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Bosch PST 6000 Series, Technical Information

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Safety instructions

1-12

1070 080 058-101 (2001.04) GB

1.8

Ensuring EMC of the completely assembled system

.

Note: The completely assembled system with the welding transformer

complies with

 

prEN 50240, the EMC product standard for resistance

welding systems, and EN 55011 (October 1997), EMC product family

standard class A, group 2, rated current > 100 A.

D

Only for industrial applications.

D

Safe clearance from residential areas 

y

 30 m.

D

Safe clearance to communication systems (wireless, telephone) 

y

 10 m.

D

Cable length of mains feeder 

y

 10 m.

D

Interference suppression measures: When switchgear cabinet doors are

open, operation of radio devices or cell phones is permitted only beyond

a safe clearance of 

y

 2 m.

Summary of Contents for PST 6000 Series

Page 1: ...lity to ship both small 1lb products and large 200lb automation parts regardless of your location www wakeindustrial com Visit Our Website Wake Industrial is not affiliated with nor an authorized distributor or representative of any manufacturers brands or products listed All Products from Wake Industrial LLC come with Sales and Repairs Fast Shipping Quality Guarantee With standards like our 1 yea...

Page 2: ...PST 6000 XXX Thyristor Power Unit with integrated control function Technical Information PST 6000 101 Edition ...

Page 3: ...l Information 1070 080 058 101 2001 04 GB Reg no 16149 03 E 2000 2001 This manual is the exclusive property of Robert Bosch GmbH also in the case of Intellectual Property Right applications Without their consent it may not be reproduced or given to third parties Discretionary charge 10 ...

Page 4: ......

Page 5: ...fits and modifications by the user 1 14 1 11 Maintenance repair 1 15 1 12 Working safely 1 16 2 Setup 2 1 2 1 Features 2 1 2 2 Modules and components 2 2 2 3 Function 2 4 2 4 Monitoring 2 4 3 Notes on Rating 3 1 4 Commissioning 4 1 5 Maintenance 5 1 6 Malfunction 6 1 7 Type overview 7 1 7 1 Features 7 1 8 PST 6100 XXX L 8 1 8 1 PST 6100 XXX L overview 8 1 8 2 Explanation of drawings 8 1 8 3 PST 61...

Page 6: ...front panel 9 2 9 4 Technical data PST 6250 XXX L 9 4 9 5 Dimensioned drawing PST 6250 XXX L 9 5 9 6 Electrical connection PST 6250 XXX L 9 6 9 7 Load diagram PST 6250 XXX L 9 7 9 8 Accessories PST 6250 XXX L 9 8 9 8 1 Dimensioned drawing accessories kit 9 8 9 9 Ordering accessories 9 10 10 CE declaration of conformity 10 1 A Annex A 1 A 1 Index A 1 ...

Page 7: ...es prescribed for their configuration mounting and proper operation Nevertheless there is some residual risk Therefore you should read this manual before installing connecting or com missioning the products Store this manual in a place to which all users have access at any time This manual describes the D PST 6000 thyristor power units The functions of the integrated weld timer are described in a ...

Page 8: ...ANGER This symbol is used wherever insufficient or lacking compliance with in structions may result in personal injury CAUTION This symbol is used wherever insufficient or lacking compliance with in structions may result in damage to equipment or data files Note This symbol is used to draw the user s attention to special cir cumstances L This symbol is used if user activities are required Modifica...

Page 9: ...result in personal injury of the user or third parties or in damage to equipment the workpiece to be welded or environmental damage Therefore our products must never be used for any other than their respective intended purpose Note For operation in residential environments in trade and commer cial applications and small enterprises an individual permit of the na tional authority or test institutio...

Page 10: ...th cardiac pacemakers no entry signs should be posted because pacemaker malfunction missed pulses total failure pacemaker program interference or even program destruction is to be expected Note We recommend that warning sings like the one shown below are posted at every entrance to manufacturing shops housing resistance welding equipment No entry for persons with cardiac pacemakers Danger DIN 4002...

Page 11: ...ponents or non compliance with the warning notes given in this manual can result in serious bodily injury or property damage Only skilled persons as defined in IEV 826 09 01 who are familiar with the contents of this manual may install and service the products described Such personnel are D those who being well trained and experienced in their field and familiar with the relevant standards are abl...

Page 12: ...iding a degree of protection of no less than IP 54 DANGER Danger of injury and of damage to property through incorrect instal lation Devices and in particular operating means must be installed so as to be properly safeguarded against unintentional operation or con tact DANGER Risk of injury from sharp edged sheet metal Wear protective gloves DANGER Danger of personal injury and damage to property ...

Page 13: ...xisting modules well before you install a new module Any and all warranty excluded in case of non compliance CAUTION Heat accumulation Thyristor power units must be mounted with a minimum clearance of 100 mm on top and at the bottom Without this minimum clearance heat may accumulate and cause power unit failure CAUTION In the case of air cooled thyristor power units the temperature inside the hous...

Page 14: ...educe the water flow thus im pairing the performance of the cooling system with time Therefore you should ensure that your cooling water has the follow ing properties D pH value 7 to 8 5 D Degree of hardness Dmax 10 German degrees 1 German degree 1 25 British degrees 1 05 US degrees 1 8 French degrees D Chlorides max 20 mg l D Nitrates max 10 mg l D Sulfates max 100 mg l D Insoluble substances max...

Page 15: ...em is safely isolated from supply and de energized D Connect to earth and short circuit D Cover up or safeguard all live parts DANGEROUS ELECTRICAL VOLTAGE Handling live parts at mains voltage may result in death severe bodily injury or considerable damage to property unless appropriate precautions are taken For this reason the electrical connection must always be made by an electrical expert in c...

Page 16: ...network phase grounded is not permitted Note It is recommended that the whole welding system be operated within a separate welding power network CAUTION Connecting lines and signal lines must be laid so as to avoid nega tive effects on the function of the units through capacitive or induc tive interference Interference is frequently coupled and de coupled in long cables Therefore thyristor power u...

Page 17: ...ake sure that cable cross sectional areas are sufficiently large L All conductor cross sections must be large enough for the loads to be con nected L U1 connection Connect to L1 system phase L V1 connection Connect to L2 system phase L U2 and V2 welding transformer outputs Connect to welding trans former ...

Page 18: ...ems and EN 55011 October 1997 EMC product family standard class A group 2 rated current 100 A D Only for industrial applications D Safe clearance from residential areas y 30 m D Safe clearance to communication systems wireless telephone y 10 m D Cable length of mains feeder y 10 m D Interference suppression measures When switchgear cabinet doors are open operation of radio devices or cell phones i...

Page 19: ...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 CAUTION Damage to property through insufficient cooling of the modules Ensure that the modules are properly cooled during operation Con den...

Page 20: ...ons may have negative effects on the safety of the unit Product modification may cause death severe or light personal injury damage to property or environmental damage Therefore please contact us prior to making any modification This is the only way to determine whether modified components are suitable for use with our products ...

Page 21: ...l modes of the system Releasing the EMERGENCY STOP facility must by no means result in an uncontrolled restart of the system First check the EMER GENCY STOP circuit then switch the unit on DANGER Danger of explosion of batteries Do not forcefully open batteries do not attempt to charge solder or incinerate the battery Empty batteries should always be replaced by new ones The applicable regulations...

Page 22: ...istance welding systems magnetic field strengths have to be expected which are above the limit values spe cified in VDE 0848 Part 4 Especially if manual guns are used the limit values for extremities may be exceeded In cases of doubt you should measure the field strength and take additional measures to ensure safety and health at work CAUTION The strong magnetic fields occurring in the resistance ...

Page 23: ...ntrol and monitoring functions D Control functionality separate from monitoring functionality D Air or water cooled D Less cabling required due to system component integration D Functionality designed for welding quality optimization D Easily integrated into a portable welding box system SCHWEISSKOFFER D BOS 5000 operator interface provides for easy programming operation and diagnostics PST 6000 X...

Page 24: ...gramming optional D one slot for retrofitting a quality module optional U1 V1 U2 V2 D 64711 Erbach 107 Made in Germany U1 V1 U2 V2 BOS 5000 V24 Mains Slot for Q module PST 6100 XXX L BOS 5000 A D D R Welding transformer Local PC programming logging diagnostics fault display Host PC programming logging diagnostics fault display Heat sink type specific I O system Slot for field bus module Field bus ...

Page 25: ...r Synchronization voltage 27 VAC Firing 5 kHz UPR Feedback 24 VAC Temperature message Stop circuit 24VDC supply external device Shunt trip Pressure Transformer temperature current sensor type specific I O interface Field bus module for programming optional prepared for quality module Thyristor power unit Block diagram of a thyristor power unit ...

Page 26: ...nal design of the AC welding process 2 4 Monitoring In order to ensure high operational reliability various monitoring functions are incorporated in the PST 6000 thyristor power unit There is a thermostatic switch to signal any overload on the thyristor power unit to the weld timer The weld timer will then output a Thyristor unit fault message When the fault has been cleared the error message is r...

Page 27: ...by the PST 6000 thyristor power unit The weld time ts and the overall weld cycle duration tsp must be known to determine the duty cycle tsp ts Weld time and overall weld cycle duration The duty cycle is computed as follows ED ts tsp 100 Example ED 2 per 4 per In the graph shown above the weld time is 2 periods and the overall weld cycle duration is 4 periods This results in a duty cycle ED 50 100 ...

Page 28: ...Notes on Rating 3 2 1070 080 058 101 2001 04 GB Notes ...

Page 29: ... D Check the mechanical system of the welding outfit D Check the electrical installation D Check the auxiliary equipment D pneumatic system D cooling water or cooling system D Check the operability of the emergency stop devices D Cutting in the thyristor power unit D Apply mains voltage D The thyristor power unit starts working The green Power LED on the front panel of the weld timer CPU lights up...

Page 30: ...Commissioning 4 2 1070 080 058 101 2001 04 GB Notes ...

Page 31: ... test procedures at the ac tive system the applicable safety and accident prevention regula tions must be strictly observed In any case suitable insulated tools must be used Danger of life through inappropriate EMERGENCY STOP facilities EMERGENCY STOP facilities must be operative in all modes of the system Releasing the EMERGENCY STOP facility must by no means result in an uncontrolled restart of ...

Page 32: ... and terminals of all connecting cables for tight fit at regular intervals Check all cables for damage D Check or replace battery at regular intervals D Clean the air cooler D Maintenance of cooling water circuit Check for leaks corrosion and moisture condensation ...

Page 33: ... VOLTAGE Danger of life in case of contact with live parts Disconnect the system from the mains supply before troubleshoot ing or replacing a fuse Thermal detector response The thyristor power unit contains a thermostatic switch which transmits a message to the integrated weld timer if the temperature reaches or rises above 80 C 5 C If this happens the weld timer blocks any further sequence The gr...

Page 34: ...Malfunction 6 2 1070 080 058 101 2001 04 GB Notes ...

Page 35: ...kVA D Air cooling D Integrated control function D Rated voltage 400 to 600 Volt 50 60 Hz D Rated current 110 A continuous thermal current PST 6250 XXX L D Thyristor power unit for welding transformers up to max 250 kVA D Air cooling D Integrated control function D Rated voltage 400 to 600 Volt 50 60 Hz D Rated current 200 A continuous thermal current ...

Page 36: ...Type overview 7 2 1070 080 058 101 2001 04 GB Notes ...

Page 37: ...n of drawings The following drawings show the D front plate with modules of the thyristor power unit D integrated weld timer D slot for the parallel serial or fieldbus I O interface D slot prepared for retrofitting a quality module D slot for fieldbus interface for programming optional D technical data D dimensions and mounting options D mains connection D connection of the welding transformer D l...

Page 38: ... 5 6 7 8 9 U1 V1 U2 V2 PST 6100 XXX L front panel 1 M6 mounting options D rear panel D left side panel mounting cutout required 2 mains supply connection 3 thyristor power unit symbol 4 welding transformer connection 5 integrated weld timer 6 slot for type specific I O interface D parallel I O interface D serial I O interface D fieldbus I O interface ...

Page 39: ...PST 6100 XXX L 8 3 1070 080 058 101 2001 04 GB 7 slot for retrofitting a quality module 8 slot for fieldbus interface for programming 9 battery compartment ...

Page 40: ...0 relative humidity as per VDE 0113 Moisture condensation on the thyristor power units must be prevented Air pressure Any within a range of up to 2000 m above sea level Line voltage connection grounded TN or TT system 400 V 20 to 600 V 10 50 60 Hz Nominal system current max continuous thermal current 130 A Voltage supply Weld timer CPU I O interface 24 V DC min 19 V DC up to max 30 V DC as per EN ...

Page 41: ...ttom of thyristor power unit Accessories kit 078 273 Front view Side view right as seen from the front Mounting cut out recommended for mounting on left side panel Plan view Drawings not true to scale Dimensions without tolerances 0 5 sealing face 3 mm flat gasket required plate for optional mounting Dimensioned drawing PST 6100 XXX L ...

Page 42: ... L V2 U2 V1 U1 PE Side view right as seen from the front all terminals max 50 mm2 to welding transformer from mains Electrical connection PST 6100 XXX L Note For the connections of the various control functions please see the respective manuals PST 6000 Control and I O Level Description ...

Page 43: ... XXX L Note For a general description of load diagrams see Section 3 900 800 700 600 500 400 300 200 100 1 10 100 1000 ED in primary continuous current air cooling calculated primary peak current air cooling ts 0 2s 1 000 000 spots I prim ED in A Load diagram PST 6100 XXX L ...

Page 44: ...it is available for mounting the inverter with its back on the mounting plate Accessories kit mounting plate Mounting plate dimensions Dimensions without tolerances Range of nominal sizes above to for angles short leg length to to up to greater than above 1 5 thick radiuses without dimensions R2 tool Dimensioned drawing accessories kit ...

Page 45: ...100 XXX L 8 9 1070 080 058 101 2001 04 GB D For I O module see Technical Information PST 6000 Control and I O Level Description D For insertable profiles for electric connection see the section on order ing ...

Page 46: ...nection 1070 918 779 Accessories kit for PST 6100 XXX L mounting 1070 078 273 SSR 81 00 current sensor without fixing device in the form of a toroid coil 55 mm internal diameter with 5 pole sleeve terminal 1070 048 099 SSR 81 01 08 current sensor with fixing device e g for various electrode makes on request Mating connector for SSR 81 0X current sensor 1070 913 489 Sensor cable LiYCY 2x2x0 75 mm2 ...

Page 47: ...on of drawings The following drawings show the D front plate with modules of the thyristor power unit D integrated weld timer D slot for the parallel serial or fieldbus I O interface D slot prepared for retrofitting a quality module D slot for fieldbus interface for programming optional D technical data D dimensions and mounting options D mains connection D connection of the welding transformer D ...

Page 48: ... 9 U1 V1 U2 V2 V2 U2 3 PST 6250 XXX L front panel 1 M6 mounting options D rear panel D left side panel mounting cutout required 2 mains supply connection 3 thyristor power unit symbol 4 welding transformer connection 5 integrated weld timer 6 slot for type specific I O interface D parallel I O interface D serial I O interface D fieldbus I O interface ...

Page 49: ...PST 6250 XXX L 9 3 1070 080 058 101 2001 04 GB 7 slot for retrofitting a quality module 8 slot for fieldbus interface for programming 9 battery compartment ...

Page 50: ...0 relative humidity as per VDE 0113 Moisture condensation on the thyristor power units must be prevented Air pressure Any within a range of up to 2000 m above sea level Line voltage connection grounded TN or TT system 400 V 20 to 600 V 10 50 60 Hz Nominal system current max continuous thermal current 200 A Voltage supply Weld timer CPU I O interface 24 V DC min 19 V DC up to max 30 V DC as per EN ...

Page 51: ...t Mounting cut out recommended for mounting on left side panel Plan view Drawings not true to scale Dimensions without tolerances 0 5 sealing face 3 mm flat gasket required plate for optional mounting 100 mm min installation clear ance at top and bottom of thyristor power unit Accessories kit 078 273 Dimensioned drawing PST 6250 XXX L ...

Page 52: ... L V2 U2 V1 U1 PE Side view right as seen from the front all terminals max 95 mm2 to welding transformer from mains Electrical connection PST 6250 XXX L Note For the connections of the various control functions please see the respective manuals PST 6000 Control and I O Level Description ...

Page 53: ...neral description of load diagrams see Section 3 1800 1600 1400 1200 1000 800 600 400 200 1 10 100 3400 3200 3000 2800 2600 2400 2200 2000 ED in primary continuous current air cooling calculated primary peak current air cooling ts 0 2s 1 000 000 spots I prim ED in A Load diagram PST 6250 XXX L ...

Page 54: ...it is available for mounting the inverter with its back on the mounting plate Accessories kit mounting plate Mounting plate dimensions Dimensions without tolerances Range of nominal sizes above to for angles short leg length to to up to greater than above 1 5 thick radiuses without dimensions R2 tool Dimensioned drawing accessories kit ...

Page 55: ...250 XXX L 9 9 1070 080 058 101 2001 04 GB D For I O module see Technical Information PST 6000 Control and I O Level Description D For insertable profiles for electric connection see the section on order ing ...

Page 56: ...nection 1070 918 466 Accessories kit for PST 6250 XXX L mounting 1070 078 273 SSR 81 00 current sensor without fixing device in the form of a toroid coil 55 mm internal diameter with 5 pole sleeve terminal 1070 048 099 SSR 81 01 08 current sensor with fixing device e g for various electrode makes on request Mating connector for SSR 81 0X current sensor 1070 913 489 Sensor cable LiYCY 2x2x0 75 mm2 ...

Page 57: ...CE declaration of conformity 10 1 1070 080 058 101 2001 04 GB 10 CE declaration of conformity ...

Page 58: ...CE declaration of conformity 10 2 1070 080 058 101 2001 04 GB Notes ...

Page 59: ...ion U1 1 11 U2 1 11 V1 1 11 V2 1 11 Welding transformer 1 11 Cooling 8 4 9 4 Cooling water 1 8 Chlorides 1 8 Degree of hardness 1 8 Insoluble substances 1 8 Nitrates 1 8 pH value 1 8 Sulfates 1 8 Corrosion 8 4 9 4 Current sensor 8 10 9 10 D Degree of protection 8 4 9 4 Dimensioned drawing accessories kit 8 8 9 8 Dimensioned drawing PST 6100 XXX L 8 5 Dimensioned drawing PST 6250 XXX L 9 5 Duty cyc...

Page 60: ... 8 4 9 4 N Nominal system current 8 4 9 4 Notes on rating 3 1 O Operation 1 13 Ordering accessories 8 10 9 10 Output currents 3 1 Overall weld cycle duration 3 1 Overload 2 4 Overvoltage protection 8 4 9 4 P Pacemaker 1 4 PE connection 1 11 PST 6100 XXX L 8 1 PST 6100 XXX L front panel 8 2 PST 6100 XXX L overview 8 1 PST 6250 XXX L 9 1 PST 6250 XXX L front panel 9 2 PST 6250 XXX L overview 9 1 Q Q...

Page 61: ...3 1 Thyristor unit temperature 6 1 Training courses 1 5 Type 8 4 9 4 Type overview 7 1 V Voltage supply 8 4 9 4 W Weight 8 4 9 4 Weld time 3 1 Weld timer 2 2 8 4 9 4 Welding current maximum 1 13 Welding splashes 1 16 Wire range 8 4 9 4 Working safely 1 16 ...

Page 62: ...Annex A 4 1070 080 058 101 2001 04 GB ...

Page 63: ...A 1 1070 080 058 101 2001 04 GB 1070 080 058 101 2001 04 GB TI WS AT VWS Printed in Germany ...

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