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

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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
Page 1 and 2: PSI 6000PSI 6000 Medium-Frequency I
Page 4 and 5: ContentsVContentsPage1 Safety instr
Page 6 and 7: ContentsVIIPage12 PSI 6500.XXX W1 .
Page 8 and 9: Safety instructions 1-11 Safety ins
Page 10 and 11: Safety instructions 1-31.3 Intended
Page 14 and 15: Safety instructions 1-7DANGEROUS EL
Page 16 and 17: Safety instructions 1-91.7 Electric
Page 18 and 19: Safety instructions 1-11CAUTIONConn
Page 20 and 21: Safety instructions 1-131.9 Ensurin
Page 22 and 23: Safety instructions 1-151.11 Retrof
Page 24 and 25: Safety instructions 1-171.13 Workin
Page 26 and 27: Setup 2-12 Setup2.1 FeaturesDDDDDDD
Page 28 and 29: Setup 2-3Welding transformerU1V1W1P
Page 30 and 31: Setup 2-52.4 MonitoringIn order to
Page 32 and 33: Setup 2-7kAsplash limitgalvanized s
Page 34 and 35: Notes on Rating 3-13 Notes on Ratin
Page 36 and 37: Commissioning 4-14 CommissioningDAN
Page 38 and 39: Maintenance 5-15 MaintenanceDANGERO
Page 40 and 41: Malfunction 6-16 MalfunctionAlthoug
Page 43 and 44: 7-2Type overviewPSI 6200.XXX W1D Me
Page 45 and 46: 8-2PSI 6025.XXX L18.2 PSI 6025.XXX
Page 47 and 48: 8-4PSI 6025.XXX L18.3 Technical dat
Page 49 and 50: 8-6PSI 6025.XXX L18.5 Electrical co
Page 51 and 52: 8-8PSI 6025.XXX L18.7 Accessories,
Page 53 and 54: 8-10PSI 6025.XXX L18.8 Ordering, PS
Page 55 and 56: 9-2PSI 6100.XXX L1/L2/W1/W29.3 PSI
Page 57 and 58: 9-4PSI 6100.XXX L1/L2/W1/W29.4 Tech
Page 59 and 60: 9-6PSI 6100.XXX L1/L2/W1/W29.5 Dime
Page 61 and 62: 9-8PSI 6100.XXX L1/L2/W1/W29.7 Elec
Page 63 and 64:
9-10PSI 6100.XXX L1/L2/W1/W2The hea
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9-12PSI 6100.XXX L1/L2/W1/W29.10 Lo
Page 67 and 68:
9-14PSI 6100.XXX L1/L2/W1/W2DDDFor
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9-16PSI 6100.XXX L1/L2/W1/W2Notes:1
Page 71 and 72:
10 -2PSI 6200.XXX W1/W210.3 PSI 620
Page 73 and 74:
10 -4PSI 6200.XXX W1/W210.4 Technic
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10 -6PSI 6200.XXX W1/W210.6 Electri
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10 -8PSI 6200.XXX W1/W2The heat sin
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10 -10PSI 6200.XXX W1/W210.9 Load d
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10 -12PSI 6200.XXX W1/W210.11 Order
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11 -2PSI 6300.XXX L1/L2/W1/W211.3 P
Page 85 and 86:
11 -4PSI 6300.XXX L1/L2/W1/W211.4 T
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11 -6PSI 6300.XXX L1/L2/W1/W211.5 D
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11 -8PSI 6300.XXX L1/L2/W1/W211.7 E
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11 -10PSI 6300.XXX L1/L2/W1/W2The h
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11 -12PSI 6300.XXX L1/L2/W1/W211.10
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11 -14PSI 6300.XXX L1/L2/W1/W2DDDFo
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11 -16PSI 6300.XXX L1/L2/W1/W2Notes
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12 -2PSI 6500.XXX W112.2 PSI 6500.X
Page 101 and 102:
12 -4PSI 6500.XXX W112.3 Technical
Page 103 and 104:
12 -6PSI 6500.XXX W112.5 Electrical
Page 105 and 106:
12 -8PSI 6500.XXX W1The heat sink o
Page 107 and 108:
12 -10PSI 6500.XXX W112.8 Accessori
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12 -12PSI 6500.XXX W1Notes:1070 080
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13 -2CE declaration of conformityNo
Page 113 and 114:
A-2AnnexElectrical connection PSI 6
Page 115 and 116:
A-4AnnexNotes:1070 080 059-101 (200
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