 (99.01) GB 1-7 Units without Monitoring Contact ÜK ATTENTION! When the ÜK is permanently connected to +24V, the squeeze times are to be selected long enough so as to ensure that the parts to be welded are opti- mally pressed together before the weld time starts. Start Simulation ATTENTION! If the equipment is started remotely, there results a program sequence which can cause hazardous machine movements. So check before remote start up that no one is in the danger zone of the welding equipment! Fault Reset WARNING! - Danger of physical injury! If the start signal is present on fault reset, the weld timer immediately starts the program sequence! Hazardous machine movements may be the result! Therefore, before fault reset, you should make sure that there are no per- sons in the danger zone of the welding equipment! - Danger of bruises through electrode movement! All users, line designers, welding machine manufacturers and welding gun producers are obliged to connect the output signal of the Bosch weld timer which initiates the electrode movement so that the applicable safety regulations are complied with. The risk of bruises can be considerably reduced by means of, e.g., ‘ two-handed start ‘ guard rails ‘ light barriers etc. !

1070 080 037-101 (99.01) GB 1-8 Working safely WARNING! - During operation of the welding equipment welding splashes are to be expected! The consequence may be injuries to the eyes or burns. Therefore: ‘ wear protective goggles ‘ wear protective gloves ‘ wear flame-retardant clothes - Danger of injury at sheet metal edges and danger of getting burnt at the parts to be welded! Therefore: ‘ wear protective gloves NOTE The strong magnetic fields arising in connection with resistance welding may cause lasting damages to wrist watches, pocket watches, or cards with magnetic stripes (e.g. EC cards). Therefore, you should not carry any such items on you when working in the direct vicinity of the welding equipment. !

Overview 1070 080 037-101 (99.01) GB 2-1 2 Overview NOTE For comfortable programming and setting of parameters of the PS 5000 use a PC with the welding software ”BOS 5000” installed. In normal operation of the welding unit the complete function range of this package is not really re- quired. Because of this the BT220 is available to you as a stationary control ter- minal of your PS 5000 (supported control types: PSS 5100.510 and PSS 5200.510; please ask for other supported types). It is designed for installation in the machine operating panel of the welding unit. So faults, warnings and messages of the PS 5000 can be displayed in clear text and basic welding data may be quickly and easily displayed or changed. Fig. 2-1: Front View BT220 This manual contains information on ‘ the mechanics ‘ the electrical connection and ‘ the functions of the BT220. ATTENTION! Danger of malfunctions and damage! Wrong installation and faulty connection can lead to unexpected or wrong unit reactions and hence to hazardous situations. So please respect the de- tails in the present manual. Follow all the instructions in this manual (instructions are identified by the sign ”’”). They are for your own safety and for problem-free commissioning. ‘ Display of faults, warnings and messages of the PS 5000. The BT220 can manage a maximum of 100 events present at the same time in the message memory. ‘ Display and modification of different welding and process data. ‘ Diagnostic memory for max. 400 events (ring memory). The contents of the diagnostic memory can be output via the serial interface to a printer. Functions

1070 080 037-101 (99.01) GB 2-2 ‘ BT220-1: with 1 RS232 interface for the connection of 1 x PS 5000 or 1 x STK multi-contact interface board. ‘ BT220-2: with 2 RS232 interfaces for the connection of 2 x PS 5000 or 1 x STK multi-contact interface board and 1 x Report printer. ‘ BT220-3/7: with 1 RS485 and 1 RS232 interface for the connection of 1 x STK multi-contact interface board (RS485) and 1 x Report printer (RS232). ‘ STK x: Multi-contact interface board for the connection of max. 7 PS 5000 via RS232 interfaces. In the basic design the STK is already prepared for the connection of 3 PS 5000. It can be easily retrofitted with additional plug-in RS232 interface modules. For communication with a BT220-x, the multi-contact interface board is optionally available with a separate RS485 or RS232 interface. You can find more information on the multi-contact in- terface board on page 7-1. BT220-1 X1 X4 max. 15m 1st PS 5000 RS232 Fig. 2-2: Connection of a PS 5000 Constructions Options Application Examples

Overview 1070 080 037-101 (99.01) GB 2-3 BT220-2 X1 X5 max. 15m X1 X4 max. 15m 1st PS 5000 2nd PS 5000 RS232 RS232 Fig. 2-3: Connection of 2 PS 5000 BT220-x 1st PS 5000 X1 2nd PS 5000 3rd PS 5000 4th PS 5000 5th PS 5000 6th PS 5000 7th PS 5000 Multi-contact in- terface board STK X1 X1 X1 X1 X1 X1 Cable lengths for - RS232 connections max.15m - RS485 connections max.1000m RS232 RS232 RS232 RS232 RS232 RS232 RS232 Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 7 Channel 8 RS232 or RS485 Fig. 2-4: Connection of max. 7 PS 5000 to BT220 via STK multi-contact interface board

Installation and Assembly 1070 080 037-101 (99.01) GB 3-1 3 Installation and Assembly The BT220 is intended for installation in a control panel, a control cabinet or a front plate. Weight: approx. 1.5 kg Installation position: 0_ to max. 90_ slant Installation type: in a desk or hinged frame, sealed as per IP 65 Degree of protection: IP 65 (front face); IP 40 (back face) Dimensions: Required assembly cutout: 262 mm x 92 mm Required installation depth: 110 mm Front dimensions: 277 mm x 112 mm Temperature: Operating temperature range: 0_C to +50_C Storage temperature range: -30_C to +70_C Air humidity: 20% to 80% rel. air humidity ’ Please refer to the information in chapter ”Safety Instructions” relative to installation and assembly. ’ Install the BT220 so that ergonomic operation is guaranteed. Also the operator must have a clear view of all moving machine parts at all times! Remember how quickly the front panel can become dirty with an inclined or horizontal installation. ’ Avoid installation places which are exposed to direct sunshine (reduction of display legibility; additional heat). ’ Provide a minimum all-round clearance of 50mm for sufficient ventilation and cable routing. ’ Run all connection cables in loops, and use strain reliefs for all cables. ’ Keep as far away as possible away from sources of interference, how- ever at least 25cm. With strong magnetic fields we recommend the in- stallation of partition plates. ’ Only use silicon-free sealing, adhesive or insulating media. max. 90° Minimum all�round clearance of 50 mm BT220 Fig. 3-1: Installation positions and distances

BT220 Technical Information and Operation 1070 080 037-101 (99.01) GB 3-2 ’ Fix the BT220 with the 4 screw terminals. For this purpose, first insert the BT220 into the assembly cutout and then engage the screw terminals in the recesses on the top and bottom sides of the BT220 housing. Then tighten the screw terminals.

Electrical Connection 1070 080 037-101 (99.01) GB 4-1 4 Electrical Connection Supply inputs, outputs and interfaces are isolated from each other. ’ Disconnect the unit from power before wiring the BT220. ’ Make sure that the circuits of relays or contactors, which are installed in the same installation room as the BT220 include the corresponding free- wheeling diodes or RC spark-quenching devices. 1 5 6 9 X4 X1 X2 PE/Screening X1: 24VDC power input X2: Outputs (indicator lamps, ready state) X4: RS232 interface for the connection of PS 5000, or STK multi-contact interface board Fig. 4-1: Connections on the BT220-1 1 5 6 9 X4 X5 X1 X2 PE/Screening 1 5 6 9 X1: 24 VDC power input X2: Outputs (indicator lamps, ready state) X4: RS232 interface for the connection of PS 5000 or report printer X5: RS232 interface for the connection of PS 5000, or STK multi-contact interface board Fig. 4-2: Connections on the BT220-2 Remarks BT220-2: If an STK multi-contact interface board is connected to X5, only a report printer may be connected to X4. Position of the Connec- tions

1070 080 037-101 (99.01) GB 4-2 1 5 6 9 1 13 14 25 X4 X5 X1 X2 PE/Screening X1: 24 VDC power input X2: Outputs (indicator lamps, ready state) X4: RS232 interface for connection of report printer X5: RS485 interface for connection of STK multi-contact interface board Fig. 4-3: Connections on the BT220-3/7 4.1 Power Supply (X1) Connection: Screw terminal plugs MSTB 2.5 / 5-ST-5.08 Supply voltage: 19...33 VDC; typ. 24 VDC Current consumption: < 0.35 A X1 +24 VDC 0 VDC PE Fig. 4-4: Terminal Assignment X1 Remarks If you wish to use the outputs on X2, you must connect the supply voltage to X2 as well.

Electrical Connection 1070 080 037-101 (99.01) GB 4-3 4.2 Lamp and Ready Outputs (X2) Connection: Screw terminal plugs MSTB 2.5 / 8-ST-5,08 Output current: (with 24 VDC supply); permanently short-circuit- proof Supply voltage: 19...33 VDC; typ. 24 VDC The outputs for the display of warnings and fault messages are functionally identical with the warning (red LED) and fault message (yellow LED) on the front panel of the BT220. The output signals are static (not flashing). NOTE Overloading the output drivers possible! ’ Use the outputs only for control of the relays or PLC inputs. Via the ready output a connected PLC can recognize whether serial com- munication is functioning properly. X2 Warning 0 VDC +24 VDC Ready Fault res. Fig. 4-5: Terminal Assignment X2

1070 080 037-101 (99.01) GB 4-4 4.3 RS232 Interfaces BT220-1: X4 BT220-2: X4 and X5 BT220-3/7: X4 Connection: Sub-D socket, 9-pin. Type: RS232 Lead length: max. 15m Lead type: shielded, core cross-section min. 0.14mm2 Transmission rate: adjustable: 300, 600, 1200, 2400, 4800, 9600, 19200, 38400, 76800 bits/s default: 9600 Parameters: adjustable: 7 or 8 data bits, even / odd / no parity, 1 or 2 stop-bits default: 8N1 (8 data bits, no parity, 1 stop-bit) Handshake: adjustable: without, Hardware-Handshake (RTS, CTS), Software-Handshake (XON, XOFF), Software-Handshake + DTR default: Software-Handshake (XON, XOFF) 1 2 3 RX TX 4 max. 15 m BT220 Shield continuity via the metal housing of the plug connection, or via a spade connector on the housing 5 GND 6 7 8 9 PS 5000 (X1; Sub-D, 9-pin) RX TX GND Socket Plug 2 3 5 DTR 4 DSR 6 RTS 7 CTS 8 Fig. 4-6: Connection of PS 5000 to BT220 Connection: PS 5000 - BT220

Electrical Connection 1070 080 037-101 (99.01) GB 4-5 Prerequisite for shown connection: Hardware-Handshake 3 7 READY RX 11 max. 15 m BT220 GND Printer (Sub-D, 25-pin) CTS TX GND Socket Socket 8 3 5 Shield continuity via the metal housing of the plug connection or via a spade connector on the housing Fig. 4-7: Connection of a Serial Printer Remarks Many printers output the READY signal to Pin 20. In such cases the CTS input on the BT220 must be connected with Pin 20 on the printer. 1 2 3 TX RTS�/�DTR 4 max. 15 m BT220 5 CTS 6 7 8 STK (Channel 4; Sub-HD, 15-pin) RX TX GND Socket Socket 2 3 5 DTR 4 DSR 6 RTS 7 CTS 8 RX GND Shield continuity via the metal housing of the plug connection or via a spade connector on the housing Fig. 4-8: Connection of the STK multi-contact interface board: Channel 4 fitted with RS232 interface Connection: Report Printer - BT220 RS232 Connection: STK - BT220

1070 080 037-101 (99.01) GB 4-6 4.4 RS485 Interface BT220-3/7: X5 Connection: Sub-D socket, 25-pin. Type: RS485 Lead length: max. 1000m Lead type: 2-wire, twisted and shielded, core cross-section min. 0.14mm2 Transmission rate: adjustable: 38400, 57600, 76800, 115200 bits/s Parameters: 7 data bits, even parity, 1 stop-bit (7E1) max. 1000 m BT220 Shield continuity via the metal housing of the plug connection or via a spade connector on the housing Connection on one side: for short data cables or low frequency interference Connection on both sides: for long data cables or high frequency interference STK (Channel 4; Sub-HD, 15-pin) A B +5�V Socket Socket 14 15 21 A B 4 11 0�V 7 +5�V 15 0�V 8 provision for bus termination provision for bus termination Fig. 4-9: Connection of the STK multi-contact interface board. Channel 4 fitted with RS485 Interface With high transmission rates or long data cables we recommend the use of a bus termination. The necessary resistors can for example be integrated into both plugs of the transmission lead: BT220 Rt approximately equal to the characteristic resistance of the lead (typically 50-120 Ohm) Ru Pull-up resistor Rd Pull-down resistor STK (Channel 4; Sub-D, 15-pin) Pin 15 Pin 8 Pin 4 Pin 11 A B Ru Rt Rd Pin 21 Pin 7 Pin 14 Pin 15 A B Ru Rt Rd Fig. 4-10: Bus Termination for RS485 Connections RS485 Connection: STK - BT220 RS485 Connection: Bus Termination

Operation 1070 080 037-101 (99.01) GB 5-1 5 Operation Numerical keys Cursor keys Command keys Fig. 5-1: Front View BT220 For the input of numerical values (inc. decimal point and minus sign). F calls up the function key mode. In this mode you have access to weld- ing and process data (see page 5-4). depends on the current state of the BT220: - acknowledges events, parameter changes or queries - triggers functions - branches into sub-menus. I,0 switches welding specific functions on or off within the function key mode. i calls up hidden Help texts, depending on the current status. shows the day, date, time and calendar week (see page 5-3). MEN depending on the current status of the BT220: - calls up the Main Menu of the BT220 (for menu tree see page 5-33) - cancels parameter changes - cancels a function awaiting acknowledgment. VAR initiates a parameter change. A " depending on the current state of the BT220: - scrolls through the messages present - scrolls through the diagnostic memory - selects a parameter for modification Y B depending on the current state of the BT220: - scrolls through menus - scrolls through setting options - scrolls through texts comprising more than 2 lines. Numerical keys Command keys Cursor keys

1070 080 037-101 (99.01) GB 5-2 5.1 Display and Acknowledge Events, if necessary Display Fault Warning Message Cursor keys Acknowledge key Help key Fig. 5-2: Front View BT220 After it is switched on the BT220 is in Message Display Mode. All events which are transmitted by the connected weld timers can be displayed and acknowledged, if necessary. If no event has occurred, the text “No message” is shown in the display (see Figure). Whole display text flashes: An event is present and must be acknowl- edged with the key . Call up Help on the event: Key i Close Help: Key i Display text does not flash: An event which does not have to be ac- knowledged or has already been acknowl- edged (is logically TRUE) is present. As soon as the event is no longer present, the corresponding display text is automatically deleted. Call up Help on the event: Key i Close Help: Key i Fault (red LED flashes): Fault/error message is present. ’ Remedy fault and acknowledge with . Warning (yellow LED flashes): A warning is present. ’ Remedy the cause and acknowledge with . Message (green LED): There is more than 1 event present. You can select the event automatically dis- played by the BT220 (see page 5-24). Other events present can be found in the message memory (max. 100) and dis- played with the cursor keys A and ". You can find additional information on the message memory on page 5-17.

Operation 1070 080 037-101 (99.01) GB 5-3 5.2 Display / Change Internal Time Setting of the BT220 The BT220 is fitted with an internal clock. Whenever an event appears, disappears or is acknowledged, the BT220 stores the current time and date in the diagnostic memory as well as the corresponding text. ’ Therefore, make sure the clock is set to the right time. In the following description we assume that the BT220 is in message display mode (see chapter 5.1, page 5-2). The function may be called up from several other operating states, but on completion always returns to the message display mode. 1. Press key . The first line in the display shows the current value for the day, date, time, calendar week. The BT220 calculates the details of the day and calendar week automati- cally from the date value. 2. Values are incorrect: Proceed to Step 3. Values are correct: Press MEN key. The BT220 returns to the message display mode. 3. Press VAR key. The currently changeable figure flashes. 4. Move the cursor with the cursor keys A and " to the figure to be changed and enter the new value - via the numerical keys or - via the keys Y and B. In this way set the correct date and time. 5. To store current values: press . To cancel changes: press MEN. Proceed to Step 2. 5.3 Set System Language The language for message and menu texts can be set. The BT220 offers German and English as standard. Other languages can be added as re- quired (max. 10 in total). In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1 Press the MEN key. The menu item ”Diagnostic memory” appears in the second display line. 2. Keep pressing the B key until the text ”Change language” is displayed in the second display line. 3. First press the key, then the VAR key. 4. Use the keys Y and B to set the new language. 5. To activate the displayed language: press . To cancel changing the current language: press MEN. 6. Press the MEN key twice to return to the message display mode. Procedure Procedure

1070 080 037-101 (99.01) GB 5-4 5.4 Displaying / Changing Welding and Process Data ’ Do not change data without instructions. All data is transmitted on-line to the weld timer. Wrongly entered data can cause damage to the equip- ment or the part to be welded! ’ Make sure that the required welding program and the required weld timer have been correctly selected before you change data. For the selection see page 5-7. Via the BT220 you have access to the following data: ‘ F1 Help. Options: - Display Help text. ‘ F2 Sequence. Options: - Display and change the pre-squeeze time, squeeze time, 1. weld time, 1. heat, 1. cool time, 2. weld time, 2. heat, pulsation, 2. cool time, 3. weld time, 3. cool time, 3. heat, hold time, off time. ‘ F3 Monitoring. Options: - Activate/deactivate current monitoring. - Display and change +/- tolerance, ”conditional tolerance band”, conditional welds, reference current. Depending on the selectable mode (STANDARD or MIXED) you have access to the above mentioned parameters for WLD, 1.WLD, 2.WLD or 3.WLD. ‘ F4 Last weld. Options: - Display reference and actual current, average phase angle. ‘ F5 Slope. Options: - Activate/deactivate the slope. - Display and change the start and end slope (time and heat, each). ‘ F6 Pressure Profile. Options: - Activate/deactivate control of the pressure regulating valve. - Display and change the basic pressure (up to SQZ), welding pressure (from SQZ). ‘ F7 Stepper Diagnostics. Options: - Display the current electrode wear values (for max. 8 electrodes). - Acknowledge tip dress, acknowledge electrode change (for one single electrode or for all electrodes collectively by entering electrode number ”0”). ‘ F8 FPO_1 (freely programmable output). Options: - Activate/deactivate the output. - Display and change 3 high and 3 low times. ‘ F9 Heat Correction. Options: - Display and change heat correction parameters of all electrodes. To display or change the welding or process data of all programs of the con- nected PS 5000, switch the BT220 to the ”Function Key Mode”. Overview

Operation 1070 080 037-101 (99.01) GB 5-5 Remarks When events are present or occur which have to be acknowledged, the BT220 automatically switches to the message display mode (see chapter 5.1, page 5-2). Display and modification of the welding or process data is only possible when you have acknowledged all events. The BT220 in this case automati- cally returns to the last active display level of the function key mode. In the following description of the procedure we assume that the BT220 is in the message display mode (see chapter 5.1, page 5-2). The function key mode can also be called up from some other operating statuses, but on completion always returns to the message display mode. 1. Press key F. The BT220 now waits for the input of the function number (1 to 9). In the ”Overview” section on the previous page you will find all the avail- able functions listed numerically (Fx). 2. Enter - the required number using the numerical keys, or - press theB key (automatically selects the lowest applicable function number: here ”1”). 3. Press key . BT220 is now in the ”Main Menu” of the function key mode. The display shows the previously selected function. Remarks When at the end of the first display line the character ”q” (”0” with a horizontal line through the middle) is displayed, there is a sub-menu to the function shown. In this operating mode the following actions can be selected : - Return to the message display mode - Step through the Main Menu - Select program and/or weld timer for data display/modification - Change to the sub-menu of the displayed function (only possible when the character ”q” appears at the end of the first display line) - Switching the displayed function on, off, over. The following figure shows you the individual options: Procedure: Calling up the Function Key Mode Operating Options in the Main Menu of the Function Key Mode

1070 080 037-101 (99.01) GB 5-6 Message display mode Function Key Mode (Main Menu) . . MEN F B F 1 9 " B Y I 0 to F1 from F1 to F9 from F9 To the individual sub-menus: VAR A Select program and weld timer for data display / modification; see also page 5-7) (see A) . . 0 9 from the Main Menu Enter pro- gram or weld timer number Select ”pro- gram” or ”TIM” (weld timer) to the Main Menu (Cancel) (Ok) see page 5-8 x = press corresponding key Return to message dis- play mode see page 5-9 see page 5-11 see page 5-12 see page 5-13 see page 5-14 see page 5-15 see page 5-16 F1 Help F2 Sequence F9 Heat Correction F3 Monitoring F4 Last Weld F5 Slope F6 Pressure Profile F7 Stepper Diagnostics F8 FPO_1 ON OFF ON OFF ON OFF ON OFF Standard Mixed I 0 I 0 I 0 I 0 B Y (see A) B Y (see A) B Y (see A) B Y (see A) B Y (see A) B Y (see A) B Y (see A) A " Fig. 5-3: Command Options in the Main Menu of the Function Key Mode

Operation 1070 080 037-101 (99.01) GB 5-7 5.4.1 Selection of Program and Weld timer In order to display or change the data of a program stored on a connected weld timer (TIM) via the BT220, you must select both the relevant timer number and the relevant program number. Values between ”0” and ”255” are admissible for input as program numbers. The possible timer numbers depend on the number of timers actually con- nected and start with ”1”. Depending on the BT220 version used the follow- ing assignment applies: BT220-1 without STK multi-contact interface board: TIM1 = Timer at X4 BT220-2 without STK multi-contact interface board: TIM1 = Timer at X4 TIM2 = Timer at X5 BT220-x with STK multi-contact interface board TIM1 = Timer at Channel 1 TIM2 = Timer at Channel 2 TIM3 = Timer at Channel 3 TIM4 = Timer at Channel 5 TIM5 = Timer at Channel 6 TIM6 = Timer at Channel 7 TIM7 = Timer at Channel 8 Remarks - Please note that channel 4 of the multi-contact interface board is always used for communication with the BT220! - Numbers of timers not connected (TIMx) are not recognized on selection and not accepted. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6). MEN VAR . . 0 9 Enter pro- gram or weld timer number Select ”Pro- gram” or ”TIM” (weld timer) x = press corresponding key Cancel inputs Accept inputs Change pro- gram or weld timer number A " Fig. 5-4: Operating Sequence: Selection of Program and Weld timer

1070 080 037-101 (99.01) GB 5-8 5.4.2 F2: Sequence Here you have access to basic parameters which determine the sequence of a welding process; e.g. pre-squeeze time, squeeze time, 1. weld time, 1. heat, 1. cool time, 2. weld time, 2. heat, pulsation, 2. cool time, 3. weld time, 3. cool time, 3. heat, hold time, off time. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F2: Sequence”. A " MEN VAR . . 0 9 Enter program or weld timer number Select ”pro- gram” or ”TIM” x = press corresponding key Cancel inputs Accept inputs Call up Sub- Menu B Y Change value is ”program” or ”TIM” dis- played? yes . . 0 9 Enter para- meter value no Back to the Main Menu " Scroll display backward Scroll display forward F2: Sequence Fig. 5-5: Operating Sequence: F2 Sequence

Operation 1070 080 037-101 (99.01) GB 5-9 5.4.3 F3: Monitoring Current monitoring can be switched on or off by selecting the corresponding mode (STANDARD or MIXED) selectively for individual sections of the weld- ing cycle (WLD, 1.WLD, 2.WLD or 3.WLD). Only when current monitoring is switched on do you have access to the corresponding set of parameters, consisting of: +tolerance, -tolerance, ”conditional tolerance”, conditional welds, reference current. STANDARD mode: Monitoring can be switched on or off for weld time. Monitoring is deactivated for 1.WLD, 2.WLD and 3.WLD. MIXED mode: Monitoring can be switched on or off for 1.WLD, 2.WLD and 3.WLD independently of one another. Monitoring is deactivated for weld time. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F3: Monitoring”.

1070 080 037-101 (99.01) GB 5-10 Monitoring OFF Change pro- gram or weld timer number MEN VAR . . 0 9 Enter program or weld timer number Select ”pro- gram” or ”TIM” x = press corresponding key Cancel inputs Accept inputs Call up Sub- Menu B Y Change current parameter yes . . 0 9 Enter para- meter value no Back to the Main Menu " I 0 Monitoring ON B is ”program” or ”TIM” dis- played? VAR proceed to A A MEN Cancel inputs Accept inputs Select MIXED mode I 0 Select STAN- DARD mode B Y B yes no A " Is STANDARD mode selected? Is the term ”Current Monitoring” dis- played in the first display line? yes no proceed to A Back to the Main Menu " proceed to B Y B Scroll display backward Scroll display forward Scroll display forward Scroll display forward or backward Scroll display for- ward or backward Back to the Main Menu " F3: Monitoring Fig. 5-6: Operating Sequence: F3 Monitoring

Operation 1070 080 037-101 (99.01) GB 5-11 5.4.4 F4: Data of the Last Weld This function displays (for WLD, 1.WLD, 2.WLD and 3.WLD) the reference currents, actual currents and average phase angles of the previous welding cycle. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F4: Last Weld”. A " MEN VAR . . 0 9 Enter program or weld timer number Select ”pro- gram” or ”TIM” x = press corresponding key Cancel inputs Accept inputs Call up Sub- Menu B Y Scroll display backward Only when ”pro- gram” or ”TIM” are displayed: Back to the Main Menu " Change pro- gram or weld timer number Scroll display forward F4: Data of last weld Fig. 5-7: Operating Sequence: F4 Last Weld

1070 080 037-101 (99.01) GB 5-12 5.4.5 F5: Slope Switches the slope on and off. When the slope function is active, the timer increases (at the start of welding) or decreases (at the end of welding) the welding heat for a definable time period. When the slope is active, both the duration and the heat values at the begin- ning and end of welding can be entered for the startslope and endslope. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F5: Slope”. Change pro- gram or weld timer number MEN VAR . . 0 9 Enter program or weld timer number Select ”pro- gram” or ”TIM” x = press corresponding key Cancel inputs Accept inputs Call up Sub- Menu B Y Change current parameter yes . . 0 9 Enter para- meter value no Back to the Main Menu " is ”program” or ”TIM” dis- played? VAR proceed to A A MEN Cancel inputs Accept inputs B A " Scroll display backward Scroll display forward Scroll display forward Slope ON I 0 Slope OFF Back to the Main Menu " F5: Slope Fig. 5-8: Operating Sequence: F5 Slope

Operation 1070 080 037-101 (99.01) GB 5-13 5.4.6 F6: Pressure Profile Switches the pressure control on and off. Only when the pressure control function is active can the individual pressure parameters be displayed/changed. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F6: Pressure Profile”. Change pro- gram or weld timer number MEN VAR . . 0 9 Enter program or weld timer number Select ”pro- gram” or ”TIM” x = press corresponding key Cancel inputs Accept inputs Call up Sub- Menu B Y Change current parameter yes . . 0 9 Enter para- meter value no Back to the Main Menu " is ”program” or ”TIM” dis- played? VAR proceed to A A MEN Cancel inputs Accept inputs B A " Scroll display backward Scroll display forward Scroll display forward Pressure Profile ON I 0 Pressure Profile OFF Back to the Main Menu " F6: Pressure Profile Fig. 5-9: Operating Sequence: F6 Pressure Profile

1070 080 037-101 (99.01) GB 5-14 5.4.7 F7: Stepper Diagnostics Here you have the following options: - to display electrode wear (Wr) (for max. 8 electrodes). Only electrodes with a wear value > 0% are displayed. The wear display is in integers. - to acknowledge ”Tip dress” (individual or all electrodes) - to acknowledge ”Electrode Change” (individual or all electrodes) In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F7: Stepper Diagnostics”. Change weld timer number MEN VAR . . 0 9 Enter weld timer number x = press corresponding key Cancel selection Acknowl- edge ”Tip dress” or ”Electrode change” Call up Sub- Menu B Y Select electrode number yes . . 0 9 Enter electrode number (1 to 31: ”0” for all) no Back to the Main Menu " is ”TIM” dis- played? VAR proceed to A A MEN Cancel inputs Accept inputs B Scroll display backward Scroll display forward Scroll display forward Back to the Main Menu " only when ”Elec- trode no.” is dis- played in the sec- ond display line Set Electrode number to ”0” F7: Stepper Diagnostics Fig. 5-10: Operating Sequence: F7 Stepper Diagnostics

Operation 1070 080 037-101 (99.01) GB 5-15 5.4.8 F8: FPO_1 (freely programmable analog output) Activation and deactivation of the freely programmable analog output. Only when the analog output is activated can the individual parameters be displayed/changed. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F8: FPO_1”. Change parameter Change pro- gram or weld timer number MEN VAR . . 0 9 Enter program or weld timer number Select ”pro- gram” or ”TIM” x = press corresponding key Cancel inputs Accept inputs Call up Sub- Menu B Y yes no Back to the Main Menu " is ”program” or ”TIM” dis- played? VAR proceed to A A MEN Cancel inputs Accept inputs B A " Scroll display backward Scroll display forward Scroll display forward FPO_1 ON I 0 FPO_1 OFF Back to the Main Menu " . . 0 9 Enter new value Select parameter A " F8: FPO_1 Fig. 5-11: Operating Sequence: F8 FPO_1 (freely programmable analog output)

1070 080 037-101 (99.01) GB 5-16 5.4.9 F9: Heat Correction Display and change the heat correction values of individual electrodes. NOTE The current values are only read out from the connected timers after the BT220 has been switched on. If data has been changed via an additionally connected programming unit, the BT220 will not display the modified data before it has been re-initialized (cycling power) or communication between BT220 and the weld timer has been re-established. In the following description of the operating sequence we assume that the BT220 is in the Main Menu of the function key mode (see page 5-6) and displays ”F9: Heat Correction”. x = press corresponding key Call up Sub- Menu B Y yes no Back to the Main Menu " proceed to A A B Scroll display backward Scroll display forward Scroll display forward Back to the Main Menu " F9: Heat Correction is ”Electrode no.” or ”TIM” displayed? Change elec- trode or weld timer num- ber . . 0 9 Enter electrode or weld timer number is ”Electrode no.” or ”TIM” displayed? VAR MEN Cancel inputs Accept inputs A " Change parameter MEN VAR Cancel in- puts Accept inputs . . 0 9 Enter new value Select parameter A " Fig. 5-12: Operating Sequence: F9 Heat Correction

Operation 1070 080 037-101 (99.01) GB 5-17 5.5 Deleting the Message Memory Events are logged in - the diagnostic memory (see page 5-18) and entered in - the message memory. The message memory with battery back-up acts as a ”collecting tank” for maximum 100 events, which are logically TRUE, or have to be acknowl- edged. If the message memory contains more than one entry, the green message LED on the front panel of the BT220 flashes. Entries in the message memory are only deleted when - an event which does not have to be acknowledged changes again into the state ”logically FALSE” (=Depart message), or - an event which has to be acknowledged is acknowledged by you with the key. Normally each entry is removed again from the message memory in this way. As an exception it can happen that the BT220 may not receive a ”Depart message” for an event present. This effect may for example happen when during an event the communica- tion between BT220 and PS 5000 is interrupted for some reason and during the interruption the event again changes to logically FALSE; the correspon- ding entry was never removed from the message memory. Using the function ”Close all messages” you delete all entries in the mess- age memory. ATTENTION! Events which have to be acknowledged are deleted! Random deletion of events which must be acknowledged can impair the safety of the unit or severely disturb or even interrupt the production pro- cess. ’ Make sure that no negative effects on the safety or the production pro- cess are to be expected before you delete the message memory! In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press MEN key. The menu item ”Diagnostic memory” appears in the second display line. 2. Press key . 3. Press key B . The text ”Close all messages” appears in the second dis- play line. 4. Press key . 5. To delete the message memory: first press VAR key then . To cancel the function Press MEN. 6. Press MEN key to return to the message display mode. Procedure

1070 080 037-101 (99.01) GB 5-18 5.6 Display Diagnostic Memory To log all events the BT220 has a diagnostic memory with a battery back-up. It is structured as a ring memory and comprises a maximum of 400 entries. Should the memory be completely full the oldest entry is overwritten by the new entry. Each entry consists of 2 information blocks: - Max. 2 lines for the event message in clear text - 2 lines for the event number and time tags (for appearance, disappear- ance and acknowledgment of the event). You can have the contents of the diagnostic memory displayed on the moni- tor step-by-step. Here the definition of a ”Time for evaluation” is possible. Only entries with time tags within this time period are then considered for the display. In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press the MEN key. The menu item ”Diagnostic memory” appears in the second display line. 2. Press key twice. The text ”All entries from...” inc. the date and time of the oldest entry ap- pears in the first display line. The cursor flashes in the input field ”Day”. Should the diagnostic memory not contain any entries you receive a corresponding message. Then acknowledge the message with and press the MEN key. The BT220 returns to the message display mode. ’ If you do not want to limit the evaluation time: Press key . Proceed to step 6. 3. Move the cursor with the cursor keys A and " to the figure to be changed and enter the new value via - the numerical keys or - the keys Y and B. In this way you define the beginning of the evaluation time. 4. Press key . The text ”All entries to ...” inc. date and time of the latest entry appears in the first display line. The cursor flashes in the input field ”Day”. 5. Move the cursor with the cursor keys A and " to the figure to be changed and enter the new value via - the numerical keys or - the keys Y and B. In this way you define the end of the time. 6. Press key . The display shows the latest entry. The flashing number at the end of the first display line only serves for your orientation and indicates the position of the displayed entry within the diagnostic memory. The higher the value, the older the entry concerned. Should there not be any entries, the message ”Selected time period ex- ceeded!” appears on the display. 7. At this point you have several control options: - to scroll 1 entry forward or backward: press A or " Procedure

Operation 1070 080 037-101 (99.01) GB 5-19 Should you reach the beginning or end of the diagnostic memory, the BT220 displays the message ”Selected time period exceeded!” (see Figure below). - to change between both information blocks of an entry: press Y or B - to return to the message display mode: press MEN key twice. - to enter a new time period for evaluation: first press the MEN key then press the key. Proceed to step 3. x = press corresponding key Message in clear text 2 lines of 40 char- acters, each displayable on the monitor No.: arrive:_________ depart:___ quit:__ xxx DD.MM.YY HH:MM:SS HH:MM:SS HH:MM:SS Date Time (arrive message) Time (depart message) Time (acknowledg- ment) Event number Message: ”Selected time period exceeded” Message: ”Selected time period exceeded!” A " A " B Y Latest entry Oldest entry max. 400 A " A " A " to the latest entry to the oldest entry A " Fig. 5-13: Display Structure of the Diagnostic Memory Remarks To - print the diagnostic memory: see page 5-20 - delete the diagnostic memory: see page 5-23

1070 080 037-101 (99.01) GB 5-20 5.7 Printing the Diagnostic Memory Remarks In principle all BT220 variants are able to control a connected printer. With the BT220-1, however, only 1 serial interface is available which is required for the connection of the PS 5000. ’ When switched on, the PS 5000 should not be disconnected from the BT220-1! ’ For this reason use the BT220-2 or BT220-3/7 if you want to use the ”Print” function. For printing you need a printer with a serial interface. On page 4-5 you will find instructions for connecting a printer. ’ Switch off the printer before you connect or separate either unit! ’ If both units are connected you can switch the printer on. ’ Make sure that the interface parameters on the printer are set to the fol- lowing values : 8 data bits, no parity, 1 stop-bit, hardware-handshake ’ Make sure that the font size of the printer is set to “12 CPI” (= 96 char- acters per line) and there is sufficient paper. Align the paper to start on a new page. ’ Switch the printer On-line, should this be necessary to receive data (see Printer manual). You have the option of printing the contents of the diagnostic memory - unsorted (= all entries in chronological order) or - sorted (= according to event numbers, chronologically within a number). In both cases the definition of a ”Time for evaluation” is possible. Only entries with time tags within this time period are then considered for printing. In the following description we assume that the BT220 is in message display mode (see chapter 5.1, page 5-2). 1. Press the MEN key. The menu item ”Diagnostic memory” appears in the second display line. 2. Press the B key. The text ”Print” appears in the second display line. 3. Press the key. The text ”Diagnostic memory unsorted” appears in the second display line. ’ If you want to print the unsorted memory: Proceed to step 4. If you want to print the sorted memory: Press the B key. Proceed to step 4. 4. Press the key. The text ”All entries from ...” inc. date and time of the oldest entry is dis- played in the first display line. The cursor flashes in the input field ”Day”. If the diagnostic memory does not contain any entries you receive a Procedure

Operation 1070 080 037-101 (99.01) GB 5-21 corresponding message. Acknowledge the message with and then press the MEN key. The BT220 returns to the message display mode. ’ If you do not want to limit the evaluation time: Press key . Proceed to step 8. 5. Move the cursor with the cursor keys A and " to the figure to be changed and enter the new value via - the numerical keys or - the keys Y and B. In this way you define the beginning of the evaluation time period. 6. Press key . The text ”All entries to ...” inc. date and time of the latest entry appears in the first display line. The cursor flashes in the input field ”Day”. 7. Move the cursor with the cursor keys A and " to the figure to be changed and enter the new value via - the numerical keys or - the keys Y and B den neuen Wert ein. In this way you define the end of the time period. 8. Press key . If you have selected ”unsorted”: Proceed to step 10. If you have selected ”sorted”: Proceed to step 9. 9. Select the range of event numbers in question. For this purpose, move the cursor with the cursor keys A and " to the figure to be changed and enter the new value via - the numerical keys or - the keys Y and B . - to cancel the dialog without printing: Press the MEN key twice. The BT220 returns to the message display mode. - to acknowledge the displayed values: Press key . 10.The BT220 initializes its printer interface. Then it asks you to confirm the printer status: Press key . The printing process starts.

1070 080 037-101 (99.01) GB 5-22 __________________________________________ No.: arrive:_________ depart:___ quit:___ TIM 1: Weld without command 81 21.04.98 20:19:44 20:19:50 20:19:49 __________________________________________ No.: arrive:_________ depart:___ quit:___ TIM 1: Sequence inhibited program 2 94 21.04.98 20:20:06 20:20:11 20:20:10 _________________________________________ No.: arrive:_________ depart:___ quit:___ TIM 1: Power unit not ready 83 21.04.98 20:20:46 20:21:26 20:20:53 __________________________________________ No.: arrive:_________ depart:___ quit:___ TIM 1: Emergency stop open / 24V= error 80 21.04.98 20:21:33 20:21:42 20:21:41 __________________________________________ No.: arrive:_________ depart:___ quit:___ TIM 1: External weld off 102 21.04.98 20:21:33 20:21:37 20:21:39 __________________________________________ No.: arrive:_________ depart:___ quit:___ PS5 error: TIM1: coupling error 5 21.04.98 22:40:35 22:40:54 (function key mode) = continue 5 21.04.98 22:47:41 22:53:00 5 21.04.98 22:53:01 22:53:03 5 21.04.98 22:53:27 22:53:38 5 21.04.98 22:54:01 22:56:30 5 21.04.98 23:01:27 23:04:54 5 21.04.98 23:05:22 23:05:54 5 22.04.98 12:09:16 12:11:56 5 22.04.98 12:13:07 12:13:10 Diagnostic memory unsorted print ended_____________22.04.98__12:13:41______Week: 17 All entries from message 1 to 2047 ___________________________________________No.: arrive:__________ depart:___ quit:___ PS5 error: TIM1: coupling error 5 21.04.98 22:40:35 22:40:54 (function key mode) = continue 5 21.04.98 22:47:41 22:53:00 5 21.04.98 22:53:01 22:53:03 5 21.04.98 22:53:27 22:53:38 5 21.04.98 22:54:01 22:56:30 5 21.04.98 23:01:27 23:04:54 5 21.04.98 23:05:22 23:05:54 5 22.04.98 12:09:16 12:11:56 5 22.04.98 12:13:07 12:13:10 5 22.04.98 12:13:34 12:14:38 ___________________________________________No.: arrive:__________ depart:___ quit:___ TIM 1: Emergency stop open / 24V= error 80 21.04.98 20:21:33 20:21:42 20:21:41 ___________________________________________No.: arrive:__________ depart:___ quit:___ TIM 1: Weld without command 81 21.04.98 20:19:44 20:19:50 20:19:49 ___________________________________________No.: arrive:__________ depart:___ quit:___ TIM 1: Power unit not ready 83 21.04.98 20:20:46 20:21:26 20:20:53 ___________________________________________No.: arrive:__________ depart:___ quit:___ TIM 1: Sequence inhibited program 2 94 21.04.98 20:20:06 20:20:11 20:20:10 ___________________________________________No.: arrive:__________ depart:___ quit:___ TIM 1: External weld off 102 21.04.98 20:21:33 20:21:37 20:21:39 Sorted (= according to order of event numbers) Unsorted (= only in chronological order) Fig. 5-14: Examples: Diagnostic Memory Print-Outs

Operation 1070 080 037-101 (99.01) GB 5-23 5.8 Deleting the Diagnostic Memory Normally the diagnostic memory with battery back-up need not be deleted. Due to its internal ring structure it stores up to 400 entries before the oldest entry is overwritten by a new incoming one. Nevertheless, it may be useful to delete the diagnostic memory at certain times. NOTE Loss of important report data! If you delete the diagnostic memory you will lose the logged data which may be used for subsequent error diagnostics or quality assurance. ’ Therefore, you should print the diagnostic memory contents before the deleting if the memory contains important data (for printing see page 5-20). In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press the MEN key. The menu item ”Diagnostic memory” appears in the second display line. 2. Press the key. 3. Keep pressing the B key until the text ”Delete diagnostic memory” ap- pears in the second display line. 4. Press the key. 5. To delete the diagnostic memory: first press the VAR key then . The BT220 displays: ”Diagnostic memory will be deleted!” To cancel the function: press the MEN key. 6. Press the MEN key to return to the message display mode. Procedure

1070 080 037-101 (99.01) GB 5-24 5.9 Adapting the BT220 Display In this section you find all internal display functions of the BT220. ’ Set these functions during commissioning. 5.9.1 Setting the Message Display Mode In case of several active events, the BT220 automatically shows one event on the display. The event automatically displayed can be defined in accord- ance with the following criteria: Last value with priority: the latest event with the highest priority is displayed first (default setting) Last value without priority: the latest event is displayed first First value with priority: the oldest event with the highest priority is displayed first First value without priority: the oldest event is displayed first. In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press the MEN key. The menu item ”Diagnostic memory” appears in the second display line. 2. Keep on pressing the B key until the text ”Special function” is displayed in the second display line. 3. Press the key. 4. Keep on pressing the B key until the text ”System functions” is displayed in the second display line. 5. Press the key three times. 6. The current setting is displayed behind the text ”Mode”. To change the message display mode: Press the VAR key. To cancel the function: Press the MEN key twice. 7. Select the required mode using the keys Y and B. 8. To activate the selected mode: Press the key. To keep the current setting: Press the MEN key. Proceed to step 6. Procedure

Operation 1070 080 037-101 (99.01) GB 5-25 5.9.2 Setting the Flash Rate Events which have to be acknowledged are shown in the display as flashing text. The times for the on and off phases are adjustable. In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press the MEN key. The menu item ”Diagnostic memory” appears in the second display line. 2. Keep on pressing the B key until the text ”Special function” is displayed in the second display line. 3. Press the key. 4. Keep on pressing the B key until the text ”System functions” is displayed in the second display line. 5. Press the key twice. 6. Keep on pressing the B key until the text ”Flash rate” is displayed in the second display line. 7. Press the key. 8. The current setting is displayed behind the text ”Flash rate”. To change values: Press the VAR key. To cancel function: Press the MEN key twice. 9. Move the cursor with the cursor keys A and " to the figure to be changed and enter the new value (range: 0.1 to 3.9 sec.) via - the numerical keys or - the keys Y and B . Define both times in this way. 10.To activate selected values: Press the key. To keep the current setting: Press the MEN key. Proceed to step 8. Procedure

1070 080 037-101 (99.01) GB 5-26 5.9.3 Setting ”Automatic Message Scrolling” In case of events with a text of more than 2 lines, the BT220 only shows the first 2 lines initially. The remaining text can then be made visible in the follow- ing way: - manually using the keys Y and B (these call up the previous and the next two lines) or - automatically using the ”Message Scroll” function (display of the next two lines within a certain time period). In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press the MEN key. The menu item ”Diagnostic memory” appears in the second display line. 2. Keep pressing the B key until the text ”Special function” is displayed in the second display line. 3. Press the key. 4. Keep on pressing the B key until the text ”System functions” is displayed in the second display line. 5. Press the key twice. 6. Press the B key until the text ”Autom. message scroll” is displayed in the second display line. 7. Press the key. 8. The current setting is displayed in the first line. To change values: Press the VAR key. To cancel the function: Press the MEN key twice. 9. Move the cursor with the cursor keys A and " to the entry to be changed and enter the new value using the keys Y and B (scroll time range: 1 to 99 sec.). 10.To activate selected values: Press key . To keep the current setting: Press the MEN key. Proceed to step 8. Procedure

Operation 1070 080 037-101 (99.01) GB 5-27 5.9.4 Display Parameters This function is used to set the display brightness. ’ Set the brightness so that the display can be optimally read at any time of the day. Please note that a reduced brightness protects the VFD tube of the display monitor. In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press the MEN key. The menu item ”Diagnostic memory” appears in the second display line. 2. Keep pressing the B key until the text ”Special function” is displayed in the second display line. 3. Press the key. 4. Keep on pressing the B key until the text ”System functions” is displayed in the second display line. 5. Press the key twice. 6. Press the B key until the text ”Display parameter” is displayed in the sec- ond display line. 7. Press the key. 8. The current setting is displayed in the first line. To change values: Press the VAR key. To cancel the function: Press the MEN key twice. 9. Enter the new value using the keys Y and B (30%, 50%, 75% or 100%; standard: 75%). 10.To activate selected values: Press key . To keep the current setting: Press the MEN key. Proceed to step 8. Procedure

1070 080 037-101 (99.01) GB 5-28 5.10 Testing the BT220 Keyboard If need be you can test the keyboard for proper functioning. In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press the MEN key. The menu item ”Diagnostic memory” appears in the second display line. 2. Keep pressing the B key until the text ”Special function” is displayed in the second line. 3. Press the key. 4. Keep on pressing the B key until the text ”Test functions” is displayed in the second line. 5. Press the key twice. The test mode is active. The code of a pressed key is displayed in the first display line. Exception: MEN key (reserved for canceling the test). 6. To cancel the keyboard test: Press the MEN key twice. Procedure

Operation 1070 080 037-101 (99.01) GB 5-29 5.11 Configuring the Printer Interface (X4) Remarks With BT220-1: the settings of the interface described below are only ac- tive when you print out the diagnostic memory. The BT220-1 in this case automatically changes the interface parameters. After the printing process the parameters necessary for communication with the PS 5000 (19200 bits/s; 8 data bits; even parity; 1 stop-bit) are set again. Communication with a peripheral unit is only possible when - the connection cable is correctly wired (inc. any necessary Handshake leads), - the interface parameter settings of both units are identical. In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press the MEN key. The menu item ”Diagnostic memory” appears in the second display line. 2. Keep pressing the B key until the text ”Special function” is displayed in the second line. 3. Press the key. 4. Keep on pressing the B key until the text ”System functions” is displayed in the second display line. 5. Press the key. 6. Keep on pressing the B key until the text ”Print parameter” is displayed in the second display line. 7. Press the key twice. 8. The current parameters are displayed in the first display line. To change values: Press the VAR key. To cancel the function: Press the MEN key twice. 9. Move the cursor with the cursor keys A and " to the setting to be changed and enter the new value using the keys Y and B . Value range: Baud rate: 300, 600, 1200, 2400, 4800, 9600, 19200, 38400, 76800 Handshake: without = no flow control Hardware = flow control through CTS, RTS leads Xon/Xoff = flow control with control symbol Xon/Xoff Xon/Xoff + DTR = inc. testing of the DSR input Protocol: 7O1, 7E1, 7N2, 7O2, 7E2, 8N1, 8O1, 8E1, 8N2 1st character: Number of data bits 2nd character: O =odd parity E = even parity N = no parity 3rd character: Number of stop-bits 10.To activate selected values: Press key . To keep the current setting: Press the MEN key. Proceed to step 8. Procedure

1070 080 037-101 (99.01) GB 5-30 5.12 Inhibiting the Control Function To protect the BT220 from unauthorized access a 4-digit freely definable key code can be assigned both to the - menu items within the BT220 (see page 5-33) and to the - menu items in the function key mode (see page 5-6). Access to a protected menu level is only possible when the correct key code is entered. Here you can decide for the menu items of the function key mode whether access to a menu item or only changes within a menu items should be pro- tected by a key code. Various strategies can be considered for access protection: - User group oriented: Define a specific key code for each user group (e.g. system administra- tor, master, technician etc.). Depending on the privileges/tasks of the individual user group you may then assign the relevant key code to the individual menu items. Disadvantage: a user with extensive privileges must generally know all key codes of the lower-level user groups. - Function oriented: Define a specific key code for each ”critical” function area (from a safety point of view) (e.g. changing welding parameters, deleting diagnostic or message memory, changing key codes (!!) etc.). Depending on the function areas you may then assign the relevant key code to the individual menu items. Disadvantage: any user with comprehensive machine-related tasks has to know all - or at least several - key codes of the individual function areas. ATTENTION! Unauthorized alteration of or prying into key codes possible! ’ Use a separate key code for protecting the menu item ”Change key code” (for menu structure see page 5-33). ’ Only make this key code known to authorized people. People who know this key code can display all key codes stored and also change them! NOTE Deleting or overwriting the BT220 internal data is possible! Via the menu item ”Text management” (for menu structure see page 5-33) functions can be called up which delete or overwrite the internal data of the BT220. ’ Therefore, you should protect the menu item ”Text management” from unauthorized access. ’ Only make this key code known to authorized people. Unauthorized people who know this key code could damage the BT220.

Operation 1070 080 037-101 (99.01) GB 5-31 In the following description we assume that the BT220 is in the message dis- play mode (see chapter 5.1, page 5-2). 1. Press the MEN key. The menu item ”Diagnostic memory” appears in the second display line. 2. Keep pressing the B key until the text ”Special function” is displayed in the second line. 3. Press the key. 4. Keep on pressing the B key until the text ”System functions” is displayed in the second display line. 5. Press the key. 6. Press the�B key until the text ”Change key code” is displayed in the second display line. 7. Press the key. 8. The text ”Menu” appears in the second display line. - To cancel the function: Press the MEN key. To change key codes of - internal menu items of the BT220: press the key and proceed to step 9. - functions of the function key mode: proceed to step 14. 9. The currently selected BT220 menu item and the key code assigned to it appear in the first display line (”Code”). Code ”0000” means: menu item is not protected. 10.- To cancel the function: Press the MEN key twice. - To select menu items (for structure see page 5-33): Press Y or B - To change the key code: Press the VAR key. 11.Move the cursor with the cursor keys A and " to the figure to be changed and enter the the required key code via - the numerical keys or - the keys Y and B . 12.To activate the displayed key code: Press the key. To cancel the changes: Press the MEN key. 13.- To process further internal menu items of the BT220: proceed to 10. - To process menu items of the function key mode: Press MEN. 14.Press the B key. The text ”Function keys/Symbols” appears in the second display line. 15.Press the key. The ”Entry number” flashes. An entry must contain the following details: - function number (F1 - F50) in the function key mode, which should be protected - whether a key code must be entered for access or for a modification (Query..=> Call up / change) - the assigned key code. Code ”0000” means: function number is not protected. You can see from the function number displayed directly behind the entry number (e.g.: ”1: F2”) whether an entry already contains data. A total of 50 entries can be stored. Procedure

1070 080 037-101 (99.01) GB 5-32 16.- To select an entry: Press Y or B. - To change the data of the selected entry: Press the VAR key. - To cancel the function: Press the MEN key twice. 17.The cursor flashes in the first line. - To change the function number: Keep pressing the " key until the cursor flashes in the first possible location behind the entry number. Then select the required function number with Y or B. Should the selected function number already exist in another entry, it is automatically deleted there as soon as the changes to the current entry are activated. - To delete the function number: Place the cursor behind the function number using " . Then press the A key. - To change the query type: Keep pressing the " key until the text ”Call up” or ”Change” flashes. Then select the required type with Y or B. - To change the key code: Keep pressing the " key until the cursor flashes behind the text ”Code”. Then enter the required key code with the numerical keys or with Y or B . - To activate changes: Press the key and proceed to step 16. - To cancel the changes: Press the MEN key and proceed to step 16.

Operation 1070 080 037-101 (99.01) GB 5-33 5.13 Overview: BT220 Specific Functions and Parameters Diagnostic memory Print Special functions Change language (p. 5-3) Display diagnostic memory (p. 5-18) Close all messages (p. 5-17) Delete diagnostic memory (p. 5-23) Diagnostic memory unsorted (p. 5-20) Diagnostic memory sorted (p. 5-20) Transfer texts Available text memory Initialize text memory Transfer mother text System functions Display Print parameters (p. 5-29) Change key code (p. 5-30) Message display mode (p. 5-24) Flash rate (p. 5-25) Autom. message scroll (p. 5-26) Display parameter (p. 5-27) Test functions Key test (p. 5-28) x = press corresponding key B Y B Y B Y B Y B Y B Y B Y B Y B Y B Y B Y B Y B Y B Y B Y B Y Message display mode A MEN to A MEN to A MEN to A MEN to A MEN to A MEN to A MEN to A MEN to A MEN to A MEN to A MEN to A MEN to A MEN to A MEN to A MEN to A MEN to A MEN see B see B see B see B see B see B see B see B see B see B see B see B see B see B see B see B see B B: with to the function, back with MEN Text management Fig. 5-15: Menu Tree of the BT220 Specific Functions and Parameters

Maintenance 1070 080 037-101 (99.01) GB 6-1 6 Maintenance 6.1 Battery A battery is necessary to back up the internal memory modules. Depending on the operating environment, the battery must be changed after certain cy- cles. Battery type: Lithium-Thionychloride (Sonnenschein SL-160) hermetically sealed Size: AA (R6, UM-3) Capacity: 1.9 Ah Storage capability: Capacity loss <10% after 10 years at 25_C Data retention: > 2.5 years over the whole temperature range (0_C to +50_C) > 7.5 years at 40_C > 15 years at 20_C Remarks When the battery is replaced, the contents of the diagnostic memory and message memory are deleted. 1. Switch the unit off. 2. Remove all connection cables from the BT220. 3. Make sure that the BT220 cannot fall out of the assembly cutout and loosen the screw terminals on the top and bottom of the BT220 housing. Take out the screw terminals and draw the unit out of the assembly cutout. 4. Lay the BT220 front side facing down on a soft, even surface. Loosen the 4 screws (1) and pull the housing upwards. The battery (3) is on the underside of the main circuit board. 1 5 6 9 1 1 1 1 2 3 + Fig. 6-1: Changing the Battery 5. Unsolder the battery from the solder support points. Ensure correct po- larity and solder in the new battery. 6. Put the housing carefully back on and screw it tight. 7. Reinstall the BT 220 and plug in all the cables again. Changing Battery

1070 080 037-101 (99.01) GB 6-2 6.2 Reset Should a software reset of the BT220 be necessary (e.g. after faults of the BT220), proceed as follows: 1. Switch off the BT220 power supply. 2. Press and hold down keys ”1” and Y at the same time. 3. Switch the BT220 power supply back on. Then you can release the keys. 6.3 Software release To display the current software status of the BT220: 1. Press the MEN key. 2. Press the key i. (Software status: the last 3 digits in the first display line) 3. To return to the message display mode: Press key i then press the MEN key.

Appendix 1070 080 037-101 (99.01) GB 7-1 7 Appendix 7.1 Information on the STK multi-contact interface board Connection: Screw terminal plug MSTB 2.5 / 3-ST-5.08 Supply voltage: 24 VDC Current consumption: approx. 1 A X1 +24 VDC 0 VDC PE Fig. 7-1: Terminal Assignment X1 For the setting use DIP switch block S1. The Baud rate setting is only effec- tive for the interface at channel 4 (connection to the BT220). Front panel S1 Fig. 7-2: Position of S1 On Off 1 2 3 4 5 6 7 8 S1 res. res. res. res. res.: reserved. Must be OFF. Baud rate: 19200: ON 9600: OFF Number of connected PS 5000 (example setting: 3) Baud rate (here: 19200) No.: 1 PS 5000: 2 PS 5000: 3 PS 5000: 4 PS 5000: 5 PS 5000: 6 PS 5000: 7 PS 5000: Switch 6 7 8 OFF OFF ON OFF ON OFF OFF ON ON ON OFF OFF ON OFF ON ON ON OFF ON ON ON Fig. 7-3: Setting the Baud Rate and Number of Connected PS 5000 ’ Make sure that the selected Baud rate is identical with that on the BT220. Power Supply (to X1) Setting the ”Baud Rate” and ”Number of Con- nected PS 5000”

1070 080 037-101 (99.01) GB 7-2 For the connection of max. 7 PS 5000 the multi-contact interface board can be fitted with RS232 interface modules. All interface leads are isolated from the power supply to X1. Connection: Sub-HD socket, 15-pin Type: RS232 Cable length: max. 15m Cable type: shielded, core cross-section min. 0.14mm2 Transmission rate: 19200 bits/s Parameters: 8E1 (8 data bits, even parity, 1 stop-bit) Handshake: Software handshake (XON, XOFF) 1 2 3 RX TX 4 max. 15 m STK (channels 1-3 and 5-8; Sub-HD, 15-pin) Shield continuity via metal housing of the plug connection or via a spade connector on the housing 5 GND 6 7 8 9 PS 5000 (X1; Sub-D, 9-pin) TX RTS�/�DTR CTS Socket Plug 2 3 5 RX 4 6 7 GND 8 +5V 15 Fig. 7-4: Connection of PS 5000 to the STK multi-contact interface board ATTENTION! Malfunctions and damage are possible! Pin 15 of the Sub-HD socket is connected to a 5V auxiliary voltage. ’ Make sure that pin 15 is not wired. No external consumer should be con- nected without consulting us. Communication between STK and BT220 is established via a separate in- terface module (RS232 or RS485) on the multi-contact interface board (channel 4). Information on the wiring is available in - chapter 4.3 from page 4-4 (for RS232 connection) or in - chapter 4.4 on page 4-6 (for RS485 connection). Connection: STK - PS 5000 Connection: STK - BT220

Appendix 1070 080 037-101 (99.01) GB 7-3 7.2 List of Figures Fig. 2-1: Front View BT220 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2-2: Connection of a PS 5000 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2-3: Connection of 2 PS 5000 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2-4: Connection of max. 7 PS 5000 to BT220 via STK multi-contact interface board 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 3-1: Installation positions and distances 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 4-1: Connections on the BT220-1 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 4-2: Connections on the BT220-2 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 4-3: Connections on the BT220-3/7 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 4-4: Terminal Assignment X1 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 4-5: Terminal Assignment X2 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 4-6: Connection of PS 5000 to BT220 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 4-7: Connection of a Serial Printer 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 4-8: Connection of the STK multi-contact interface board: Channel 4 fitted with RS232 interface 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 4-9: Connection of the STK multi-contact interface board. Channel 4 fitted with RS485 Interface 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 4-10: Bus Termination for RS485 Connections 4-6 . . . . . . . . . . . . . . . . . . . . . . . . Fig. 5-1: Front View BT220 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 5-2: Front View BT220 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 5-3: Command Options in the Main Menu of the Function Key Mode 5-6 . . . . Fig. 5-4: Operating Sequence: Selection of Program and Weld timer 5-7 . . . . . . . . Fig. 5-5: Operating Sequence: F2 Sequence 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 5-6: Operating Sequence: F3 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Fig. 5-7: Operating Sequence: F4 Last Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Fig. 5-8: Operating Sequence: F5 Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Fig. 5-9: Operating Sequence: F6 Pressure Profile . . . . . . . . . . . . . . . . . . . . . . . 5-13 Fig. 5-10: Operating Sequence: F7 Stepper Diagnostics . . . . . . . . . . . . . . . . . . . 5-14 Fig. 5-11: Operating Sequence: F8 FPO_1 (freely programmable analog output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Fig. 5-12: Operating Sequence: F9 Heat Correction . . . . . . . . . . . . . . . . . . . . . . . 5-16 Fig. 5-13: Display Structure of the Diagnostic Memory . . . . . . . . . . . . . . . . . . . . . 5-19 Fig. 5-14: Examples: Diagnostic Memory Print-Outs . . . . . . . . . . . . . . . . . . . . . . . 5-22 Fig. 5-15: Menu Tree of the BT220 Specific Functions and Parameters . . . . . . 5-33 Fig. 6-1: Changing the Battery 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 7-1: Terminal Assignment X1 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 7-2: Position of S1 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 7-3: Setting the Baud Rate and Number of Connected PS 5000 7-1 . . . . . . . . Fig. 7-4: Connection of PS 5000 to the STK multi-contact interface board 7-2 . . .

Appendix 1070 080 037-101 (99.01) GB 7-5 7.3 Subject index A Acknowledge electrode change, 5-14 Acknowledge tip dress, 5-14 Air humidity, 3-1 Analog output, 5-15 Application Examples, 2-2 Assembly, 3-1 B BT220 Degree of protection, 3-1 Fixation, 3-2 Menu tree, 5-33 Weight, 3-1 BT220-1, 2-2 BT220-2, 2-2 BT220-3/7, 2-2 Bus termination, 4-6 C Cable routing, 3-1 Changing battery, 6-1 Close all messages, 5-17 Command keys, 5-1 Connection, 4-1 Lamps, 4-3 of PS 5000 to BT220, 4-4 of STK to BT220, 4-5, 4-6 Printer, 4-5 PS 5000 to STK, 7-2 Ready signal, 4-3 Constructions, BT220, 2-2 D Degree of protection, 3-1 Diagnostic memory delete, 5-23 display, 5-18 print, 5-20 Dimensions, 3-1 Display, 5-2 Brightness, 5-27 Flash rate, 5-25 Message scrolling, 5-26 Display software release, 6-2 E Electrical connection, 4-1 EMERGENCY-OFF devices, 1-5 Error message, 5-2 Event Acknowledge, 5-2 Active, 5-2 Call up Help, 5-2 Explanation of pictographs, 1-1 Explanation of symbols, 1-1 F Fault message, 5-2 FPO_1, 5-15 Front View BT220, 5-2 Function key mode, 5-4 Main menu, 5-6 H Heat correction, 5-16 I Inhibiting the control function, 5-30 Installation, 1-6, 3-1 Interfaces, 4-1 RS232, 4-4 RS485, 4-6 Bus Termination, 4-6 K Key code, 5-30 Keyboard, test, 5-28 Keys, 5-1

1070 080 037-101 (99.01) GB 7-6 L Lamp outputs, 4-3 Last weld, 5-11 LED’s on front panel, 5-2 List of Figures, 7-3 M Magnetic fields, 1-3 Maintenance, 6-1 Menu Tree of the BT220 Main Menu, 5-33 Message Display Mode, 5-2 Adjust, 5-24 Message memory, delete, 5-17 Minimum all-round clearance, 3-1 Modifications by the user, 1-5 Monitoring, 5-9 Monitoring contact, 1-7 N Normal use, 1-4 O Operation, 5-1 Operation of manual welding guns, 1-3 Options, 2-2 Overview, BT220 menu functions, 5-33 P Phone no., Training center, 1-4 Power supply connection BT220, 4-2 STK multi-contact interface board, 7-1 Pressure control, 5-13 Printer, 4-5 Interface parameters, 5-29 Priorities, 5-24 Program number, 5-7 Protection from unauthorized access, 5-30 Q Qualified personnel, 1-4 R Ready output, 4-3 Reset of the BT220, 6-2 S S1, 7-1 Safety instructions EMERGENCY-OFF devices, 1-5 Fault reset, 1-7 Maintenance/Repair, 1-5 Modifications, 1-5 Retrofits, 1-5 Spare parts, 1-5 Sequence, 5-8 Set System Language, 5-3 Setting the time, 5-3 Slope, 5-12 Squeeze times, 1-7 Start remotely, 1-7 Start Simulation, 1-7 Stepper, 5-14 Stepper Diagnostics, 5-14 STK, 2-2, 7-1 STK multi-contact interface board, 2-2, 7-1 Baud rate for BT220, 7-1 Channel position, 2-3 Connections, 2-3 Connections to PS 5000, 7-2 Power supply, 7-1 S1, 7-1 Setting the number of PS 5000, 7-1 X1, 7-1

Appendix 1070 080 037-101 (99.01) GB 7-7 T Temperature ranges, 3-1 Test procedures, 1-5 TIM, 5-7 Tip wear, 5-14 Training courses, 1-4 V Ventilation, 3-1 W Warning, 5-2 Wear display, 5-14 Weld timer number, 5-7 Welding data, 5-4 Actual current, 5-11 Cool time, 5-8 Current monitoring, 5-9 Heat, 5-8 Heat correction, 5-16 Hold time, 5-8 Monitoring Conditional welds, 5-9 Reference current, 5-9 Tolerance, 5-9 Off time, 5-8 Phase angle, 5-11 Pre-squeeze time, 5-8 Pressure control Base pressure, 5-13 Welding pressure, 5-13 Program number, 5-7 Pulsation, 5-8 Slope, 5-12 Squeeze time, 5-8 Weld time, 5-8 Welding splashes, 1-8 Working safely, 1-8 X X1 BT220, 4-2 STK multi-contact interface board, 7-1 X2, BT220, 4-3