PSI 6000 Medium-Frequency Inverters Technical ... - Bosch Rexroth

PSI 6000PSI 6000 Medium-Frequency Inverterswith integrated control functionTechnical InformationEdition101

PSI 6000PSI 6000 Medium-Frequency Inverterswith integrated control functionTechnical Information1070 080 059-101 (2001.04) GBReg. no. 16149-03E 2000, 2001This 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 DM 10.--

ContentsVContentsPage1 Safety instructions ............................ 1 -11.1 Safety instructions and symbols attached to the product ...... 1--11.2 Safety instructions and symbols used in this manual ......... 1--21.3 Intended use ........................................... 1--31.4 No admittance for persons fitted with cardiac pacemakers .... 1--41.5 Qualified personnel ..................................... 1--51.6 Installation and assembly ................................ 1--61.7 Electrical connection .................................... 1--91.8 System perturbation ..................................... 1--121.9 Ensuring EMC of the completely assembled system ......... 1--131.10 Operation of the medium-frequency inverters ............... 1--141.11 Retrofits and modifications by the user ..................... 1--151.12 Maintenance, repair ..................................... 1--161.13 Working safely ......................................... 1--171.14 CE conformity .......................................... 1--182 Setup ........................................ 2-12.1 Features .............................................. 2--12.2 Modules and components ................................ 2--22.3 Function ............................................... 2--42.4 Monitoring ............................................. 2--52.5 Advantages and benefits of medium-frequency welding ...... 2--63 Notes on Rating .............................. 3 -13.1 Load diagrams ......................................... 3--24 Commissioning ............................... 4 -15 Maintenance .................................. 5 -16 Malfunction .................................. 6 -17 Type overview ................................ 7 -17.1 Features .............................................. 7--11070 080 059-101 (2001.04) GB

VIContentsPage8 PSI 6025.XXX L1 .............................. 8 -18.1 Explanation of drawings ................................. 8--18.2 PSI 6025.XXX L1 front panel ............................. 8--28.3 Technical data, PSI 6025.XXX L1 ......................... 8--48.4 Dimensioned drawing, PSI 6025.XXX L1 ................... 8--58.5 Electrical connection, PSI 6025.XXX L1 .................... 8--68.6 Load diagram, PSI 6025.XXX L1 .......................... 8--78.7 Accessories, PSI 6025.XXX L1 ........................... 8--88.7.1 Dimensioned drawing, accessories kit ..................... 8--88.8 Ordering, PSI 6025.XXX L1 .............................. 8--109 PSI 6100.XXX L1/L2/W1/W2 .................... 9 -19.1 PSI 6100.XXX L1/L2/W1/W2 overview ..................... 9--19.2 Explanation of drawings ................................. 9--19.3 PSI 6100.XXX L1/L2/W1/W2 front panel ................... 9--29.4 Technical data, PSI 6100.XXX L1/L2/W1/W2 ................ 9--49.5 Dimensioned drawing, PSI 6100.XXX L1/L2 ................ 9--69.6 Dimensioned drawing, PSI 6100.XXX W1/W2 ............... 9--79.7 Electrical connection, PSI 6100.XXX L1/L2/W1/W2 .......... 9--89.8 Cooling water connection, PSI 6100.XXX W1/W2 ........... 9--99.9 Load diagram, PSI 6100.XXX L1/W1 ...................... 9--119.10 Load diagram, PSI 6100.XXX L2/W2 ...................... 9--129.11 Accessories, PSI 6100.XXX L1/L2/W1/W2 ................. 9--139.11.1 Dimensioned drawing, accessories kit ..................... 9--139.12 Ordering, PSI 6100.XXX L1/L2/W1/W2 .................... 9--1510 PSI 6200.XXX W1/W2 .......................... 10 -110.1 PSI 6200.XXX W1/W2 overview .......................... 10--110.2 Explanation of drawings ................................. 10--110.3 PSI 6200.XXX W1/W2 front panel ......................... 10--210.4 Technical data, PSI 6200.XXX W1/W2 ..................... 10--410.5 Dimensioned drawing, PSI 6200.XXX W1/W2 ............... 10--510.6 Electrical connection, PSI 6200.XXX W1/W2 ................ 10--610.7 Cooling water connection, PSI 6200.XXX W1/W2 ........... 10--710.8 Load diagram, PSI 6200.XXX W1 ......................... 10--910.9 Load diagram, PSI 6200.XXX W2 ......................... 10--1010.10 Accessories, PSI 6200.XXX W1/W2 ....................... 10--1110.11 Ordering, PSI 6200.XXX W1/W2 .......................... 10--1211 PSI 6300.XXX L1/L2/W1/W2 .................... 11 -111.1 PSI 6300.XXX L1/L2/W1/W2 overview ..................... 11--111.2 Explanation of drawings ................................. 11--111.3 PSI 6300.XXX L1/L2/W1/W2 front panel ................... 11--211.4 Technical data, PSI 6300.XXX L1/L2/W1/W2 ................ 11--411.5 Dimensioned drawing, PSI 6300.XXX L1/L2 ................ 11--611.6 Dimensioned drawing, PSI 6300.XXX W1/W2 ............... 11--711.7 Electrical connection, PSI 6300.XXX L1/L2/W1/W2 .......... 11--811.8 Cooling water connection, PSI 6300.XXX W1/W2 ........... 11--911.9 Load diagram, PSI 6300.XXX L1/W1 ...................... 11--1111.10 Load diagram, PSI 6300.XXX L2/W2 ...................... 11--1211.11 Accessories, PSI 6300.XXX L1/L2/W1/W2 ................. 11--1311.11.1 Dimensioned drawing, accessories kit ..................... 11--1311.12 Ordering, PSI 6300.XXX L1/L2/W1/W2 .................... 11--151070 080 059-101 (2001.04) GB

ContentsVIIPage12 PSI 6500.XXX W1 ............................. 12 -112.1 Explanation of drawings ................................. 12--112.2 PSI 6500.XXX W1 front panel ............................ 12--212.3 Technical data, PSI 6500.XXX W1 ........................ 12--412.4 Dimensioned drawing, PSI 6500.XXX W1 .................. 12--512.5 Electrical connection, PSI 6500.XXX W1 ................... 12--612.6 Cooling water connection, PSI 6500.XXX W1 ............... 12--712.7 Load diagram, PSI 6500.XXX W1 ......................... 12--912.8 Accessories, PSI 6500.XXX W1 .......................... 12--1012.9 Ordering, PSI 6500.XXX W1 ............................. 12--1113 CE declaration of conformity .................. 13 -1A Annex ........................................ A -1A.1 Index ................................................. A--11070 080 059-101 (2001.04) GB

VIIIContentsNotes:1070 080 059-101 (2001.04) GB

Safety instructions 1-11 Safety instructionsThe products described were developed, manufactured and tested in compliancewith the fundamental safety requirements of the EU machine directive.These products normally poses no danger to persons or property if usedin accordance with the handling stipulations and safety notes prescribed fortheir configuration, mounting, and proper operation.Nevertheless, there is some residual risk!Therefore, you should read this manual before installing, connecting or commissioningthe products. Store this manual in a place to which all users haveaccess at any time!This manual describes the:D PSI 6000 medium-frequency invertersThe functions of the integrated weld timer are described in a separatemanual.1.1 Safety instructions and symbols attached to the productWarning of dangerous electrical voltage!Lug for connecting PE conductor only!1070 080 059-101 (2001.04) GB

1-2Safety instructions1.2 Safety instructions and symbols used in this manualDANGEROUS ELECTRICAL VOLTAGEThis symbol is used to warn of dangerous electrical voltage. Failure toobserve the instructions in this manual in whole or in part may result in personalinjury.DANGERThis symbol is used wherever insufficient or lacking compliance with instructionsmay result in personal injury.CAUTIONThis symbol is used wherever insufficient or lacking compliance with instructionsmay result in damage to equipment or data files.. Note: This symbol is used to draw the user’s attention to special circumstances.LThis symbol is used if user activities are required.Modifications in this manual as compared to a previous edition are markedby black vertical bars in the margin.1070 080 059-101 (2001.04) GB

Safety instructions 1-31.3 Intended usePSI 6000 MF inverters are designed for connection of PSG 3000 weldingtransformers.These MF inverters are designed for use inD resistance welding of metals andD are suitable for operation in industrial environments as per DIN EN50082-2 and 50081-2 on electromagnetic compatibility (EMC).They are not intended for any other use!DANGERAny use other than for the purpose indicated may result in personalinjury of the user or third parties or in damage to equipment, theworkpiece to be welded, or environmental damage.Therefore, our products must never be used for any other than theirrespective intended purpose!. Note: For operation in residential environments, in trade and commercialapplications and small enterprises, an individual permit of the nationalauthority or test institution is required; in Germany, pleasecontact the Regulierungsbehörde für Telekommunikation und Post(RegTP) or its local branch offices.The faultless, safe functioning of the product requires proper transport, storage,erection and installation as well as careful operation.1070 080 059-101 (2001.04) GB

1-4Safety instructions1.4 No admittance for persons fitted with cardiac pacemakersDANGERWARNING for persons fitted with cardiac pacemakers!To protect persons fitted with cardiac pacemakers, no-entry signsshould be posted because pacemaker malfunction (missed pulses,total failure), pacemaker program interference or even programdestruction is to be expected!!!. Note: We recommend that warning sings like the one shown below areposted at every entrance to manufacturing shops housing resistanceweldingequipment:No entry for persons with cardiac pacemakers!Danger!DIN 400231070 080 059-101 (2001.04) GB

Safety instructions 1-51.5 Qualified personnelThe requirements as to qualified personnel are based on the requirementsprofiles as defined by the ZVEI (Zentralverband Elektrotechnik und Elektronikindustrie-- German Electrical and Electronic Manufacturers’ Association)and the VDMA (Verband deutscher Maschinen- und Anlagenbau --German Engineering Federation) in:Weiterbildung in der Automatisierungstechnikedited by: ZVEI and VDMAMaschinenbau VerlagPostfach 71 08 64D-60498 Frankfurt.This manual is designed for technicians and engineers with special weldingtraining and skills. They must have a sound knowledge of the hardware componentsof the weld control system, the PSI 6000 medium-frequency invertersand the welding transformers.Interventions in the hardware and software of our products, unless describedotherwise in this manual, are reserved to specialized Bosch personnel.Tampering with the hardware or software, ignoring warning signs attached tothe components, or non-compliance with the warning notes given in thismanual can result in serious bodily injury or property damage.Only skilled persons as defined in IEV 826-09-01 who are familiar with thecontents of this manual may install and service the products described.Such personnel areD those who, being well trained and experienced in their field and familiarwith the relevant standards, are able to analyze the work to be carried outand recognize any hazards.D those who have acquired the same amount of expert knowledge throughyears of experience that would normally be acquired through formal technicaltraining.DANGER!An exception are persons with cardiac pacemakers!The strong magnetic fields occurring in resistance welding may affectthe proper functioning of pacemakers. This may be fatal or causeserious personal injury!Therefore, persons with pacemakers must stay clear of resistancewelding systems.We recommend that warning sings as per DIN 40023 are posted at everyentrance to manufacturing shops housing resistance-weldingequipment.Please note our comprehensive range of training courses. More informationis available from our training center (Phone: +49 / 6062 / 78-258).1070 080 059-101 (2001.04) GB

1-6Safety instructions1.6 Installation and assemblyDANGERNon-workmanlike installation or mounting may lead to personal injuryor damage to property.Therefore, it is essential that you take the technical data (environmentalconditions) into account for installation or mounting.Installation or mounting must be carried out by skilled personnelonly.DANGERInsufficient degree of protection may be life-threatening or causedamage to property!The degree of protection of MF inverters is IP 20. They must beinstalled in switchgear cubicles providing a degree of protection ofno less than IP 54.DANGERDanger of injury and of damage to property through incorrect installation!Devices and, in particular, operating means, must be installed so asto be properly safeguarded against unintentional operation or contact.DANGERRisk of injury from sharp-edged sheet metal!Wear protective gloves!DANGERDanger of personal injury and damage to property through inadequatefastening!The place for installing the welding inverters, and their method offastening, must be suitable for their weight!Injuries and bruises may be caused by lifting weights which are tooheavy or by sharp metal edges!Due to the heavy weight of individual modules several persons arerequired for installation and assembly.Wear safety shoes and safety gloves!1070 080 059-101 (2001.04) GB

Safety instructions 1-7DANGEROUS ELECTRICAL VOLTAGEBefore the modules are installed, the respective mounting stationmust be safely isolated from supply and properly safeguarded to preventunintentional or unauthorized reclosing.CAUTIONShort circuits!When cut-outs are drilled or sawed in switchgear cubicles, metalburr may get into modules already installed there. Or, when coolingwater lines are connected, water may leak into the modules installed.The possibility of short circuits occurring in the process or even thedestruction of the devices cannot be entirely ruled out.Therefore, guard any existing modules well before you install a newmodule! Any and all warranty excluded in case of non-compliance.CAUTIONHeat accumulation!MF inverters must be mounted with a minimum clearance of 100 mmon top and at the bottom. Without this minimum clearance, heat mayaccumulate and cause inverter failure.CAUTIONIn the case of air-cooled MF inverters, the temperature inside thehousing must stay within the specified range. MF inverters must alwaysbe operated under forced-air cooling conditions. Convectioncooling will not be sufficient!CAUTIONLeaks in the cooling water circuit may cause consequential damage!Cooling water leaks may damage adjacent components. Therefore,when mounting water-cooled modules, always ensure that other devicesin the switchgear cabinet are well protected against leakingcooling water.1070 080 059-101 (2001.04) GB

1-8Safety instructionsCAUTIONDamage to property through inappropriate or insufficient cooling ofthe medium-frequency inverters!Water-cooled medium-frequency inverters may only be operatedwhen the cooling water circuit is active! Condensation on water-carryingcomponents must be prevented.Damage to property through insufficient water quality in the coolingwater circuit!Deposits in the cooling system may reduce the water flow, thus impairingthe performance of the cooling system with time.Therefore, you should ensure that your cooling water has the followingproperties:D pH value : 7 to 8.5D Degree of hardness D max : 10 German degrees(1 German degree = 1.25 British degrees = 1.05 US degrees =1.8 French degrees)D Chlorides : max. 20 mg/lD Nitrates : max. 10 mg/lD Sulfates : max. 100 mg/lD Insoluble substances : max. 250 mg/lTap water usually meets these requirements. However, an algicideshould be added.LLMake sure that all contact surfaces are bright, i.e. free of paint, plastic coatingor dirt/oxidation.Mount the device in a vertical position.1070 080 059-101 (2001.04) GB

Safety instructions 1-91.7 Electrical connectionDANGEROUS ELECTRICAL VOLTAGEThe mains voltage is associated with many dangers!Possible consequences of improper handling include death or mostsevere injuries (personal injuries) and damage to property. For thisreason, the electrical connection must always be made by an electricalexpert in compliance with the valid safety regulations, the mainsvoltage and the maximum current consumption of the individualunits of the equipment.The mains voltage must match the nominal voltage given on thenameplate of the product!The equipment must be appropriately fused on the supply side!Prior to connecting an MF inverter, the following must be strictlyobserved:DDDDDPower OFF.Provide a safeguard to prevent unintentional reclosing.Verify that the system is safely isolated from supply andde-energized.Connect to earth and short circuit.Cover up or safeguard all live parts.DANGEROUS ELECTRICAL VOLTAGEHandling live parts at mains voltage may result in death, severebodily injury or considerable damage to property unless appropriateprecautions are taken.For this reason, the electrical connection must always be made byan electrical expert in compliance with the valid safety regulations,the mains voltage and the maximum current consumption of the individualunits of the equipment.Incorrect mains voltage may render the system dangerous or causeelectrical component failure!Therefore, please ensure the following:DDDDDThe mains voltage must match the nominal voltage given on thenameplate of the product!Mains voltage fluctuation or variation from the nominal voltagemust be within the specified tolerance range (see Technical Data).The equipment must be appropriately fused on the mains side!Before carrying out any work on the mains system or weldingsystem connections it must be ensured that the MF inverter hasbeen safely isolated from the supply for at least 5 minutes (capacitordischarge time).Proper and well insulated tools must be used for handling electricconnections!1070 080 059-101 (2001.04) GB

1-10Safety instructionsDANGEROUS ELECTRICAL VOLTAGEDanger of life through insufficient protective conductor system!The medium-frequency inverters must be connected to the protectiveearthing (PE) circuit of the system. Please ensure that the crosssectionalarea of cables used for protective conductor wiring is sufficientlylarge. The electrical continuity of the protective earthing circuitmust be verified in accordance with EN 60204 Part 1.DANGEROUS ELECTRICAL VOLTAGEAny residual current devices used on the mains side of the MF invertersto protect persons getting into direct or indirect contact must beof type B. As per IEC 60 755, these devices must also be capable ofsafely detecting possible residual currents of 1 kHz frequency.DANGEROUS ELECTRICAL VOLTAGEMF inverters may be operated in earth neutral systems only.Protective grounding is the only protective measure permitted as perprEN 50 178 (DIN VDE 0160)!Operation in systems with ordinary residual-current circuit-breakersis not permitted because of the risk that residual currents may flowfrom the intermediate circuit to earth and back into the systemwithout tripping the RCCB.In the case of operation with an isolating transformer, single-sidedgrounding of the intermediate circuit is not permitted.DANGEROUS ELECTRICAL VOLTAGEOperation in unbalanced networks (only one network phasegrounded) is not permitted.. Note: It is recommended that the whole welding system be operatedwithin a separate welding power network.The MF inverters are approved for operation in grounded systems (TT or TNsystems). For operation in non-grounded systems (e.g., IT systems), anisolation transformer with its center point of earth potential in secondary circuitmust be used.1070 080 059-101 (2001.04) GB

Safety instructions 1-11CAUTIONConnecting lines and signal lines must be laid so as to avoid negativeeffects on the function of the units through capacitive or inductiveinterference!Interference is frequently coupled and de-coupled in long cables.Therefore, medium-frequency inverter cables and control cablesmust be routed separately. The influence of interfering cables oncables susceptible to interference can be minimized by keeping thefollowing distances:D > 100 mm if cables are run in parallel for < 10 m,D > 250 mm if cables are run in parallel for > 10 m.MF inverters should be mounted close to the welding systems so asto avoid cable lengths of more than 25 m.CAUTIONConnection cables may come off and apply dangerous voltage tosystem components!It is crucial that cables are properly fixed.L PE connection : Connect to a central earth point. Make sure that cablecross-sectional areas are sufficiently large!LAll conductor cross-sections must be large enough for for the loads to beconnected.L U1 connection : Connect to L1 system phase.L V1 connection : Connect to L2 system phase.L W1 connection : Connect to L3 system phase.L U2 and V2 welding transformer outputs : Connect to PSG 3000 (U, V)welding transformer.1070 080 059-101 (2001.04) GB

1-12Safety instructions1.8 System perturbationWhen operating a medium-frequency inverter a harmonic load must be accountedfor in the mains system. This load is caused by the ”B6” rectifier circuitwith a smoothing capacitor.The following figure shows the typical curve of the mains voltage (top) andthe related mains current (bottom) in one phase during the welding process:Typical 300 HzThe 5th, 7th, 11th, 13th, 15th, and 17th harmonic wave are the characteristicharmonics of the mains current curve.The harmonic component depends on the welding power.. Note: The harmonic content may be considerably reduced, e.g., by usingsmoothing reactors with 4% short-circuit voltage.1070 080 059-101 (2001.04) GB

Safety instructions 1-131.9 Ensuring EMC of the completely assembled system. Note: The completely assembled system with the welding transformercomplies with prEN 50240, the EMC product standard for resistancewelding systems, and EN 55011 (October 1997), EMC product familystandard class A, group 2, rated current > 100 A.D Only for industrial applications.D Safe clearance from residential areas ≧ 30 m.D Safe clearance to communication systems (wireless, telephone) ≧ 10 m.D Cable length of mains feeder ≧ 10 m.D Interference suppression measures: When switchgear cabinet doors areopen, operation of radio devices or cell phones is permitted only beyonda safe clearance of ≧ 2m.D The assessment and certificate of conformity of a competent authorityconcerning compliance with the fundamental EMC protection is available.If these components are integrated into a portable welding box system(SCHWEISSKOFFER), the CE marking is affixed to the portable weldingbox pursuant to EMC Directive 89/336/EEC. No further EMC testing of theportable welding box is required.1070 080 059-101 (2001.04) GB

1-14Safety instructions1.10 Operation of the medium-frequency invertersDANGERDanger of personal injury and damage to property if devices are operatedbefore they have been properly installed!The devices are designed to be installed in housings or switchgearcabinets and must not be operated unless properly installed andswitchgear cabinet doors are closed!DANGERDanger of personal injury and damage to property through missingor false interpretation of fault messages!Therefore, closing of the temperature contact (thermostatic switch,break contact) must inhibit the connected timer!As regards fault analysis, see also the section on ”Malfunction”.DANGERDanger of bruises through electrode movement!All users, line designers, welding machine manufacturers and weldinggun producers are obliged to connect the output signal of theBosch weld timer which initiates the electrode movement so that theapplicable 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.CAUTIONDamage to property through insufficient cooling of the modules!Ensure that the modules are properly cooled during operation. Condensationon water-carrying components must be prevented. In thecase of air-cooled MF inverters, the temperature inside the mountingstation must remain in the specified range. In the case of watercooledMF inverters, the maximum permitted cooling-water temperaturemust not be exceeded.CAUTIONDamage to property through excessive welding current!The maximum welding current depends on the thyristor unit of themedium-frequency inverter and the welding transformer in use. Itmust not be exceeded.Therefore, the user must check the load in each case. See also thesection on ”Load diagrams”.Any and all warranty excluded in case of non-compliance.1070 080 059-101 (2001.04) GB

Safety instructions 1-151.11 Retrofits and modifications by the userDANGERRetrofits or modifications may have negative effects on the safety ofthe unit!Product modification may cause death, severe or light personalinjury, damage to property or environmental damage.Therefore, please contact us prior to making any modification. Thisis the only way to determine whether modified components aresuitable for use with our products.1070 080 059-101 (2001.04) GB

1-16Safety instructions1.12 Maintenance, repairDANGEROUS ELECTRICAL VOLTAGEPrior to any maintenance work - unless described otherwise - thesystem must always be switched off!In the event of necessary measurement or test procedures on the activesystem, these have to be performed by skilled electrical personnel.In any case, suitable insulated tools must be used!DANGEROUS ELECTRICAL VOLTAGEIf you need to open the MF inverter housing, disconnect the systemfrom supply and wait at least 5 minutes before you open the housingso as to ensure that the MF inverter is de-energized.DANGERDanger of life through inappropriate EMERGENCY-STOP facilities!EMERGENCY-STOP facilities must be operative in all modes of thesystem. Releasing the EMERGENCY-STOP facility must by no meansresult in an uncontrolled restart of the system! First check the EMER-GENCY-STOP circuit, then switch the unit on!DANGERDanger of explosion of batteries!Do not forcefully open batteries, do not attempt to charge, solder orincinerate the battery.Empty batteries should always be replaced by new ones!The applicable regulations on the disposal of empty batteries or accumulatorsmust be observed.DANGERThe right to perform repair/maintenance work on the components ofthe medium-frequency inverters is reserved to the BOSCH servicedepartment or to repair/maintenance units authorized by BOSCH!CAUTIONOnly use spare parts approved by BOSCH!1070 080 059-101 (2001.04) GB

Safety instructions 1-171.13 Working safelyDANGERDuring operation of the welding equipment welding splashes are tobe expected! They may cause eye injuries or burns.Therefore:D wear protective gogglesD wear protective glovesD wear flame-retardant clothesDANGERDanger of injury from sheet metal edges and danger of burns fromweld metal!Therefore: - wear protective glovesDANGERIn the environment of resistance welding systems, magnetic fieldstrengths have to be expected which are above the limit values specifiedin VDE 0848 Part 4. Especially if manual guns are used, the limitvalues for extremities may be exceeded.In cases of doubt, you should measure the field strength and takeadditional measures to ensure safety and health at work.CAUTIONThe strong magnetic fields occurring in the resistance welding processmay cause permanent damage to wrist watches, pocketwatches, or cards with magnetic stripes (e.g. EC cards).Therefore, you should not carry any such items on you when workingin the immediate vicinity of the welding equipment.1070 080 059-101 (2001.04) GB

1-18Safety instructions1.14 CE conformityCAUTIONThe CE mark is valid for the medium-frequency inverter only with respectto the Low-Voltage Directive. Concerning EMC, it is alwaysnecessary to consider the entire application.The CE mark for MF inverter - welding transformer combinations refersto industrial applications.For other combinations/applications, the certificate must be derivedfrom the above, or a new certificate must be issued, if necessary, bythe line designer / user.1070 080 059-101 (2001.04) GB

Setup 2-12 Setup2.1 FeaturesDDDDDDDDDDDIntegrated control functionality for medium frequency weldingIntegrated welding controlFlexible parallel and/or serial I/O interfacesFieldbus interfaces for communicationIntegrated control and monitoring functionsControl functionality separate from monitoring functionalityAir or water cooledLess cabling required due to system component integrationFunctionality designed for welding quality optimizationEasily integrated into a portable welding box system(SCHWEISSKOFFER)BOS-5000 operator interface provides for easy programming, operationand diagnosticsPSI 6200.XXX9to54kAPSI 6500.XXX9 to 120 kAPSI 6100.XXX3to20kAPSI 6025.XXX0.5 to 7 kAPSI 6300.XXX6to36kAPSG 3025 PSG 3050 PSG 3075 PSG 3100 PSG 3200PSI 6000 medium frequency inverter series with PSG 3000 weld transformers1070 080 059-101 (2001.04) GB

2-2Setup2.2 Modules and componentsThe PSI 6000 medium-frequency inverters serve to control the PSG 3000welding transformers.Integrated features:D the weld timer (central processing unit, CPU)D one slot for the type-specific I/O interfaceD one slot for the field bus module for programming (optional)D one slot for retrofitting a quality module (optional)PSI 6000MainsU1Slot for Q moduleV1Heat sinkD- 64711 Erbach 107 Made in GermanyW1U1 V1 W13/PE~U2 V2 2/~2/PE~- +U2ADRtype-specific I/O systemSlot for field bus moduleV24Field bus for progr. (option)BOS-5000BOS-5000Local PC: programming, logging, diagnostics, fault displayHost PC: programming, logging, diagnostics, fault displayV2Current sensor(toroid)Pressure controlvalveSolenoidElectrodesWelding transformerSetup for welding1070 080 059-101 (2001.04) GB

Setup 2-3Welding transformerU1V1W1PE6-pulse bridge rectifierwith direct current linkcircuit and transistor inverterU2V2Medium-frequencyinverterPowersupplyControlCurrent measurementWeld timer (CPU)TemperaturemessageStop circuit24VDC supplyexternaldeviceShunt tripPressuretype-specificI/O interfaceQuality moduleField bus moduleforprogrammingBlock diagram of a medium-frequency inverter1070 080 059-101 (2001.04) GB

2-4Setup2.3 FunctionThe medium-frequency welding system (MF welding system) is designed fordirect current resistance welding. Its key components are the PSI 6000 medium-frequencyinverter and the PSG 3000 MF welding transformer.The figure below shows the basic functional design of the MF welding process.Weld timer3~+---Timer MF inverter TransformerrectifierElectrodesBasic functional design of the 1 kHz MF welding processThe 50 / 60 Hz mains AC is first rectified by a bridge connected rectifier(B6 connection). The direct current generated connects a transistorized H-bridge alternatingly to the PSG 3000 welding transformer at a frequency of1 kHz. In secondary circuit, the transformer rectifies the welding current.The intensity of the welding current can be controlled by adjusting the pulsewidth. The welding current is measured either with a current sensor integratedin the secondary circuit of the PSG 3000 welding transformer or, in thecase of a welding transformer without a current sensor, with a primary currentammeter integrated in the MF inverter.U PRIMPrimary voltage[2] [1]tI SECPrimary voltagesetting rangeSecondary currentf=1kHz[2] high currentI mean value[1] low currenttPrimary and secondary voltages for medium-frequency weldingThe welding current output of the welding transformer or, resp., the primarycurrent multiplied by the transformation ratio are measured and processedin the welding control for monitoring and control purposes.1070 080 059-101 (2001.04) GB

Setup 2-52.4 MonitoringIn order to ensure high operational reliability, various monitoring functionsare incorporated in the PSI 6000 medium-frequency inverter.There is a thermostatic switch to signal any overload on the PSG 3000 weldingtransformer and/or the MF thyristor 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 reset as follows:D with the reset button on the weld timer front panelD by an input signal for acknowledgement (type-specific)D by an input on the BOS-5000 operator interfaceD by an input on the Bosch operator terminal (BT)1070 080 059-101 (2001.04) GB

2-6Setup2.5 Advantages and benefits of medium-frequency weldingThe PSI 6000 medium-frequency inverters supply an MF output voltage andDC welding current. As a result, the welding process can be controlled morethoroughly and faster and becomes more steady. The ”good” welding rangebecomes larger.The medium-frequency welding current is clocked at 1 kHz. The current regulationsystem is faster and more precise compared to 50 Hz welding.1kHzFrequencyUMedium-frequencyinverter output voltageIWelding currentttt1msMedium-frequency weldingDDDDDDDDA direct current flows in the secondary welding circuit of the transformer.As a result, the inductive resistance of the secondary window loses itsinfluence on the welding current with different immersion depths of theelectrode gun into the workpiece.The weight of the welding transformer is reduced. Due to the higher operatingfrequency, the iron content required as well as the volume are reducedwhile the performance data is maintained.The more steady welding current without any gaps and the possibility ofweld time variation in ms intervals allow for the metered application of energyto the spot weld and a steady growth of the spot.Longer electrode life.Good results are obtained for welding aluminium and galvanized sheets.Especially suitable for 3-sheet welding, very thin sheets and fine spot applications.Fewer welding splashes.Medium-frequency welding with current control improves the quality ofthe spot weld.The welding system with constant-current control (KSR) compensatesthe changes in sheet resistance within the weld time and helps to obtain aconstant welding result.1070 080 059-101 (2001.04) GB

Setup 2-7kAsplash limitgalvanized sheetbare sheetbonding limitmsWelding of different sheet types, conventional 50/60 Hz weldkA**safe splash limitremaining setting rangesafe bonding limit* possible variation range with fixed settingmsWelding of galvanized sheet types with 1 kHz welding process1070 080 059-101 (2001.04) GB

2-8SetupNotes:1070 080 059-101 (2001.04) GB

Notes on Rating 3-13 Notes on RatingThe load capability of an MF inverter is always predefined by the type designationindicating the specific maximum welding transformer rating.CAUTIONOverloading may cause damage to the MF inverter!Always check the actual load applied on the MF inverter! Any and allwarranty excluded in case of damage caused by overload.To check the actual load, use the load diagram. It shows theD output currents (I PRIM in A) relative toD the duty cycle (ED in %) atD maximum ambient temperature (in C)that can be switched by the PSI 6000 MF inverter.Theweldtimet s and the overall weld cycle duration t sp must be known todetermine the duty cycle.t st spWeld time and overall weld cycle durationThe duty cycle is computed as follows:t sED = * 100%t spExample:In the graph shown above, the weld time is 4 ms andthe weld cycle duration is 8 ms.This results in a duty cycle ED = 50%.4msED = 100% = 50%8ms. Note: If different weld times or overall weld cycle times occur on amachine, the longest weld time and the shortest overall weld cycletime (to be determined, if required, by adding the longest weld time tothe shortest cool time) must be used for calculating the duty cycle!When you have calculated the duty cycle, you can use load diagrams toverify the proper selection of the MF inverter.1070 080 059-101 (2001.04) GB

3-2Notes on Rating3.1 Load diagramsVarious types of semiconductors are used as power breakers in the weldingsystems. Generally, semiconductors have an almost unlimited life if used inaccordance with the specifications.Unfortunately, however, the relatively large semiconductor chips have tosustain mechanical stress due to thermal loads. This mechanical stress mayreduce semiconductor life.Solder fatigue and defective wire bonds have been reported in literature asfactors affecting the life of IGBTs (used as power breakers in the PSI 6000MF inverters).As regards the weld diodes of the MF transformers (PSG 3000), the loadsacting on these large silicon wafers may have the effect that crystal impuritiesas they are found in every silicon crystal may lead to diode failure.Semiconductor manufacturers state life characteristics for calculation purposes.There, varying with the junction temperature gradient, the number oftemperature cycles available until the calculated end of the semiconductorservice life is stated. Every weld spot represents one temperature cycle.We have taken these conditions into account in the rating of our systems.Our PSI 6000 load diagrams also include peak current curves indicating thecalculated service life in each case.The temperature gradient, which -- among other contributing factors -- dependson the welding current, secondary resistance, weld time and ambienttemperature is taken into account in the service life calculation. Because ourcurves shown are based on 45C ambient temperature, while 25C would bea realistic assumption, you may expect a service life three times as long asthe one stated.On principle, service life is extended with the lower temperatures achievedwith water cooling as compared to air cooling. However, depending on theapplication, the temperature may drop more steeply during the cooling timeafter a weld spot due to the superior cooling capacity of water, which in turnshortens the life time due to the higher temperature gradient. However, it ispossible to have the cooling water running only during the weld time, whichalso allows you to save water.If you need further information in respect of any specific application, pleasecontact us.The load diagrams show the inverter output currents or, respectively, the primarycurrents of the welding transformers.To determine secondary currents, multiply the primary currents by the transformationratio.1070 080 059-101 (2001.04) GB

Commissioning 4-14 CommissioningDANGEROUS ELECTRICAL VOLTAGEDanger of life in case of contact with live parts!Upon commissioning, the MF inverter is energized!If the medium-frequency inverter housing is to be opened, switch offthe system and wait for at least 5 minutes until the medium-frequencyinverter is de-energized.CAUTIONCooling!Please make sure that there is sufficient cooling capacity.In the case of water cooled MF inverters, ensure that the cooling waterinlet connection is turned on and check the water temperature.Any and all warranty excluded in case of non-compliance.DDDDDDDDDCheck the mechanical system of the welding outfit.Check the electrical installation.Check the auxiliary equipment:D pneumatic systemD cooling water or cooling system.Check the operability of the emergency devices.Cutting in the MF inverter:D Apply mains voltage.D The MF inverter starts working. After approx. 10 s, the DC link voltageis charged at full voltage and the green ”Power” LED on the front panelof the weld timer (CPU) lights up.Check power supply and 24 V DC supply.Check peripheral I/O signals:D sensor signals,D communication with other weld timers.Check weld programs (for programmed current values and weld times).Cutting off the MF inverter:D When the power supply is switched off, the bridge rectifiers areblocked and the DC link voltage is discharged.D Verify the safe isolation from supply.1070 080 059-101 (2001.04) GB

4-2CommissioningNotes:1070 080 059-101 (2001.04) GB

Maintenance 5-15 MaintenanceDANGEROUS ELECTRICAL VOLTAGEAll maintenance work must be carried out by skilled electricians incompliance with the valid safety regulations, the mains voltage andthe maximum current input values of the individual system components.Prior to connecting an MF inverter, the following must be strictlyobserved:D Power OFF.D Provide a safeguard to prevent unintentional reclosing.D Verify the safe isolation from supply.D Connect to earth and short circuit.D Cover up or safeguard all live parts.DANGEROUS ELECTRICAL VOLTAGEPrior to any maintenance work - unless described otherwise - thesystem must always be switched off!If the system had been active shortly before, wait until the system istotally de-energized before starting the maintenance work (e.g. becauseof charged capacitors, etc.). For the duration of the maintenancework the system must always be protected against re-closing.In the event of necessary measurement or test procedures at the activesystem, the applicable safety and accident prevention regulationsmust be strictly observed. In any case, suitable insulated toolsmust be used!If the medium-frequency inverter housing is to be opened, switch offthe system and wait for at least 5 minutes for the medium-frequencyinverter to de-energize.Danger of life through inappropriate EMERGENCY-STOP facilities!EMERGENCY-STOP facilities must be operative in all modes of thesystem. Releasing the EMERGENCY-STOP facility must by no meansresult in an uncontrolled restart of the system!Danger of explosion of batteries!Batteries must not be opened forcefully, recharged, soldered at thecell body or thrown into fire!Replace empty batteries with new ones only!1070 080 059-101 (2001.04) GB

5-2MaintenanceDANGEROUS ELECTRICAL VOLTAGEThe right to perform repair/maintenance work on the timer componentsis 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 accordingto regulations.DDDDCheck connections and terminals of all connecting cables for tight fit atregular intervals. Check all cables for damage.Check or replace battery at regular intervals.Clean the air cooler.Maintenance of cooling water circuit:Check for leaks, corrosion and moisture condensation.1070 080 059-101 (2001.04) GB

Malfunction 6-16 MalfunctionAlthough the design of the MF inverters is quite rugged, malfunctions mayoccur in a few exceptional cases, e.g. for the following reasons:D incorrect electrical connection or mains voltage surges,D insufficient cooling or overload on the MF thyristor unit may trigger thethermal detector,D current parameters set are higher than the maximum current permitted orthe monitoring values.In case of failure, the green LED ”Ready” on the front panel of the weldtimer unit goes out. Further information is provided by the diagnostics function,the error message display on the BOS-5000 operator interface, or amessage on the BT Bosch operator terminal.DANGEROUS ELECTRICAL VOLTAGEDanger of life in case of contact with live parts!Disconnect the system from the mains supply before trouble shootingor replacing a fuse!Thermal detector responseThe MF thyristor unit contains an NTC thermistor detector, which transmits amessage to the integrated weld timer if the temperature reaches or risesabove ² 65 C(+5 C)If this happens, the weld timer blocks any further sequence.The green LED ”Ready” on the front panel of the weld timer unit goes out andthe message ”Thyristor unit temperature” is output.Possible causesDirt accumulation in heat sinkExcessive ambient temperatureCapacity of MF thyristor unit too lowNo or insufficient cooling water flowCorrective actionClean out the heat sinkCheck for sufficient convection.Checking external forced ventilationmay be required.Compute duty cycle and check selectionusing load diagram (see section”Notes on Rating”).Check cooling water inlet and/or temperature.1070 080 059-101 (2001.04) GB

6-2MalfunctionNotes:1070 080 059-101 (2001.04) GB

7-2Type overviewPSI 6200.XXX W1D Medium-frequency inverter 9 to 54 kAD Water coolingD Integrated control functionD Rated voltage 400 to 480 Volt, 50/60 HzD Rated current 220 A (continuous thermal current)D Preferably for connecting welding transformersD PSG 3100.00 AD PSG 3200.00 AD Seam-welding functionality also availablePSI 6200.XXX W2D Medium-frequency inverter 9 to 54 kAD Rated voltage 480 to 690 Volt, 50/60 HzD Other than that like PSI 6200.XXX W1PSI 6300.XXX L1/W1D Medium-frequency inverter 6 to 36 kAD Air cooling (L1), water cooling (W1)D Integrated control functionD Rated voltage 400 to 480 Volt, 50/60 HzD Rated current 110 A (continuous thermal current)D Preferably for connecting welding transformersD PSG 3100.00 APSI 6300.XXX L2/W2D Medium-frequency inverter 6 to 36 kAD Air cooling (L2), water cooling (W2)D Integrated control functionD Rated voltage 480 to 690 VoltD Rated current 110 A (continuous thermal current)D Preferably for connecting welding transformersD PSG 3100.00 APSI 6500.XXX W1D Medium-frequency inverter 9 to 120 kA with PSG 3100D Water coolingD Integrated control functionD Rated voltage 400 to 480 Volt, 50/60 HzD Rated current 660 A (continuous thermal current) with cubicle coolingunitD Preferably for connecting welding transformersD PSG 3100.00 AD PSG 3200.00 AD Seam-welding functionality also available1070 080 059-101 (2001.04) GB

PSI 6025.XXX L1 8-18 PSI 6025.XXX L18.1 Explanation of drawingsThe following drawings show theD front plate with modules of the MF inverterD integrated weld timerD slot for the parallel, serial or fieldbus I/O interfaceD slot prepared for retrofitting a quality moduleD slot for fieldbus interface for programming (optional)DDDDDtechnical datadimensions and mounting optionsmains connectionD connection of the PSG 3000 welding transformerload diagramaccessories and part numbers. Note: Drawings do not include heat sinks.1070 080 059-101 (2001.04) GB

8-2PSI 6025.XXX L18.2 PSI 6025.XXX L1 front panel[1][1] [1][2]U1V1[5][6] [7]W1D - 64711 Erbach 107 Made in Germany[3]U1 V1 W13/PE~U2 V22/PE~2/~ADR-+[8][4]U2V2[9][1][1][1]PSI 6025.XXX L1 front panel[1] M6 mounting optionsD rear panelD left side panel (mounting cutout required)[2] mains supply connection[3] MF inverter symbol[4] PSG 3000 welding transformer connection[5] integrated weld timer[6] slot for type-specific I/O interface:D parallel I/O interfaceD serial I/O interfaceD fieldbus I/O interface1070 080 059-101 (2001.04) GB

PSI 6025.XXX L1 8-3[7] slot for retrofitting a quality module[8] slot for fieldbus interface for programming[9] battery compartment1070 080 059-101 (2001.04) GB

8-4PSI 6025.XXX L18.3 Technical data, PSI 6025.XXX L1TypeWeld timerI/O interfaceQuality moduleDegree of protectionInverter ambient temperatureHeat sinkTemperature monitoringStorage temperatureCorrosion3-phase MF inverter, module designed forrecessed mountingintegratedSlot for parallel, serial or fieldbus interfaceSlot prepared for retrofittingIP 20; designed for modular enclosure or forinstallation in switchgear cabinets with IP 54max. 55 Cair, max. 45 C, temperature controlled; withoutfan cowlintegrated-- 25 Cto+70 CThe ambient air must be free of acids, causticsolutions, corrosive agents, salts andmetal vapors of any major concentrationHumidity Humidity class F as per DIN 40040;20 C at 90% relative humidity;40 C at 50% relative humidity (as perVDE 0113);Moisture condensation on the MF invertersmust be prevented.Air pressureLine voltage connectiongrounded TN or TT systemNominal system current;max. continuous thermal currentMax. output currentMax. secondary current; dependingon the transformer usedVoltage supply;Weld timer CPU;I/O interfaceClock frequencyOvervoltage protectionAny within a range of up to 2000 m abovesea level400 V --20% to 480 V +10%; 50/60 Hz20 A100 A7 kA (PSG 3025)24 V DC; min. 19 V DC up to max. 30 V DCas per EN 61131-2, (external power supply),or, alternatively, power supply from the weldcurrent system (internal power supply)1kHzMOV; Metal Oxide VaristorElectrical connection, mains supplyand transformer via box terminal; max. 50 mm 2Wire range 16 mm 2Basic switchgear cabinet lossMax. ventilating and cooling lossdissipated via external air-coolerSwitchgear cabinet loss at max. powerWeightMounting position69 W40 W100 Wapprox. 15 kgvertical or with its back on mounting plate1070 080 059-101 (2001.04) GB

PSI 6025.XXX L1 8-58.4 Dimensioned drawing, PSI 6025.XXX L1Side view, right(as seen from the front)Front viewAccessories kitplate for optionalmountingVentilationclearancesealing face,3 mm flat gasketrequiredMounting cut-out recommended formounting on left side panelPlan view100 mm min. installation clearanceat top and bottom of MFinverter!Drawings not true to scale. Dimensions without tolerances: ±0.5Dimensioned drawing, PSI 6025.XXX L11070 080 059-101 (2001.04) GB

8-6PSI 6025.XXX L18.5 Electrical connection, PSI 6025.XXX L1Side view, right(as seen from the front)from mainsPEU1V1W1all terminalsmax. 50 mm 2U2V2to PSG 3000 weldingtransformerElectrical connection, PSI 6025.XXX L1. Note: For the connections of the various control functions, please seethe respective manuals ”PSI 6000, Control and I/O Level Description”.1070 080 059-101 (2001.04) GB

PSI 6025.XXX L1 8-78.6 Load diagram, PSI 6025.XXX L1. Note: For a general description of load diagrams, see Section 3.1140120100I prim (ED) in A8060402001 10 100ED in %primary continuous current, air coolingcalculated primary peak current, air cooling, t s = 0.1s, 1 000 000 spotsLoad diagram, PSI 6025.XXX L11070 080 059-101 (2001.04) GB

8-8PSI 6025.XXX L18.7 Accessories, PSI 6025.XXX L18.7.1 Dimensioned drawing, accessories kitAn accessories kit is available for mounting the inverter with its back on themounting plate.Accessories kit, mounting plate Mounting plate dimensionstool1.5 thickradiuses without dimensions = R2Dimensions without tolerancesRange of nominalfor angles(short leglength)abovesizesabovegreaterthanup toto totoDimensioned drawing, accessories kit1070 080 059-101 (2001.04) GB

PSI 6025.XXX L1 8-9DDDFor PSG 3000 welding transformers, see Technical Information, PSG3000 MF Welding Transformers, part no. 1070 080 087.For I/O module,see Technical Information, PSI 6000, Control and I/O Level Description.For insertable profiles for electric connection, see the section on ordering.1070 080 059-101 (2001.04) GB

8-10PSI 6025.XXX L18.8 Ordering, PSI 6025.XXX L1DesignationPart no.PSI 6025.100 L1 medium-frequency inverter 1070 080 997Not included in shipment:DesignationInsertable profile for pin connectors on small wire sizes, lineconnection and welding transformer connectionPart no.1070 918 779Accessories kit for PSI 6025.XXX L1 mounting 1070 078 273SSR 81.00 current sensor without fixing device,in the form of a toroid coil;55 mm internal diameter; with 5-pole sleeve terminalSSR 81.01-08 current sensor with fixing device;e.g. for various electrode makes1070 048 099on requestMating connector for SSR 81.0X current sensor 1070 913 489Sensor cable LiYCY 2x2x0,75 mm 2 shielded 1070 913 4941070 080 059-101 (2001.04) GB

PSI 6100.XXX L1/L2/W1/W2 9-19 PSI 6100.XXX L1/L2/W1/W29.1 PSI 6100.XXX L1/L2/W1/W2 overviewD PSI 6100.XXX L1 :D air-cooledD 400 V --20% to 480 V +10%, 50/60 HzD PSI 6100.XXX L2 :D air-cooledD 480 V --20% to 690 V +10%, 50/60 HzD PSI 6100.XXX W1 :D water-cooledD 400 V --20% to 480 V +10%, 50/60 HzD PSI 6100.XXX W2 :D water-cooledD 480 V --20% to 690 V +10%, 50/60 Hz9.2 Explanation of drawingsThe following drawings show theD front plate with modules of the MF inverterD integrated weld timerD slot for the parallel, serial or fieldbus I/O interfaceD slot prepared for retrofitting a quality moduleD slot for fieldbus interface for programming (optional)DDDDDtechnical datadimensions and mounting optionsmains connectionD connection of the PSG 3000 welding transformerload diagramaccessories and part numbers. Note: No heat sinks or water connections shown on drawings.1070 080 059-101 (2001.04) GB

9-2PSI 6100.XXX L1/L2/W1/W29.3 PSI 6100.XXX L1/L2/W1/W2 front panel[1][1] [1][2]U1V1[5][6] [7]W1D - 64711 Erbach 107 Made in Germany[3]U1 V1 W13/PE~U2 V22/PE~2/~ADR-+[8][4]U2V2[9][1][1][1]PSI 6100.XXX L1/L2/W1/W2 front panel[1] M6 mounting optionsD rear panelD left side panel (mounting cutout required)[2] mains supply connection[3] MF inverter symbol[4] PSG 3000 welding transformer connection[5] integrated weld timer[6] slot for type-specific I/O interface:D parallel I/O interfaceD serial I/O interfaceD fieldbus I/O interface1070 080 059-101 (2001.04) GB

PSI 6100.XXX L1/L2/W1/W2 9-3[7] slot for retrofitting a quality module[8] slot for fieldbus interface for programming[9] battery compartment1070 080 059-101 (2001.04) GB

9-4PSI 6100.XXX L1/L2/W1/W29.4 Technical data, PSI 6100.XXX L1/L2/W1/W2TypeWeld timerI/O interfaceQuality moduleDegree of protectionInverter ambient temperature3-phase MF inverter, module designedfor recessed mountingintegratedSlot for parallel, serial or fieldbus interfaceSlot prepared for retrofittingIP 20; designed for modular enclosureor for installation in switchgear cabinetswith IP 54max. 55 CCooling L1/L2: air, max. 45 C with Boschfan cowl, temperaturecontrolledthrough inverterW1/W2: water, 4 l/min; max. 30 CTemperature monitoringStorage temperatureCorrosionintegrated-- 25 Cto+70 CThe ambient air must be free of acids,caustic solutions, corrosive agents,salts and metal vapors of any majorconcentrationHumidity Humidity class F as per DIN 40040;20 C at 90% relative humidity;40 C at 50% relative humidity (as perVDE 0113);Moisture condensation on the MF invertersmust be prevented.Air pressureLine voltage connectiongrounded TN or TT systemNominal system current;max. continuous thermal currentMax. output currentMax. secondary current; depending onthe transformer usedVoltage supply;Weld timer CPU;I/O interfaceClock frequencyOvervoltage protectionAny within a range of up to 2000 mabove sea levelL1/W1: 400 V -20% to 480 V +10%; 50/60 HzL2/W2: 480 V -20% to 690 V +10%; 50/60 Hz110 A400 A20 kA (PSG 3100)24 V DC; min. 19 V DC up to max.30 V DC as per EN 61131-2, (externalpower supply), or, alternatively, powersupply from the weld current system(internal power supply)1kHzMOV; Metal Oxide VaristorElectrical connection, mains supplyand transformer via box terminal; max. 50 mm 2Wire range 35 mm 2Basic switchgear cabinet lossL1/W1: 69 WL2/W2: 100 W1070 080 059-101 (2001.04) GB

PSI 6100.XXX L1/L2/W1/W2 9-5Max. cooling losses L1/L2: 360 WW1: 420 WW2: 500 WSwitchgear cabinet loss at max. power L1: 170 WL2: 200 WW1: 110 WW2: 140 WWeight L1: approx. 20 kgL2: approx. 21 kgW1: approx. 25 kgW2: approx. 26 kgMounting positionvertical or with its back on mountingplate1070 080 059-101 (2001.04) GB

9-6PSI 6100.XXX L1/L2/W1/W29.5 Dimensioned drawing, PSI 6100.XXX L1/L2Side view, right(as seen from the front)Front viewAccessories kitplate for optionalmountingVentilationclearancesealing face,3 mm flat gasketrequiredMounting cut-out recommended formounting on left side panelPlan view100 mm min. installation clearanceat top and bottom of MFinverter!Drawings not true to scale. Dimensions without tolerances: ±0.5Dimensioned drawing, PSI 6100.XXX L1/L21070 080 059-101 (2001.04) GB

PSI 6100.XXX L1/L2/W1/W2 9-79.6 Dimensioned drawing, PSI 6100.XXX W1/W2Side view, right(as seen from the front)Front viewAccessories kitplate for optionalmountingAccessories kitnipple (brass)with standard taperbore IAWDIN EN 560, externalthread M16x1.5sealing face,3 mm flat gasketrequiredMounting cut-out recommended formounting on left side panelPlan view100 mm min. installation clearanceat top and bottom of MFinverter!Drawings not true to scale. Dimensions without tolerances: ±0.5Dimensioned drawing, PSI 6100.XXX W1/W21070 080 059-101 (2001.04) GB

9-8PSI 6100.XXX L1/L2/W1/W29.7 Electrical connection, PSI 6100.XXX L1/L2/W1/W2Side view, right(as seen from the front)from mainsPEU1V1W1all terminalsmax. 50 mm 2U2V2to PSG 3000 weldingtransformerElectrical connection, PSI 6100.XXX L1/L2/W1/W2. Note: For the connections of the various control functions, please seethe respective manuals ”PSI 6000, Control and I/O Level Description”.1070 080 059-101 (2001.04) GB

PSI 6100.XXX L1/L2/W1/W2 9-99.8 Cooling water connection, PSI 6100.XXX W1/W2cooling watercooling water inletnipple (brass)with standard taperbore IAWDIN EN 560, externalthread M16x1.5cooling water outletCooling water connection, PSI 6100.XXX W1/W21070 080 059-101 (2001.04) GB

9-10PSI 6100.XXX L1/L2/W1/W2The heat sink of the water-cooled MF inverter is connected internally to theprotective earth conductor.Maximum water inlet temperature : 30 CWater connection : M 16 x 1.5external thread (DIN EN 560,nut: DIN 13-6)PSI 6000by the customerHeat sinkPSIHose nozzleUnion nutM16x1.5washernipple with standard taper bore IAW DIN EN 560,external thread M16x1.5through hole 9 +0.5Cooling water connection1070 080 059-101 (2001.04) GB

PSI 6100.XXX L1/L2/W1/W2 9-119.9 Load diagram, PSI 6100.XXX L1/W1. Note: For a general description of load diagrams, see Section 3.1500450400I prim (ED) in A3503002502001501001 10 100ED in %primary continuous current, air or water coolingcalculated primary peak current, water cooling, t s = 0.1s, 1 000 000 spotscalculated primary peak current, air cooling, t s = 0.1s, 1 000 000 spotsLoad diagram, PSI 6100.XXX L1/W11070 080 059-101 (2001.04) GB

9-12PSI 6100.XXX L1/L2/W1/W29.10 Load diagram, PSI 6100.XXX L2/W2. Note: For a general description of load diagrams, see Section 3.1600550500450I prim (ED) in A4003503002502001501001 10 100ED in %primary continuous current, air or water coolingcalculated primary peak current, water cooling, t s = 0.1s, 1 000 000 spotscalculated primary peak current, air cooling, t s = 0.1s, 1 000 000 spotsLoad diagram, PSI 6100.XXX L2/W21070 080 059-101 (2001.04) GB

PSI 6100.XXX L1/L2/W1/W2 9-139.11 Accessories, PSI 6100.XXX L1/L2/W1/W29.11.1 Dimensioned drawing, accessories kitAn accessories kit is available for mounting the inverter with its back on themounting plate.Accessories kit, mounting plate Mounting plate dimensionstool1.5 thickradiuses without dimensions = R2Dimensions without tolerancesRange of nominalfor angles(short leglength)abovesizesabovegreaterthanup toto totoDimensioned drawing, accessories kit1070 080 059-101 (2001.04) GB

9-14PSI 6100.XXX L1/L2/W1/W2DDDFor PSG 3000 welding transformers, see Technical Information, PSG3000 MF Welding Transformers, part no. 1070 080 087.For I/O module,see Technical Information, PSI 6000, Control and I/O Level Description.For insertable profiles for electric connection, see the section on ordering.1070 080 059-101 (2001.04) GB

PSI 6100.XXX L1/L2/W1/W2 9-159.12 Ordering, PSI 6100.XXX L1/L2/W1/W2DesignationPart no.PSI 6100.100 L1 medium-frequency inverter 1070 079 211PSI 6100.200 L1 medium-frequency inverter 1070 079 359PSI 6101.321 L2 medium-frequency inverter 1070 079 286PSI 6100.330 L2 medium-frequency inverteron requestPSI 6100.100 W1 medium-frequency inverter 1070 079 210PSI 6100.100 W2 medium-frequency inverteron requestNot included in shipment:DesignationInsertable profile for pin connectors on small wire sizes, lineconnection and welding transformer connectionPart no.1070 918 779Accessories kit for PSI 6100.XXX L1/L2/W1/W2 mounting 1070 078 273SSR 81.00 current sensor without fixing device,in the form of a toroid coil;55 mm internal diameter; with 5-pole sleeve terminalSSR 81.01-08 current sensor with fixing device;e.g. for various electrode makes1070 048 099on requestMating connector for SSR 81.0X current sensor 1070 913 489Sensor cable LiYCY 2x2x0,75 mm 2 shielded 1070 913 4941070 080 059-101 (2001.04) GB

9-16PSI 6100.XXX L1/L2/W1/W2Notes:1070 080 059-101 (2001.04) GB

PSI 6200.XXX W1/W2 10 -110 PSI 6200.XXX W1/W210.1 PSI 6200.XXX W1/W2 overviewD PSI 6200.XXX W1:D water-cooledD 400 V --20% to 480 V +10%, 50/60 HzD PSI 6200.XXX W2:D water-cooledD 480 V --20% to 690 V +10%, 50/60 Hz10.2 Explanation of drawingsThe following drawings show theD front plate with modules of the MF inverterD integrated weld timerD slot for the parallel, serial or fieldbus I/O interfaceD slot prepared for retrofitting a quality moduleD slot for fieldbus interface for programming (optional)DDDDDtechnical datadimensions and mounting optionsmains connectionD connection of the PSG 3000 welding transformerload diagramaccessories and part numbers. Note: No water connections shown on drawings.1070 080 059-101 (2001.04) GB

10 -2PSI 6200.XXX W1/W210.3 PSI 6200.XXX W1/W2 front panel[2][1] [1]U1 V1 W1[3][4][7][8] [9]U1 V1 W13/PE~ADRU2 V22/~2/PE~D - 64711 Erbach 107 Made in Germany-+[10][11][6][1] [1]U2V2[5]PSI 6200.XXX W1/W2 front panel[1] M6 mounting optionsD rear panel[2] fan[3] mains supply connection[4] MF inverter symbol1070 080 059-101 (2001.04) GB

PSI 6200.XXX W1/W2 10 -3[5] Cooling water connectionnipple (brass) with standard taper bore IAW DIN EN 560,external thread M16x1.5[6] PSG 3000 welding transformer connection[7] integrated weld timer[8] slot for type-specific I/O interface:D parallel I/O interfaceD serial I/O interfaceD fieldbus I/O interface[9] slot for retrofitting a quality module[10] slot for fieldbus interface for programming[11] battery compartment1070 080 059-101 (2001.04) GB

10 -4PSI 6200.XXX W1/W210.4 Technical data, PSI 6200.XXX W1/W2TypeWeld timerI/O interfaceQuality moduleDegree of protectionInverter ambient temperature3-phase MF inverter, module designed forrecessed mountingintegratedSlot for parallel, serial or fieldbus interfaceSlot prepared for retrofittingIP 20; designed for modular enclosure or forinstallation in switchgear cabinets with IP 54max. 55 CCooling W1/W2: water 4 l/min.; max. 30 CTemperature monitoringStorage temperatureCorrosionintegrated-- 25 Cto+70 CThe ambient air must be free of acids, causticsolutions, corrosive agents, salts andmetal vapors of any major concentrationHumidity Humidity class F as per DIN 40040;20 C at 90% relative humidity;40 C at 50% relative humidity (as perVDE 0113);Moisture condensation on the MF invertersmust be prevented.Air pressureLine voltage connectiongrounded TN or TT systemNominal system current;max. continuous thermal currentMax. output currentMax. secondary current; dependingon the transformer usedVoltage supply;Weld timer CPU;I/O interfaceClock frequencyOvervoltage protectionElectrical connection, mains supplyand transformerAny within a range of up to 2000 m abovesea levelW1: 400 V -20% to 480 V +10%; 50/60 HzW2: 480 V -20% to 690 V +10%; 50/60 Hz220 A1200 A54 kA (PSG 3100)24 V DC; min. 19 V DC up to max. 30 V DCas per EN 61131-2, (external power supply),or, alternatively, power supply from the weldcurrent system (internal power supply)1kHzWire range 95 mm 2MOV; Metal Oxide VaristorBasic switchgear cabinet loss W1: 69 WW2: 100 WMax. ventilating and cooling lossdissipated via external air-coolerSwitchgear cabinet loss at max.powerhigh-current bushing terminal;max. 95 mm 2W1: 700 WW2: 800 WW1: 210 WW2: 240 WWeight W1/W2: approx. 56 kgMounting positionvertical or with its back on mounting plate1070 080 059-101 (2001.04) GB

PSI 6200.XXX W1/W2 10 -510.5 Dimensioned drawing, PSI 6200.XXX W1/W2Side view, right(as seen from the front)Front viewVentilationclearanceforVentilation clearancenipple (brass) with standardtaper bore IAW DIN EN 560,external thread M16x1.5Dimensions without tolerances: ±0.5100 mm min. installation clearanceat top and bottom of MFinverter!Dimensioned drawing, PSI 6200.XXX W1/W21070 080 059-101 (2001.04) GB

10 -6PSI 6200.XXX W1/W210.6 Electrical connection, PSI 6200.XXX W1/W2Front viewfrom mainsU1 V1 W1PEU1 V1 W1U1 V1 W13/PE~2/PE~-all terminalsD - 64711 Erbach 107 Made in GermanyU2 V2 2/~+U2U2ADR[11]V2V2to PSG 3000 weldingtransformerElectrical connection, PSI 6200.XXX W1/W2. Note: For the connections of the various control functions, please seethe respective manuals ”PSI 6000, Control and I/O Level Description”.1070 080 059-101 (2001.04) GB

PSI 6200.XXX W1/W2 10 -710.7 Cooling water connection, PSI 6200.XXX W1/W2Front viewU1 V1 W1U1V1 W13/PE~ADRU2 V22/~2/PE~D - 64711 Erbach 107 Made in Germany-+[11]U2V2cooling water inletrear sidecooling water outletfront sideCooling water connection, PSI 6200.XXX W1/W21070 080 059-101 (2001.04) GB

10 -8PSI 6200.XXX W1/W2The heat sink of the water-cooled MF inverter is connected internally to theprotective earth conductor.Maximum water inlet temperature : 30 CWater connection : M 16 x 1.5external thread (DIN EN 560,nut: DIN 13-6)PSI 6000by the customerHeat sinkPSIHose nozzleUnion nutM16x1.5washernipple with standard taper bore IAW DIN EN 560,external thread M16x1.5through hole 9 +0.5Cooling water connection1070 080 059-101 (2001.04) GB

PSI 6200.XXX W1/W2 10 -910.8 Load diagram, PSI 6200.XXX W1. Note: For a general description of load diagrams, see Section 3.116001400I prim (ED) in A120010008006004002001 10 100ED in %primary continuous currentcalculated primary peak current, water cooling, t s = 0.1s, 1 000 000 spotsLoad diagram, PSI 6200.XXX W11070 080 059-101 (2001.04) GB

10 -10PSI 6200.XXX W1/W210.9 Load diagram, PSI 6200.XXX W2. Note: For a general description of load diagrams, see Section 3.1180016001400I prim (ED) in A120010008006004002001 10 100ED in %primary continuous currentcalculated primary peak current, water cooling, t s = 0.1s, 1 000 000 spotsLoad diagram, PSI 6200.XXX W21070 080 059-101 (2001.04) GB

PSI 6200.XXX W1/W2 10 -1110.10 Accessories, PSI 6200.XXX W1/W2DDFor PSG 3000 welding transformers, see Technical Information, PSG3000 MF Welding Transformers, part no. 1070 080 087.For I/O module,see Technical Information, PSI 6000, Control and I/O Level Description.1070 080 059-101 (2001.04) GB

10 -12PSI 6200.XXX W1/W210.11 Ordering, PSI 6200.XXX W1/W2DesignationPart no.PSI 6200.100 W1 medium-frequency inverter 1070 081 748PSI 6200.321 W1 medium-frequency inverter 1070 081 749PSI 6200.100 W2 medium-frequency inverteron requestNot included in shipment:DesignationSSR 81.00 current sensor without fixing device,in the form of a toroid coil;55 mm internal diameter; with 5-pole sleeve terminalSSR 81.01-08 current sensor with fixing device;e.g. for various electrode makesPart no.1070 048 099on requestMating connector for SSR 81.0X current sensor 1070 913 489Sensor cable LiYCY 2x2x0,75 mm 2 shielded 1070 913 4941070 080 059-101 (2001.04) GB

PSI 6300.XXX L1/L2/W1/W2 11 -111 PSI 6300.XXX L1/L2/W1/W211.1 PSI 6300.XXX L1/L2/W1/W2 overviewD PSI 6300.XXX L1:D air-cooledD 400 V --20% to 480 V +10%, 50/60 HzD PSI 6300.XXX L2:D air-cooledD 480 V --20% to 690 V +10%, 50/60 HzD PSI 6300.XXX W1:D water-cooledD 400 V --20% to 480 V +10%, 50/60 HzD PSI 6300.XXX W2:D water-cooledD 480 V --20% to 690 V +10%, 50/60 Hz11.2 Explanation of drawingsThe following drawings show theD front plate with modules of the MF inverterD integrated weld timerD slot for the parallel, serial or fieldbus I/O interfaceD slot prepared for retrofitting a quality moduleD slot for fieldbus interface for programming (optional)DDDDDtechnical datadimensions and mounting optionsmains connectionD connection of the PSG 3000 welding transformerload diagramaccessories and part numbers. Note: No heat sinks or water connections shown on drawings.1070 080 059-101 (2001.04) GB

11 -2PSI 6300.XXX L1/L2/W1/W211.3 PSI 6300.XXX L1/L2/W1/W2 front panel[1][1] [1][2]U1V1[5][6] [7]W1D - 64711 Erbach 107 Made in Germany[3]U1 V1 W13/PE~U2 V22/PE~2/~ADR-+[8][4]U2V2[9][1][1][1]PSI 6300.XXX L1/L2/W1/W2 front panel[1] M6 mounting optionsD rear panelD left side panel (mounting cutout required)[2] mains supply connection[3] MF inverter symbol[4] PSG 3000 welding transformer connection[5] integrated weld timer[6] slot for type-specific I/O interface:D parallel I/O interfaceD serial I/O interfaceD fieldbus I/O interface1070 080 059-101 (2001.04) GB

PSI 6300.XXX L1/L2/W1/W2 11 -3[7] slot for retrofitting a quality module[8] slot for fieldbus interface for programming[9] battery compartment1070 080 059-101 (2001.04) GB

11 -4PSI 6300.XXX L1/L2/W1/W211.4 Technical data, PSI 6300.XXX L1/L2/W1/W2TypeWeld timerI/O interfaceQuality moduleDegree of protectionInverter ambient temperature3-phase MF inverter, module designedfor recessed mountingintegratedSlot for parallel, serial or fieldbus interfaceSlot prepared for retrofittingIP 20; designed for modular enclosureor for installation in switchgear cabinetswith IP 54max. 55 CCooling L1/L2: air, max. 45 C with Boschfan cowl, temperaturecontrolledthrough inverterW1/W2: water, 4 l/min; max. 30 CTemperature monitoringStorage temperatureCorrosionintegrated-- 25 Cto+70 CThe ambient air must be free of acids,caustic solutions, corrosive agents,salts and metal vapors of any majorconcentrationHumidity Humidity class F as per DIN 40040;20 C at 90% relative humidity;40 C at 50% relative humidity (as perVDE 0113);Moisture condensation on the MF invertersmust be prevented.Air pressureLine voltage connectiongrounded TN or TT systemNominal system current;max. continuous thermal currentMax. output currentMax. secondary current; depending onthe transformer usedVoltage supply;Weld timer CPU;I/O interfaceClock frequencyOvervoltage protectionAny within a range of up to 2000 mabove sea levelL1/W1: 400 V -20% to 480 V +10%; 50/60 HzL2/W2: 480 V -20% to 690 V +10%; 50/60 Hz110 A800 A36 kA (PSG 3100)24 V DC; min. 19 V DC up to max.30 V DC as per EN 61131-2, (externalpower supply), or, alternatively, powersupply from the weld current system(internal power supply)1kHzMOV; Metal Oxide VaristorElectrical connection, mains supplyand transformer via box terminal; max. 50 mm 2Wire range 35 mm 2Basic switchgear cabinet lossL1/W1: 69 WL2/W2: 100 W1070 080 059-101 (2001.04) GB

PSI 6300.XXX L1/L2/W1/W2 11 -5Max. ventilating and cooling lossdissipated via external air-coolerL1/L2: 360 WW1: 420 WW2: 500 WSwitchgear cabinet loss at max. power L1: 170 WL2: 200 WW1: 110 WW2: 140 WWeight L1: approx. 20 kgL2: approx. 21 kgW1: approx. 25 kgW2: approx. 26 kgMounting positionvertical or with its back on mountingplate1070 080 059-101 (2001.04) GB

11 -6PSI 6300.XXX L1/L2/W1/W211.5 Dimensioned drawing, PSI 6300.XXX L1/L2Side view, right(as seen from the front)Front viewAccessories kitplate for optionalmountingVentilationclearancesealing face,3 mm flat gasketrequiredMounting cut-out recommended formounting on left side panelPlan view100 mm min. installation clearanceat top and bottom of MFinverter!Drawings not true to scale. Dimensions without tolerances: ±0.5Dimensioned drawing, PSI 6300.XXX L1/L21070 080 059-101 (2001.04) GB

PSI 6300.XXX L1/L2/W1/W2 11 -711.6 Dimensioned drawing, PSI 6300.XXX W1/W2Side view, right(as seen from the front)Front viewAccessories kitplate for optionalmountingAccessories kitnipple (brass)with standard taperbore IAWDIN EN 560, externalthread M16x1.5sealing face,3 mm flat gasketrequiredMounting cut-out recommended formounting on left side panelPlan view100 mm min. installation clearanceat top and bottom of MFinverter!Drawings not true to scale. Dimensions without tolerances: ±0.5Dimensioned drawing, PSI 6300.XXX W1/W21070 080 059-101 (2001.04) GB

11 -8PSI 6300.XXX L1/L2/W1/W211.7 Electrical connection, PSI 6300.XXX L1/L2/W1/W2Side view, right(as seen from the front)from mainsPEU1V1W1all terminalsmax. 50 mm 2U2V2to PSG 3000 weldingtransformerElectrical connection, PSI 6300.XXX L1/L2/W1/W2. Note: For the connections of the various control functions, please seethe respective manuals ”PSI 6000, Control and I/O Level Description”.1070 080 059-101 (2001.04) GB

PSI 6300.XXX L1/L2/W1/W2 11 -911.8 Cooling water connection, PSI 6300.XXX W1/W2cooling watercooling water inletnipple (brass)with standard taperbore IAWDIN EN 560, externalthread M16x1.5cooling water outletCooling water connection, PSI 6300.XXX W1/W21070 080 059-101 (2001.04) GB

11 -10PSI 6300.XXX L1/L2/W1/W2The heat sink of the water-cooled MF inverter is connected internally to theprotective earth conductor.Maximum water inlet temperature : 30 CWater connection : M 16 x 1.5external thread (DIN EN 560,nut: DIN 13-6)PSI 6000by the customerHeat sinkPSIHose nozzleUnion nutM16x1.5washernipple with standard taper bore IAW DIN EN 560,external thread M16x1.5through hole 9 +0.5Cooling water connection1070 080 059-101 (2001.04) GB

PSI 6300.XXX L1/L2/W1/W2 11 -1111.9 Load diagram, PSI 6300.XXX L1/W1. Note: For a general description of load diagrams, see Section 3.1800700600I prim (ED) in A5004003002001001 10 100ED in %primary continuous current, air or water coolingcalculated primary peak current, water cooling, t s = 0.1s, 1 000 000 spotscalculated primary peak current, air cooling, t s = 0.1s, 1 000 000 spotsLoad diagram, PSI 6300.XXX L1/W11070 080 059-101 (2001.04) GB

11 -12PSI 6300.XXX L1/L2/W1/W211.10 Load diagram, PSI 6300.XXX L2/W2. Note: For a general description of load diagrams, see Section 3.1800750700650I prim (ED) in A6005505004504003503002502001501001 10 100ED in %primary continuous current, air or water coolingcalculated primary peak current, water cooling, t s = 0.1s, 1 000 000 spotscalculated primary peak current, air cooling, t s = 0.1s, 1 000 000 spotsLoad diagram, PSI 6300.XXX L2/W21070 080 059-101 (2001.04) GB

PSI 6300.XXX L1/L2/W1/W2 11 -1311.11 Accessories, PSI 6300.XXX L1/L2/W1/W211.11.1 Dimensioned drawing, accessories kitAn accessories kit is available for mounting the inverter with its back on themounting plate.Accessories kit, mounting plate Mounting plate dimensionstool1.5 thickradiuses without dimensions = R2Dimensions without tolerancesRange of nominalfor angles(short leglength)abovesizesabovegreaterthanup toto totoDimensioned drawing, accessories kit1070 080 059-101 (2001.04) GB

11 -14PSI 6300.XXX L1/L2/W1/W2DDDFor PSG 3000 welding transformers, see Technical Information, PSG3000 MF Welding Transformers, part no. 1070 080 087.For I/O module,see Technical Information, PSI 6000, Control and I/O Level Description.For insertable profiles for electric connection, see the section on ordering.1070 080 059-101 (2001.04) GB

PSI 6300.XXX L1/L2/W1/W2 11 -1511.12 Ordering, PSI 6300.XXX L1/L2/W1/W2DesignationPart no.PSI 6300.100 L1 medium-frequency inverter 1070 081 688PSI 6300.330 L1 medium-frequency inverter 1070 079 325PSI 6300.321 L1 medium-frequency inverter 1070 081 689PSI 6300.330 L2 medium-frequency inverter 1070 079 331PSI 6300.100 W1 medium-frequency inverter 1070 084 595PSI 6300.100 W2 medium-frequency inverteron requestNot included in shipment:DesignationInsertable profile for pin connectors on small wire sizes, lineconnection and welding transformer connectionPart no.1070 918 779Accessories kit for PSI 6300.XXX L1/L2/W1/W2 mounting 1070 078 273SSR 81.00 current sensor without fixing device,in the form of a toroid coil;55 mm internal diameter; with 5-pole sleeve terminalSSR 81.01-08 current sensor with fixing device;e.g. for various electrode makes1070 048 099on requestMating connector for SSR 81.0X current sensor 1070 913 489Sensor cable LiYCY 2x2x0,75 mm 2 shielded 1070 913 4941070 080 059-101 (2001.04) GB

11 -16PSI 6300.XXX L1/L2/W1/W2Notes:1070 080 059-101 (2001.04) GB

PSI 6500.XXX W1 12 -112 PSI 6500.XXX W112.1 Explanation of drawingsThe following drawings show theD front plate with modules of the MF inverterD integrated weld timerD slot for the parallel, serial or fieldbus I/O interfaceD slot prepared for retrofitting a quality moduleD slot for fieldbus interface for programming (optional)DDDDDtechnical datadimensions and mounting optionsmains connectionD connection of the PSG 3000 welding transformerload diagramaccessories and part numbers. Note: No water connections shown on drawings.1070 080 059-101 (2001.04) GB

12 -2PSI 6500.XXX W112.2 PSI 6500.XXX W1 front panel[2][1][3]U1 V1 W13/PE~[6] [7] [8]U2 V2 2/~2/PE~ADRD- 64711 Erbach 107 Made in Germany-+[9][10][1][4] [5][1][12][11]PSI 6500.XXX W1 front panel1070 080 059-101 (2001.04) GB

PSI 6500.XXX W1 12 -3[1] M6 mounting optionsD rear panel[2] mains supply connection with shrouding cover[3] MF inverter symbol[4] cooling water connection, supplynipple (brass) with standard taper bore IAW DIN EN 560,external thread M16x1.5[5] cooling water connection, dischargenipple (brass) with standard taper bore IAW DIN EN 560,external thread M16x1.5[6] integrated weld timer[7] slot for type-specific I/O interface:D parallel I/O interfaceD serial I/O interfaceD fieldbus I/O interface[8] slot for retrofitting a quality module[9] slot for fieldbus interface for programming[10] battery compartment[11] PSG 3000 welding transformer connection (with shrouding cover)[12] hose connection between the two water coolers1070 080 059-101 (2001.04) GB

12 -4PSI 6500.XXX W112.3 Technical data, PSI 6500.XXX W1TypeWeld timerI/O interfaceQuality moduleDegree of protectionInverter ambient temperatureCoolingTemperature monitoringStorage temperatureCorrosion3-phase MF inverter, module designed forrecessed mountingintegratedSlot for parallel, serial or fieldbus interfaceSlot prepared for retrofittingIP 20; designed for modular enclosure or forinstallation in switchgear cabinets with IP 54max. 45 C; If thermal outputs exceed50% of the rated ouput, a cabinet coolingsystem starts running, which adjusts theambient temperature to 35 C.water 10 l/min.; max. 30 Cintegrated-- 25 Cto+70 CThe ambient air must be free of acids, causticsolutions, corrosive agents, salts andmetal vapors of any major concentrationHumidity Humidity class F as per DIN 40040;20 C at 90% relative humidity;40 C at 50% relative humidity (as perVDE 0113); Moisture condensation on theMF inverters must be prevented.Air pressureLine voltage connectiongrounded TN or TT systemNominal system current;max. continuous thermal currentMax. output currentMax. secondary current; dependingon the transformer usedVoltage supply;Weld timer CPU;I/O interfaceClock frequencyOvervoltage protectionElectrical connection, mains supplyand transformerWire rangeBasic switchgear cabinet lossMax. ventilating and cooling loss dissipatedvia external water-coolerSwitchgear cabinet loss at max. powerWeightMounting positionAny within a range of up to 2000 m abovesea level400 V --20% to 480 V +10%; 50/60 Hz660 A, with cubicle cooling unit2400 A120 kA (PSG 3100)24 V DC; min. 19 V DC up to max. 30 V DCas per EN 61131-2, (external power supply),or, alternatively, power supply from theweld current system (internal power supply)1kHzMOV; Metal Oxide Varistorwith cable lugs;M10 bolts for each connection2to4cables,120mm 2 each100 W4400 W850 Wapprox. 70 kg, mech. load may be distributedvertical or with its back on mounting plate1070 080 059-101 (2001.04) GB

PSI 6500.XXX W1 12 -512.4 Dimensioned drawing, PSI 6500.XXX W1Side view, right(as seen from the front)396356.5194.5 99Front view2783830.75110396for M6638411600653860[1]Side view, left(as seen from the front)Dimensions without tolerances: ±0.57.5100 mm min. installation clearanceat top and bottom of MFinverter!30,75 110Rear viewnipple (brass) with standardtaper bore IAWDIN EN 560,external thread M16x1.5Dimensioned drawing, PSI 6500.XXX W11070 080 059-101 (2001.04) GB

12 -6PSI 6500.XXX W112.5 Electrical connection, PSI 6500.XXX W1from mainsU1 V1 W1 PEFront viewU1 V1 W13/PE~U2 V2 2/~2/PE~ADRD- 64711 Erbach 107 Made in Germany-+electrical connections:2 to 4 cables, max. 120 mm 2 , ea.,with cable lugs on M10 boltsU2V2to PSG 3000 weldingtransformerElectrical connection, PSI 6500.XXX W1. Note: For the connections of the various control functions, please seethe respective manuals ”PSI 6000, Control and I/O Level Description”.1070 080 059-101 (2001.04) GB

PSI 6500.XXX W1 12 -712.6 Cooling water connection, PSI 6500.XXX W1Front viewU1 V1 W13/PE~U2 V2 2/~2/PE~ADRD- 64711 Erbach 107 Made in Germany-+hose connectionfor cooling watercooling watersupplycooling waterdischargeCooling water connection, PSI 6500.XXX W11070 080 059-101 (2001.04) GB

12 -8PSI 6500.XXX W1The heat sink of the water-cooled MF inverter is connected internally to theprotective earth conductor.Maximum water inlet temperature : 30 CWater connection : M 16 x 1.5external thread (DIN EN 560,nut: DIN 13-6)PSI 6000by the customerHeat sinkPSIHose nozzleUnion nutM16x1.5washernipple with standard taper bore IAW DIN EN 560,external thread M16x1.5through hole 9 +0.5Cooling water connection1070 080 059-101 (2001.04) GB

PSI 6500.XXX W1 12 -912.7 Load diagram, PSI 6500.XXX W1. Note: For a general description of load diagrams, see Section 3.12600240022002000I prim (ED) in A180016001400120010008006001 10 100ED in %primary continuous currentcalculated primary peak current, t s = 0.1s, 1 000 000 spotsLoad diagram, PSI 6500.XXX W11070 080 059-101 (2001.04) GB

12 -10PSI 6500.XXX W112.8 Accessories, PSI 6500.XXX W1DDFor PSG 3000 welding transformers, see Technical Information, PSG3000 MF Welding Transformers, part no. 1070 080 087.For I/O module,see Technical Information, PSI 6000, Control and I/O Level Description.1070 080 059-101 (2001.04) GB

PSI 6500.XXX W1 12 -1112.9 Ordering, PSI 6500.XXX W1DesignationPart no.PSI 6500.XXX W1 medium-frequency inverter 1070 079 302Not included in shipment:DesignationSSR 81.00 current sensor without fixing device,in the form of a toroid coil;55 mm internal diameter; with 5-pole sleeve terminalSSR 81.01-08 current sensor with fixing device;e.g. for various electrode makesPart no.1070 048 099on requestMating connector for SSR 81.0X current sensor 1070 913 489Sensor cable LiYCY 2x2x0,75 mm 2 shielded 1070 913 4941070 080 059-101 (2001.04) GB

12 -12PSI 6500.XXX W1Notes:1070 080 059-101 (2001.04) GB

CE declaration of conformity 13 -113 CE declaration of conformity1070 080 059-101 (2001.04) GB

13 -2CE declaration of conformityNotes:1070 080 059-101 (2001.04) GB

Annex A-1AAnnexA.1 IndexAAccessories kit, 8--10, 9--15, 11--15Accessories PSI 6025.XXX L1, 8--8Accessories PSI 6100.XXX L1/L2/W1/W2, 9--13Accessories PSI 6200.XXX W1/W2, 10--11Accessories PSI 6300.XXX L1/L2/W1/W2, 11--13Accessories PSI 6500.XXX W1, 12--10Airpressure,8--4,9--4,10--4,11--4,12--4Ambient temperature, 3--1, 8--4, 9--4, 10--4, 11--4,12--4Assembly, 1--6BBasic switchgear cabinet loss, 8--4, 9--4, 10--4,11--4, 12--4Battery, 5--1Battery compartment, 8--3, 9--3, 10--3, 11--3, 12--3Block diagram of a medium--frequency inverter, 2--3CCables, 1--11CE conformity, 1--18CE declaration of conformity, 13--1CE marking, 1--13Clock frequency, 8--4, 9--4, 10--4, 11--4, 12--4Commissioning, 4--1Components, 2--2ConnectionU1, 1--11U2, 1--11V1, 1--11V2, 1--11W1, 1--11Welding transformer, 1--11Cooling, 9--4, 10--4, 11--4, 12--4Cooling water, 1--8Chlorides, 1--8Degree of hardness, 1--8Insoluble substances, 1--8Nitrates, 1--8pH value, 1--8Sulfates, 1--8Cooling water connection PSI 6100.XXX W1/W2,9--9Cooling water connection PSI 6200.XXX W1/W2,10--7Cooling water connection PSI 6300.XXX W1/W2,11--9Cooling water connection PSI 6500.XXX W1, 12--7Corrosion, 8--4, 9--4, 10--4, 11--4, 12--4Current sensor, 8--10, 9--15, 10--12, 11--15, 12--11DDegree of protection, 8--4, 9--4, 10--4, 11--4, 12--4Dimensioned drawing PSI 6025.XXX L1, 8--5Dimensioned drawing PSI 6100.XXX L1/L2, 9--6Dimensioned drawing PSI 6100.XXX W1/W2, 9--7Dimensioned drawing PSI 6200.XXX W1/W2, 10--5Dimensioned drawing PSI 6300.XXX L1/L2, 11--6Dimensioned drawing PSI 6300.XXX W1/W2, 11--7Dimensioned drawing PSI 6500.XXX W1, 12--5Dimensioned drawing, accessories kit, 8--8, 9--13,11--13Duty cycle, 3--1EED duty cycle, 3--1Electrical connection, 1--9, 8--4, 9--4, 10--4, 11--4,12--4Electrical connection PSI 6025.XXX L1, 8--61070 080 059-101 (2001.04) GB

A-2AnnexElectrical connection PSI 6100.XXX L1/L2/W1/W2,9--8Electrical connection PSI 6200.XXX W1/W2, 10--6Electrical connection PSI 6300.XXX L1/L2/W1/W2,11--8Electrical connection PSI 6500.XXX W1, 12--6EMC, 1--13EMERGENCY--STOP facilities, 1--16, 5--1FFeatures, 2--1, 7--1Field bus module, 2--2Fieldbus interface for programming, 8--1, 9--1,10--1, 11--1, 12--1Function, 2--4HHeat sink, 8--4, 9--10, 10--8, 11--10, 12--8Humidity,8--4,9--4,10--4,11--4,12--4II/O interface, 2--2, 8--1, 8--4, 9--1, 9--4, 10--1, 10--4,11--1, 11--4, 12--1, 12--4I/O module, 8--9, 9--14, 10--11, 11--14, 12--10Insertable profile, 8--10, 9--15, 11--15Installation, 1--6Integrated weld timer, 8--1, 9--1, 10--1, 11--1, 12--1Intended use, 1--3LLine voltage connection, 8--4, 9--4, 10--4, 11--4,12--4Load capability, 3--1Load diagram, 3--1Load diagram PSI 6025.XXX L1, 8--7Load diagram PSI 6100.XXX L1/W1, 9--11Load diagram PSI 6100.XXX L2/W2, 9--12Load diagram PSI 6200.XXX W1, 10--9Load diagram PSI 6200.XXX W2, 10--10Load diagram PSI 6300.XXX L1/W1, 11--11Load diagram PSI 6300.XXX L2/W2, 11--12Load diagram PSI 6500.XXX W1, 12--9MMains supply, 8--4, 9--4, 10--4, 11--4, 12--4Maintenance, 1--16, 5--1, 5--2Malfunction, 6--1Malfunctions, 6--1Max. output current, 8--4, 9--4, 10--4, 11--4, 12--4Max. secondary current, 8--4, 9--4, 10--4, 11--4,12--4Maximum welding current, 3--1, 1--14Medium--frequency weldingAdvantages, 2--6Benefits, 2--6Modifications, 1--2Modifications by the user, 1--15Modules, 2--2Monitoring, 2--5Monitoring functions, 2--5Mounting, 1--6Mounting position, 8--4, 9--5, 10--4, 11--5, 12--4NNominal system current, 8--4, 9--4, 10--4, 11--4,12--4Notes on rating, 3--1OOperation, 1--14Ordering PSI 6100.XXX L1/L2/W1/W2, 9--15Ordering PSI 6200.XXX W1/W2, 10--12Ordering PSI 6300.XXX L1/L2/W1/W2, 11--15Ordering PSI 6500.XXX W1, 12--11Ordering, PSI 6025.XXX L1, 8--10Output currents, 3--1Overall weld cycle duration, 3--1Overload, 2--5Overvoltage protection, 8--4, 9--4, 10--4, 11--4, 12--4PPacemaker, 1--4PE connection, 1--11Primary voltage, 2--41070 080 059-101 (2001.04) GB

Annex A-3PSI 6025.XXX L1, 8--1PSI 6025.XXX L1 front panel, 8--2PSI 6100.XXX L1/L2/W1/W2, 9--1PSI 6100.XXX L1/L2/W1/W2 front panel, 9--2PSI 6100.XXX L1/L2/W1/W2 overview, 9--1PSI 6200.XXX W1/W2, 10--1PSI 6200.XXX W1/W2 front panel, 10--2PSI 6200.XXX W1/W2 overview, 10--1PSI 6300.XXX L1/L2/W1/W2, 11--1PSI 6300.XXX L1/L2/W1/W2 front panel, 11--2PSI 6300.XXX L1/L2/W1/W2 overview, 11--1PSI 6500.XXX W1, 12--1PSI 6500.XXX W1 front panel, 12--2QQualified personnel, 1--5Quality module, 2--2, 8--1, 8--4, 9--1, 9--4, 10--1,10--4, 11--1, 11--4, 12--1, 12--4R”Ready” LED, 6--1”Ready” message, 6--1Repair, 1--16, 5--2Replacement parts, 5--2Residual--current circuit--breaker, 1--10Retrofits, 1--15SSafety instructions, 1--1, 1--2Secondary current, 2--4Sensor cable, 8--10, 9--15, 10--12, 11--15, 12--11Setup, 2--1Spare parts, 1--16, 5--2Storage temperature, 8--4, 9--4, 10--4, 11--4, 12--4Switchgear cabinet loss, 8--4, 9--5, 10--4, 11--5,12--4Symbols, 1--2System perturbation, 1--12Technical data PSI 6100.XXX L1/L2/W1/W2, 9--4Technical data PSI 6200.XXX W1/W2, 10--4Technical data PSI 6300.XXX L1/L2/W1/W2, 11--4Technical data PSI 6500.XXX W1, 12--4Temperature monitoring, 8--4, 9--4, 10--4, 11--4,12--4Test procedures, 1--16, 5--1Thermal detector, 6--1Thyristor load, 3--1Thyristor unit temperature, 6--1Training courses, 1--5Type, 8--4, 9--4, 10--4, 11--4, 12--4Type overview, 7--1VVentilating and cooling loss, 8--4, 9--5, 10--4, 11--5,12--4Voltage supply, 8--4, 9--4, 10--4, 11--4, 12--4WWeight,8--4,9--5,10--4,11--5,12--4Weld time, 3--1Weld timer, 2--2, 8--4, 9--4, 10--4, 11--4, 12--4Welding current, maximum, 1--14Welding splashes, 1--17Welding transformer, 8--9, 9--14, 10--11, 11--14,12--10Wire range, 8--4, 9--4, 10--4, 11--4, 12--4Working safely, 1--17TTechnical data PSI 6025.XXX L1, 8--41070 080 059-101 (2001.04) GB

A-4AnnexNotes:1070 080 059-101 (2001.04) GB

A-11070 080 059-101 (2001.04) GB ∙ TI WS∙ AT/VWS ∙ PrintedinGermany1070 080 059-101 (2001.04) GB