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Bosch PST 6000 Series Technical Information

Bosch PST 6000 Series Technical Information

Thyristor power unit
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Related Manuals for Bosch PST 6000 Series

Summary of Contents for Bosch PST 6000 Series

  • Page 1 Email Us Visit Our Website 8 a.m. - 5 p.m. Sales Available [email protected] www.wakeindustrial.com International: 1-919-443-0207 Toll Free: 1-888-551-3082 All Products from Wake Industrial, LLC, come with: Sales and Repairs Fast Shipping Quality Guarantee We ship worldwide, offering We specialize in providing With standards like our 1 year immediate product delivery any type of shipping method...
  • Page 2 PST 6000 PST 6000.XXX Thyristor Power Unit with integrated control function Technical Information Edition...
  • Page 3 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.

  • Page 5: Table Of Contents

    Contents Contents Page Safety instructions ......Safety instructions and symbols attached to the product .
  • Page 6 Contents Page PST 6250.XXX L ......PST 6250.XXX L overview ....... Explanation of drawings .

  • Page 7: Safety Instructions

    Safety instructions Safety instructions The products described were developed, manufactured and tested in com- pliance with the fundamental safety requirements of the EU machine direc- tive. These products normally pose no danger to persons or property if used in accordance with the handling stipulations and safety notes prescribed for their configuration, mounting, and proper operation.

  • Page 8: Safety Instructions And Symbols Used In This Manual

    Safety instructions Safety instructions and symbols used in this manual DANGEROUS ELECTRICAL VOLTAGE This symbol is used to warn of dangerous electrical voltage. Failure to observe the instructions in this manual in whole or in part may result in per- sonal injury.

  • Page 9: Intended Use

    Safety instructions Intended use PST 6000 thyristor power units are designed for connection of welding trans- formers. These thyristor power units are designed for use in D resistance welding of metals and D are suitable for operation in industrial environments as per DIN EN 50082-2 and 50081-2 on electromagnetic compatibility (EMC).

  • Page 10: No Admittance For Persons Fitted With Cardiac Pacemakers

    Safety instructions No admittance for persons fitted with cardiac pacemakers DANGER WARNING for persons fitted with cardiac pacemakers! To protect persons fitted with 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-...

  • Page 11: Qualified Personnel

    PST 6000 thyristor power units and the welding transformers. Interventions in the hardware and software of our products, unless de- scribed otherwise in this manual, are reserved to specialized Bosch person- nel. Tampering with the hardware or software, ignoring warning signs attached to the components, or non-compliance with the warning notes given in this manual can result in serious bodily injury or property damage.

  • Page 12: Installation And Assembly

    Safety instructions Installation and assembly DANGER Non-workmanlike installation or mounting may lead to personal in- jury or damage to property. Therefore, it is essential that you take the technical data (environ- mental conditions) into account for installation or mounting. Installation or mounting must be carried out by skilled personnel only.
  • Page 13 Safety instructions DANGEROUS ELECTRICAL VOLTAGE Before the modules are installed, the respective mounting station must be safely isolated from supply and properly safeguarded to pre- vent unintentional or unauthorized reclosing. CAUTION Short circuits! When cut-outs are drilled or sawed in switchgear cubicles, metal burr may get into modules already installed there.
  • Page 14 Safety instructions CAUTION Damage to property through inappropriate or insufficient cooling of the thyristor power units! Water-cooled thyristor power units may only be operated when the cooling water circuit is active! Condensation on water-carrying com- ponents must be prevented. Damage to property through insufficient water quality in the cooling water circuit! Deposits in the cooling system may reduce the water flow, thus im- pairing the performance of the cooling system with time.

  • Page 15: Electrical Connection

    Safety instructions Electrical connection DANGEROUS ELECTRICAL VOLTAGE The mains voltage is associated with many dangers! Possible consequences of improper handling include death or most severe injuries (personal injuries) and damage to property. For this reason, the electrical connection must always be made by an electri- cal expert in compliance with the valid safety regulations, the mains voltage and the maximum current consumption of the individual units of the equipment.
  • Page 16 Safety instructions 1-10 DANGEROUS ELECTRICAL VOLTAGE Danger of life through insufficient protective conductor system! The thyristor power units must be connected to the protective earth- ing (PE) circuit of the system. Please ensure that the cross-sectional area of cables used for protective conductor wiring is sufficiently large.
  • Page 17 Safety instructions 1-11 PE connection : Connect to a central earth point. Make sure that cable cross-sectional areas are sufficiently large! All conductor cross-sections must be large enough for the loads to be con- nected. U1 connection : Connect to L1 system phase. V1 connection : Connect to L2 system phase.

  • Page 18: Ensuring Emc Of The Completely Assembled System

    Safety instructions 1-12 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.

  • Page 19: Operation Of The Thyristor Power Units

    All users, line designers, welding machine manufacturers and weld- ing 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.

  • Page 20: Retrofits And Modifications By The User

    Safety instructions 1-14 1.10 Retrofits and modifications by the user DANGER Retrofits or modifications 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.

  • Page 21: Maintenance, Repair

    DANGER The right to perform repair/maintenance work on the components of the thyristor power units is reserved to the BOSCH service depart- ment or to repair/maintenance units authorized by BOSCH! CAUTION Only use spare parts approved by BOSCH!

  • Page 22: Working Safely

    Safety instructions 1-16 1.12 Working safely DANGER During operation of the welding equipment welding splashes are to be expected! They may cause eye injuries or burns. Therefore: D wear protective goggles D wear protective gloves D wear flame-retardant clothes DANGER Danger of injury from sheet metal edges and danger of burns from weld metal! Therefore: - wear protective gloves...

  • Page 23: Setup

    Setup Setup Features D Integrated control functionality D Integrated weld timer D Flexible parallel and/or serial I/O interfaces D Fieldbus interfaces for communication D Integrated control 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...

  • Page 24: Modules And Components

    Setup Modules and components The PST 6000 thyristor power units serve to control the welding trans- formers. Integrated features: D the weld timer (central processing unit, CPU) D one slot for the type-specific I/O interface D one slot for the field bus module for programming (optional) D one slot for retrofitting a quality module (optional) PST 6100.XXX L Mains...
  • Page 25 Setup Welding transformer Thyristor power unit Mains trans- Firing Measuring transformer transformer former Synchronization Firing Temperature voltage 5 kHz Feedback message 27 VAC 24 VAC Weld timer (CPU) Transformer Stop circuit external Pressure temperature Shunt trip 24VDC supply device current sensor Field bus module type-specific prepared for...

  • Page 26: Function

    D with the reset button on the weld timer front panel D by an input signal for acknowledgement (type-specific) D by an input on the BOS-5000 operator interface D by an input on the Bosch operator terminal (BT) 1070 080 058-101 (2001.04) GB...

  • Page 27: Notes On Rating

    Notes on Rating Notes on Rating The load capability of a thyristor power unit is always predefined by the type designation indicating the specific maximum welding transformer rating. CAUTION Overloading may cause damage to the thyristor power unit! Always check the actual load applied on the thyristor power unit! Any and all warranty excluded in case of damage caused by overload.
  • Page 28 Notes on Rating Notes: 1070 080 058-101 (2001.04) GB...

  • Page 29: Commissioning

    Commissioning Commissioning DANGEROUS ELECTRICAL VOLTAGE Danger of life in case of contact with live parts! Upon commissioning, the thyristor power unit is energized! CAUTION Cooling! Please make sure that there is sufficient cooling capacity. In the case of water cooled thyristor power units, ensure that the cooling water inlet connection is turned on and check the water tem- perature.
  • Page 30 Commissioning Notes: 1070 080 058-101 (2001.04) GB...

  • Page 31: Maintenance

    Replace empty batteries with new ones only! DANGEROUS ELECTRICAL VOLTAGE The right to perform repair/maintenance work on the thyristor power unit components is reserved to the BOSCH service department or to repair/maintenance units authorized by BOSCH! Only use spare parts/replacement parts approved by BOSCH! Run-down batteries or accumulators must be disposed of according to regulations.
  • Page 32 Maintenance D Check connections 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: Malfunction

    Further information is provided by the diagnostics func- tion, the error message display on the BOS-5000 operator interface, or a message on the Bosch BT operator terminal. DANGEROUS ELECTRICAL VOLTAGE Danger of life in case of contact with live parts!
  • Page 34 Malfunction Notes: 1070 080 058-101 (2001.04) GB...

  • Page 35: Type Overview

    Type overview Type overview Features PST 6100.XXX L D Thyristor power unit for welding transformers up to max. 76 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.
  • Page 36 Type overview Notes: 1070 080 058-101 (2001.04) GB...

  • Page 37: Pst 6100.Xxx L

    PST 6100.XXX L PST 6100.XXX L PST 6100.XXX L overview D PST 6100.XXX L : D Thyristor power unit for welding transformers up to max. 76 kVA D Air cooling D Integrated control function D Rated voltage 400 V -20% to 600 V +10%, 50/60 Hz Explanation of drawings The following drawings show the D front plate with modules of the thyristor power unit...

  • Page 38: Pst 6100.Xxx L Front Panel

    PST 6100.XXX L PST 6100.XXX L front panel PST 6100.XXX L front panel M6 mounting options D rear panel D left side panel (mounting cutout required) mains supply connection thyristor power unit symbol welding transformer connection integrated weld timer 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 slot for retrofitting a quality module slot for fieldbus interface for programming battery compartment 1070 080 058-101 (2001.04) GB...

  • Page 40: Technical Data, Pst 6100.Xxx L

    PST 6100.XXX L Technical data, PST 6100.XXX L Type 2-phase thyristor power unit, module de- signed for recessed mounting Weld timer integrated I/O interface Slot for parallel, serial or fieldbus inter- face Quality module Slot prepared for retrofitting Degree of protection IP 20;...

  • Page 41: Dimensioned Drawing, Pst 6100.Xxx L

    PST 6100.XXX L Dimensioned drawing, PST 6100.XXX L Front view Side view, right (as seen from the front) 100 mm min. installation clear- Accessories kit 078 273 ance at top and bottom of thyristor power unit! plate for optional mounting sealing face, 3 mm flat gasket required...

  • Page 42: Electrical Connection, Pst 6100.Xxx L

    PST 6100.XXX L Electrical connection, PST 6100.XXX L Side view, right (as seen from the front) from mains all terminals max. 50 mm to welding transformer 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: Load Diagram, Pst 6100.Xxx L

    PST 6100.XXX L Load diagram, PST 6100.XXX L Note: For a general description of load diagrams, see Section 3 1000 ED in % primary continuous current, air cooling calculated primary peak current, air cooling, t = 0.2s, 1 000 000 spots Load diagram, PST 6100.XXX L 1070 080 058-101 (2001.04) GB...

  • Page 44: Accessories, Pst 6100.Xxx L

    PST 6100.XXX L Accessories, PST 6100.XXX L 8.8.1 Dimensioned drawing, accessories kit An accessories kit is available for mounting the inverter with its back on the mounting plate. 1.5 thick radiuses without dimensions = R2 tool Dimensioned drawing, accessories kit 1070 080 058-101 (2001.04) GB...
  • Page 45 PST 6100.XXX L 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. 1070 080 058-101 (2001.04) GB...

  • Page 46: Ordering Accessories

    PST 6100.XXX L 8-10 Ordering accessories Not included in shipment: Designation Part no. Insertable profile for pin connectors on small wire sizes, line 1070 918 779 connection and welding transformer connection Accessories kit for PST 6100.XXX L mounting 1070 078 273 SSR 81.00 current sensor without fixing device, 1070 048 099 in the form of a toroid coil;...

  • Page 47: Pst 6250.Xxx L

    PST 6250.XXX L PST 6250.XXX L PST 6250.XXX L overview D 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 V -20% to 600 V +10%, 50/60 Hz Explanation of drawings The following drawings show the D front plate with modules of the thyristor power unit...

  • Page 48: Pst 6250.Xxx L Front Panel

    PST 6250.XXX L PST 6250.XXX L front panel PST 6250.XXX L front panel M6 mounting options D rear panel D left side panel (mounting cutout required) mains supply connection thyristor power unit symbol welding transformer connection integrated weld timer 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 slot for retrofitting a quality module slot for fieldbus interface for programming battery compartment 1070 080 058-101 (2001.04) GB...

  • Page 50: Technical Data, Pst 6250.Xxx L

    PST 6250.XXX L Technical data, PST 6250.XXX L Type 2-phase thyristor power unit, module de- signed for recessed mounting Weld timer integrated I/O interface Slot for parallel, serial or fieldbus inter- face Quality module Slot prepared for retrofitting Degree of protection IP 20;...

  • Page 51: Dimensioned Drawing, Pst 6250.Xxx L

    PST 6250.XXX L Dimensioned drawing, PST 6250.XXX L Side view, right Front view (as seen from the front) Accessories kit 078 273 plate for optional mounting 100 mm min. installation clear- ance at top and bottom of thyristor power unit! sealing face, 3 mm flat gasket required...

  • Page 52: Electrical Connection, Pst 6250.Xxx L

    PST 6250.XXX L Electrical connection, PST 6250.XXX L Side view, right (as seen from the front) from mains all terminals max. 95 mm to welding transformer 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: Load Diagram, Pst 6250.Xxx L

    PST 6250.XXX L Load diagram, PST 6250.XXX L Note: For a general description of load diagrams, see Section 3 3400 3200 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 ED in % primary continuous current, air cooling calculated primary peak current, air cooling, t = 0.2s, 1 000 000 spots Load diagram, PST 6250.XXX L...

  • Page 54: Accessories, Pst 6250.Xxx L

    PST 6250.XXX L Accessories, PST 6250.XXX L 9.8.1 Dimensioned drawing, accessories kit An accessories kit is available for mounting the inverter with its back on the mounting plate. 1.5 thick radiuses without dimensions = R2 tool Dimensioned drawing, accessories kit 1070 080 058-101 (2001.04) GB...
  • Page 55 PST 6250.XXX L 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. 1070 080 058-101 (2001.04) GB...
  • Page 56 PST 6250.XXX L 9-10 Ordering accessories Not included in shipment: Designation Part no. Insertable profile for pin connectors on small wire sizes, line 1070 918 466 connection and welding transformer connection Accessories kit for PST 6250.XXX L mounting 1070 078 273 SSR 81.00 current sensor without fixing device, 1070 048 099 in the form of a toroid coil;...

  • Page 57: Ce Declaration Of Conformity

    CE declaration of conformity 10-1 CE declaration of conformity 1070 080 058-101 (2001.04) GB...
  • Page 58 CE declaration of conformity 10-2 Notes: 1070 080 058-101 (2001.04) GB...
  • Page 59 Annex Annex Index Symbols Cooling water, 1-8 Chlorides, 1-8 Degree of hardness, 1-8 ”Ready” LED, 6-1 Insoluble substances, 1-8 ”Ready” message, 6-1 Nitrates, 1-8 pH value, 1-8 Sulfates, 1-8 Corrosion, 8-4, 9-4 Accessories kit, 8-10, 9-10 Current sensor, 8-10, 9-10 Accessories, PST 6100.XXX L, 8-8 Accessories, PST 6250.XXX L, 9-8 Air pressure, 8-4, 9-4...
  • Page 60 Annex Ordering accessories, 8-10, 9-10 Output currents, 3-1 Humidity, 8-4, 9-4 Overall weld cycle duration, 3-1 Overload, 2-4 Overvoltage protection, 8-4, 9-4 I/O interface, 2-2, 8-1, 8-4, 9-1, 9-4 I/O module, 8-9, 9-9 Insertable profile, 8-10, 9-10 Pacemaker, 1-4 Installation, 1-6 PE connection, 1-11 Integrated weld timer, 8-1, 9-1 PST 6100.XXX L, 8-1...
  • Page 61 Annex Thyristor load, 3-1 Thyristor unit temperature, 6-1 Training courses, 1-5 Type, 8-4, 9-4 Type overview, 7-1 Voltage supply, 8-4, 9-4 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 1070 080 058-101 (2001.04) GB...

  • Page 62: Annex

    Annex 1070 080 058-101 (2001.04) GB...
  • Page 63 1070 080 058-101 (2001.04) GB · TI WS· AT/VWS · Printed in Germany 1070 080 058-101 (2001.04) GB...

This manual is also suitable for:

Pst 6100 l seriesPst 6250 l series

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