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Bosch PSU 5000 Series Instructions For Assembly And Operation Manual
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Bosch PSU 5000 Series Instructions For Assembly And Operation Manual

Bosch PSU 5000 Series Instructions For Assembly And Operation Manual

Mf welding inverters
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MF Welding Inverters
PSU 5000 / PSG 3000
Instructions for Assembly and Operation
109
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Summary of Contents for Bosch PSU 5000 Series

  • Page 1 MF Welding Inverters PSU 5000 / PSG 3000 Instructions for Assembly and Operation Version...
  • Page 2 DIN ISO 9001 Reg. no. 16149-01/2 E 1996, 1997, 1998 This manual is the exclusive property of ROBERT BOSCH GMBH, also in the case of Intellectual Property Right applications. Without their consent it may not be reproduced or given to third parties.
  • Page 4 PSU 5000 / PSG 3000 Instructions for Assembly and Operation Possible combinations of MF welding inverters / welding transformers PSU 5100.XXX / PSG 3050.00 A PSU 5100.XXX / PSG 3050.10 A PSU 5100.XXX / PSG 3075.10 A PSU 5100.XXX / PSG 3100.00 A PSU 5300.XXX / PSG 3050.00 A PSU 5300.XXX / PSG 3050.10 A PSU 5300.XXX / PSG 3075.10 A...
  • Page 5 PSU 5000 / PSG 3000 Instructions for Assembly and Operation 1070 078 224--- 109...

  • Page 6: Table Of Contents

    ............3--1 Monitoring of the secondary current with Bosch weld timers ....
  • Page 7 PSU 5000 / PSG 3000 Contents Instructions for Assembly and Operation Technical data ..........5- -1 Technical data of the PSU standard types .
  • Page 8 PSU 5000 / PSG 3000 Contents Instructions for Assembly and Operation Controlling the inverter ........8- -1 5 kHz firing pulses .
  • Page 9 PSU 5000 / PSG 3000 Contents Instructions for Assembly and Operation Electrical connection ........11- -1 11.1 PSU connection overview...

  • Page 10: Safety Instructions

    PSU 5000 / PSG 3000 Instructions for Assembly and Operation Safety instructions Safety instructions The products described were developed, manufactured and tested in compliance with the fundamental safety requirements of the EU machine directive. Nevertheless, there still is some residual risk! Please read this manual before putting any of the PSU / PSG units into operation and store it in a place to which all users have access at any time.
  • Page 11 PSU 5000 / PSG 3000 Safety instructions Instructions for Assembly and Operation There is a certain hierarchy of warnings in this manual. The warnings are printed in bold letters and marked by a warning sign at the margin. The hierarchy of the warnings is as follows: 1.

  • Page 12: Warning Of Magnetic Fields

    PSU 5000 / PSG 3000 Instructions for Assembly and Operation Safety instructions Warning of magnetic fields In the environment of resistance welding systems magnetic field strengths have to be expected which usually are below the limits specified in VDE 0848 Part 4; in cases of doubt, the field strength must be measured.

  • Page 13: Compatibility With Residual--Current Devices To En 50178

    PSU 5000 / PSG 3000 Safety instructions Instructions for Assembly and Operation Compatibility with residual- -current devices to EN 50178 ATTENTION! Compatibility with residual--current devices to EN 50178: If a residual--current device is used at the mains side of the inverter to protect per- sons in the event of direct or indirect contact, a type B device must be used.

  • Page 14: Ensuring Emc Of The Comprehensive System

    PSU 5000 / PSG 3000 Instructions for Assembly and Operation Safety instructions Ensuring EMC of the comprehensive system NOTE The comprehensive system comprising PSU in connection with PSG complies with prEN 50240, the EMC product standard for resistance welding systems, and EN 55011 (October 1997), EMC product family standard class A, group 2, rated current >...

  • Page 15: System Perturbation

    PSU 5000 / PSG 3000 Safety instructions Instructions for Assembly and Operation System perturbation When operating a welding inverter a harmonic load must be accounted for in the mains system. This load is caused by the ”B6” rectifier circuit with a smoothing capacitor.

  • Page 16: Qualified Personnel

    PSU 5000 / PSG 3000 Instructions for Assembly and Operation Safety instructions Qualified personnel This manual is designed for welding technicians and engineers with special training and specific knowledge of the welding technology. They require profound knowl- edge of the hardware components of the timer, the inverter (PSU) and the welding rectifier--transformer (PSG).

  • Page 17: Operation Of The Psu And Psg Modules

    -- Danger of bruises through electrode movement! All users, line designers, welding machine manufacturers and welding gun pro- ducers are obliged to connect the output signal of the Bosch weld timer which initiates the electrode movement so that the applicable safety regulations are complied with.

  • Page 18: Maintenance, Repair

    Replace empty batteries with new ones only! ATTENTION! -- The right to perform repair/maintenance work on the timer compenents is re- served to the BOSCH service department or to repair/maintenance units autho- rized by BOSCH! -- Only use spare parts/replacement parts approved by BOSCH! -- Spent batteries or accumulators must be disposed of as hazardous waste.

  • Page 19: Ce Conformity

    PSU 5000 / PSG 3000 Safety instructions Instructions for Assembly and Operation CE conformity NOTE The CE label is valid for the individual PSU unit with respect to the Low--Voltage Directive only. Concerning EMC, it is always necessary to consider the entire application (cf.

  • Page 20: Advantages And Benefits Of Medium- -Frequency Welding

    Instructions for Assembly and Operation Advantages and benefits of medium- -frequency welding The Bosch medium--frequency welding system uses direct current as the welding current. As a result, the welding process can be controlled more thoroughly and faster and becomes more steady. The ”good” welding range becomes larger.
  • Page 21 PSU 5000 / PSG 3000 Advantages Instructions for Assembly and Operation Benefits ` The mains load is symmetrical due to the 3--phase connection of the welding equipment. ` 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 applica- tions.
  • Page 22 The Bosch PSU / PSG MF welding system is equipped with an integrated cur- rent control. Block diagram of a medium- -frequency welding system...

  • Page 23: Structure Of A Medium--Frequency Welding System

    PSU 5000 / PSG 3000 Advantages Instructions for Assembly and Operation Benefits 1.1 Structure of a medium- - frequency welding system Mains system PSS 5000 PSU 5000 1 kHz PSG medium- -frequency transformer Welding gun 1070 078 224--- 108 1--4...

  • Page 24: Schweisskoffer

    PSU 5000 / PSG 3000 Schweisskoffer Instructions for Assembly and Operation Schweisskoffer The following components may be integrated into the Schweisskoffer as ”resis- tance welding process modules”, depending on the requirements: ` PSS 5000 weld timer This timer range comprises different PSS types with interfaces for medium--fre- quency and 50 Hz applications.

  • Page 25: Inverter

    PSU 5000 / PSG 3000 Schweisskoffer Instructions for Assembly and Operation 2.1 Inverter Inverter features: ` current ranges between 3 kA and 18 kA, ` operating voltages between 400 V and 690 V, 50 / 60 Hz, ` fast replacement through quick--action closing mechanisms, ` different transformer types may be used, ` inverters with integrated current control, ` fault diagnostics through seven--segment display and BCD code.

  • Page 26: Functional Description

    PSU 5000 / PSG 3000 Functional Instructions for Assembly and Operation description Functional description The figure below shows the difference between welding equipment with 1---phase AC and medium---frequency DC. 50 / 60 Hz 1- -phase alternating current 50 / 60 Hz Timer Thyristor Welding...
  • Page 27 PSU 5000 / PSG 3000 Functional Instructions for Assembly and Operation description The following figure shows a block diagram of an inverter system: 6- - pole bridge direct current transistorized trans- mains rectifier link circuit former- - rectifier power supply analog controller driver Welding trans-...

  • Page 28: Monitoring Of The Secondary Current With Bosch Weld Timers

    [1] low current [2] high current mean value 3.2 Monitoring of the secondary current with Bosch weld timers In its standard mode, the inverter provides independent control of the welding cur- rent depending on the firing angle or analog value setpoint.

  • Page 29: Faults

    Danger of injury and of damage to property through missing or false interpretation of fault messages! If the inverter is not controlled by a Bosch timer, it must be ensured that closing of the floating contact between terminals 4 and 5 or opening of the contact between...

  • Page 30: Psu Front Panel Views

    PSU 5000 / PSG 3000 PSU front Instructions for Assembly and Operation panel views PSU front panel views 4.1 Front panel view of PSU 5100 / PSU 5300 Mains connection U1, V1, W1, PE PSU 5XXX.1XX: 400- -480 VAC; 50 / 60 Hz Mounting eyes PSU 5XXX.2XX: 480- -690 VAC;...

  • Page 31: Front Panel View Of Psu 5200

    PSU 5000 / PSG 3000 PSU front Instructions for Assembly and Operation panel views 4.2 Front panel view of PSU 5200 Mounting eyes Mains connection U1, V1, W1, PE PSU 5XXX.1XX: 400- -480 VAC; 50 / 60 Hz PSU 5XXX.2XX: 480- -690 VAC; 50 / 60 Hz Ready message, green LED Weld time, green LED Diagnostics display...

  • Page 32: Technical Data

    PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data Technical data 5.1 Technical data of the PSU standard types 5.1.1 Electrical data PSU 5200.1XX PSU 5100.1XX PSU 5100.2XX PSU 5200.2XX PSU 5300.1XX 3- -phase; 400 VAC,- -20% to 480 VAC,+10%; 3- -phase;...

  • Page 33: Mechanical Data

    Cooling water; 4 l per min.; max. 30û C; ∆p: max. 1 bar with Bosch fan cowl water connection through M16x1.5 external thread with taper steps to DIN EN 560 max. 45 ûC 1070 078 224- -108...

  • Page 34: Technical Data Of The Psg Types

    PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data 5.2 Technical data of the PSG types 5.2.1 Electrical data 3050.00 A 3050.10 A 3075.10 A 3100.00 A 3200.00 A Primary voltage connection to connection to connection to PSU 5100.xxx PSU 5100.xxx or PSU 5200.xxx...

  • Page 35: Load Diagrams

    PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data 5.3 Load diagrams 5.3.1 Performance features of PSU 5100.XXX The PSU 5100.XXX inverter has been adapted to the capacity of the transformer-- rectifier units type PSG 3050.XXX, PSG 3075.XXX and PSG 3100.XXX. In com- bination with a transformer--rectifier type PSG 3100.XXX, its peak current is approx.

  • Page 36: Psu 5100.Xxx / Psu 5300.Xxx And Psg 3050.00 A

    PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data The power data for PSU 5100/PSU 5300 = 50 kW and PSU 5200 = 100 kW are calculated from the respective continuous current (110 A and 220 A) and the 500 V output voltage of the inverters.

  • Page 37: Psu 5100.Xxx / Psu 5300.Xxx And Psg 3050.10 A

    PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data 5.3.5 PSU 5100.XXX / PSU 5300.XXX and PSG 3050.10 A Diode integration time: 2 s PSG integration time: 60s ED (duty cycle) [%] The load curves represent ab- Limitation by transformer (and PSU) solute limit values.

  • Page 38: Psu 5100.Xxx / Psu 5300.Xxx And Psg 3075.10 A

    PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data 5.3.6 PSU 5100.XXX / PSU 5300.XXX and PSG 3075.10 A Diode integration time: 2 s PSG integration time: 60s ED (duty cycle) [%] Limitation by transformer (and PSU) The load curves represent ab- Limitation by diodes with 50 cycles weld time solute limit values.

  • Page 39: Psu 5100.Xxx / Psg 3100.00 A

    PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data 5.3.7 PSU 5100.XXX / PSG 3100.00 A Diode integration time: 2 s PSG integration time: 60s ED (duty cycle) [%] Limitation by transformer (and PSU) The load curves represent ab- Limitation by diodes with 50 cycles weld time solute limit values.

  • Page 40: Psu 5200.Xxx And Psg 3200.00 A

    PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data 5.3.8 PSU 5200.XXX and PSG 3200.00 A Diode integration time: 2 s PSG integration time: 60s ED (duty cycle) [%] Limitation by transformer (and PSU) The load curves represent ab- Limitation by diodes with 50 cycles weld time solute limit values.

  • Page 41: Psu 5200.Xxx And 2 X Psg 3100.00 A Parallel

    PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data 5.3.9 PSU 5200.XXX and 2 x PSG 3100.00 A parallel Diode integration time: 2 s PSG integration time: 60s ED (duty cycle) [%] Limitation by transformer (and PSU) The load curves represent ab- Limitation by diodes with 50 cycles weld time solute limit values.

  • Page 42: Psu 5200.Xxx / Psu 5300.Xxx And 1 X Psg 3100.00 A

    PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data 5.3.10PSU 5200.XXX / PSU 5300.XXX and 1 x PSG 3100.00 A Diode integration time: 2 s PSG integration time: 60s 100,0 ED (%) ED (duty cycle) [%] Limitation by transformer (and PSU) The load curves represent ab- Limitation by diodes with 50 cycles weld time solute limit values.

  • Page 43: Example Of Psu 5100.Xxx And Psg 3100.00 A

    PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data 5.3.11Example of PSU 5100.XXX and PSG 3100.00 A 1. Look for the related diagram (PSU 5100.XXX and PSG 3100.00 A). Diode integration time: 2 s : 22,2 1ipo 21,2 20,00 : 17,1...
  • Page 44 PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data 3. Calculate the duty cycle (ED) [2s] of the diodes on the basis of the sequence with the highest number of weld time cycles: number of weld time cycles 30 cycles x 0.02 ED [2s] = x 100 % =...

  • Page 45: Current Resistance Characteristics

    PSU 5000 / PSG 3000 Technical Instructions for Assembly and Operation data 5.3.12Current resistance characteristics µΩ PSG 3050 PSG 3075 Parallel connection 2 x PSG 3100 µΩ PSG 3200 PSG 3100 1070 078 224- -108 5--14...

  • Page 46: Operating Modes

    PSU 5000 / PSG 3000 Operating Instructions for Assembly and Operation modes Operating modes 6.1 Current control function The setpoint value of the heat is entered in scale divisions (SKT), the resulting sec- ondary current is automatically adjusted according to the corresponding diagram. The actual value of the welding current is measured at the secondary side and sig- nalled to the PSU for comparing the setpoint and actual values.
  • Page 47 PSU 5000 / PSG 3000 Operating Instructions for Assembly and Operation modes I [kA] PSU 5200.XXX (DIP switch set to 2 x PSG 3100 in parallel) I [kA] PSU 5200.XXX (DIP switch set to PSG 3200) 1070 078 224- -109 6--2...

  • Page 48: Pulse Width Mode

    PSU 5000 / PSG 3000 Operating Instructions for Assembly and Operation modes I [kA] PSU 5200.XXX / PSU 5300.XXX (DIP switch set to PSG 3100) 6.2 Pulse width mode In this operating mode, the PSU inverts the heat scale value predetermined by the timer into the corresponding pulse width.

  • Page 49: Change--Over Of Operating Modes

    Possible danger of injury and/or damage to property through unauthorized change--over of operating modes! The right to interfere with the timer compenents is reserved to the BOSCH service department or to repair/maintenance units authorized by BOSCH! If the operating mode is to be changed over, the system must be switched off be-...

  • Page 50: Settings

    PSU 5000 / PSG 3000 Operating Instructions for Assembly and Operation modes 6.4 Settings PSU front panel side X 1007 Transformer selection S1/8 ON for analog setpoint Mode selection: Primary current control: Jumper between pins 2 and 3 Secondary current control: Jumper between pins 1 and 2 S5 toggle switch...

  • Page 51: Setting Instructions

    PSU 5000 / PSG 3000 Operating Instructions for Assembly and Operation modes 6.5 Setting instructions Settings and connections of PSU 5000 for heat control: ` Set switch S5 on the analog control module to position B (cf. section 6.4). ` Connect the electrode voltage signal to terminals X11/5 and X11/6. ` Set switch S2/3 to ON for a current range of 1 to 6 kA.).

  • Page 52: Monitoring And Diagnostics

    Danger of injury and/or damage to property through missing or inappropriate inter- pretation of fault messages! If the inverter is not controlled by a Bosch timer it must be ensured that closing of the floating contact between terminals 4 and 5 or opening...

  • Page 53: Inverter Ready" Led

    PSU 5000 / PSG 3000 Monitoring and diagnostics Instructions for Assembly and Operation 7.1 ”Inverter ready” LED The LED is lighted when -- no inverter fault message is active -- the ”Stop current” input signal is not active. The function of ”Stop current” cor- responds to an inverted ”external enable”...

  • Page 54: Fault Numbers At The Seven--Segment Display

    If no fault has been recognized, the value ”0” will be displayed. In the event of a fault, the welding sequence is immediately stopped. In this case, the Bosch weld timer will immediately signal ”Power supply fault” (temperature monitoring circuit for power supply unit).
  • Page 55 The voltage for the internal logic is outside the limit values. The power supply unit board may be defective. Remedy Call Bosch service department. Overcurrent / Earth fault ` Earth fault of primary cable or primary winding of the welding current trans- former.

  • Page 56: Fault Message Encoding

    PSU 5000 / PSG 3000 Monitoring and Instructions for Assembly and Operation diagnostics 7.6 Fault message encoding All fault messages indicated at the seven--segment display can also be transmitted in binary code to an external PLC for evaluation. The pin assignment of output bits 1 to 4 is shown on page 7--2.
  • Page 57 PSU 5000 / PSG 3000 Monitoring and diagnostics Instructions for Assembly and Operation 1070 078 224--- 108 7---6...

  • Page 58: Instructions For Assembly And Operation

    Danger of injury and/or damage to property through missing or inappropriate inter- pretation of fault messages! If the inverter is not controlled by a Bosch timer it must be ensured that closing of the floating contact between terminals 4 and 5 or opening of the connection be-...

  • Page 59: Displays And Pin Assignment

    PSU 5000 / PSG 3000 Controlling Instructions for Assembly and Operation the inverter 8.1.2 Displays and pin assignment ”Weld time” LED The LED is lighted when -- 5 kHz firing pulses are received from the timer (at X5, pins 6 and 7) ”max.

  • Page 60: Weld Time Signal And Analog Input Voltage

    PSU 5000 / PSG 3000 Controlling Instructions for Assembly and Operation the inverter 8.2 24 V weld time signal and analog input voltage As an option, the inverter can be controlled by a 24 V weld time signal and an ana- log input voltage in the range of 1 to 10 V.
  • Page 61 PSU 5000 / PSG 3000 Controlling Instructions for Assembly and Operation the inverter Weld time, green LED Max. pulse width (signalled by decimal point) Change- -over of control mode by setting switch 8 of DIP switch bank S1 to ON position (cf.

  • Page 62: Adjustment Functions

    The functions described below serve to adjust the inverter to the PSG used as well as to certain timer functions. Modifications are re served to the Bosch service department or to technical person- nel authorized by Bosch. The following functions are included in the inverter:...

  • Page 63: Change--Over Of Current Range

    PSU 5000 / PSG 3000 Adjustment Instructions for Assembly and Operation functions 9.1 Change- - over of current range Switches 2 to 4 serve for the reduction of the current ranges by certain percent- ages, for example, in order to achieve a higher resolution (kA/SKT) for fine--spot applications.

  • Page 64: Adjustment Of Psu 5200 To The Welding Transformer

    PSU 5000 / PSG 3000 Adjustment Instructions for Assembly and Operation functions 9.3 Adjustment of PSU 5200 to the welding transformer PSU 5200 with PSU 5200 with PSU 5200 with 1 x PSG 3100.00 A 2 x PSG 3100.00 A PSG 3200.00 A On Off On Off...

  • Page 65: Adjustment To Timers With / Without Ksr Module And Ssu Function

    PSU 5000 / PSG 3000 Adjustment Instructions for Assembly and Operation functions 9.6 Adjustment to timers with / without KSR module and SSU function If switch S2/1 is in ON position, the internal ohmic resistance of the PSU is switched off, the measuring loop test in the PSU is disabled.

  • Page 66: Transformer Change--Over Board

    PSU 5000 / PSG 3000 Adjustment Instructions for Assembly and Operation functions 9.8 Transformer change- -over board The PSU 5100.XXX, PSU 5200.XXX and PSU 5300.XXX inverter types are equipped with an additional slot for a transformer change--over board. This slot is concealed by a dummy cover.
  • Page 67 PSU 5000 / PSG 3000 Adjustment Instructions for Assembly and Operation functions NOTE The combination between a PSG 3075.XX A or a PSG 3050.XX A with a PSU 5200.XXX is not intended to be used without a TK 5201. Transformer change- - over board TK 5201 +24 V I/O 2 x PSG 3100.00 A PSG 3200.00 A...

  • Page 68: Dimensions

    PSU 5000 / PSG 3000 Installation Instructions for Assembly and Operation Dimensions of PSU 10 Dimensions 10.1 Dimensions of PSU The figures show the housing dimensions as well as the points for connecting the mains system, cooling water and the welding transformer (PSG). 10.1.1 PSU 5100 / PSU 5300 with water cooling Front view...

  • Page 69: Psu 5100 / Psu 5300 With Air Cooling

    PSU 5000 / PSG 3000 Installation Instructions for Assembly and Operation Dimensions of PSU 10.1.2 PSU 5100 / PSU 5300 with air cooling Front view Side view Ventilation clearance Accessory kit 078273- - View from above Assembly section Sealing surface 1070 078 224--- 108 10---2...

  • Page 70: Psu 5200 With Water Cooling

    PSU 5000 / PSG 3000 Installation Instructions for Assembly and Operation Dimensions of PSU 10.1.3 PSU 5200 with water cooling Front view Side view Ventilation clearance for M6 Ventilation clearance Water inlet and outlet M 16x1.5 External thread with taper steps to DIN EN 560 View from below Water outlet...

  • Page 71: Dimensions Of Psg

    PSU 5000 / PSG 3000 Installation Instructions for Assembly and Operation Dimensions of PSG 10.2 Dimensions of PSG 10.2.1 PSG 3050.00 A and PSG 3050.10 A Cooling water Cooling water Touch guard required for primary connection! inlet G 1/4” For connection, cover type and order data, cf. attached sheet no. SKT 0058 outlet G 1/4”...

  • Page 72: Psg 3075.10 A

    PSU 5000 / PSG 3000 Installation Instructions for Assembly and Operation Dimensions of PSG 10.2.2 PSG 3075.10 A Cooling water Cooling water Touch guard required for primary connection! inlet G 1/4” For connection, cover type and order data, cf. attached sheet no. SKT 0058 outlet G 1/4”...

  • Page 73: Psg 3100.00 A

    PSU 5000 / PSG 3000 Installation Instructions for Assembly and Operation Dimensions of PSG 10.2.3 PSG 3100.00 A Cooling water Cooling water Touch guard required for primary connection! outlet G 1/4” inlet G 1/4” For connection, cover type and order data, cf. attached sheet no. SKT 0058 Information sign Earthing sign Nameplates...

  • Page 74: Psg 3200.00 A

    PSU 5000 / PSG 3000 Installation Instructions for Assembly and Operation Dimensions of PSG 10.2.4 PSG 3200.00 A Cooling water Cooling water Touch guard required for primary connection! outlet G 1/4” inlet G 1/4” For connection, cover type and order data, cf. attached sheet no. SKT 0058 Nameplates M 8 (6x) 15 deep...

  • Page 75: Cooling

    PSU 5000 / PSG 3000 Installation Instructions for Assembly and Operation Cooling 10.3 Cooling NOTE -- Damage to property in the event of inappropriate/insufficient module cooling! Water- -cooled PSU and PSG modules may only be operated when the cooling water circuit is active! Condensation is not permitted on water--carrying compo- nents.

  • Page 76: Water Connection To Psg

    PSU 5000 / PSG 3000 Installation Cooling Instructions for Assembly and Operation 10.3.2 Water connection to PSG Maximum water inlet temperature: 30 ûC WE = inlet, WA = outlet Water connection: G 1/4” internal thread (for example, see sketch) Hose by the customer internal ø...

  • Page 77: Installation And Assembly

    PSU 5000 / PSG 3000 Installation Instructions for Assembly and Operation Cooling 10.4 Installation and assembly ATTENTION! -- Danger of life and of damage to property through insufficient protection class! The protection class of the PSU modules is IP 20. PSU modules must be instal- led in a switch cabinet which must at least comply with protection class IP 54 (cf.
  • Page 78 PSU 5000 / PSG 3000 Installation Cooling Instructions for Assembly and Operation -- Damage to property through insufficient water quality in the cooling water cir- cuit! Deposits in the cooling system may reduce the water flow, thus impairing the performance of the cooling system with time. Therefore, you should ensure that your cooling water has the following proper- ties: -- pH value: 7 to 8.5...
  • Page 79 PSU 5000 / PSG 3000 Installation Instructions for Assembly and Operation Cooling 1070 078 224- -108 10--12...

  • Page 80: Electrical Connection

    PSU 5000 / PSG 3000 Electrical Instructions for Assembly and Operation connection 11 Electrical connection The MF welding inverter is connected to the supplying mains. WARNING! -- Working with system voltage may result in death, severe bodily injury or consi- derable damage to property unless the appropriate precautionary measures are taken.

  • Page 81: Psu Connection Overview

    PSU 5000 / PSG 3000 Electrical Instructions for Assembly and Operation connection 11.1 PSU connection overview X5 - - to/from weld timer -- 5 kHz firing signal -- temperature contact Mains supply -- weld timer power supply (U1, V1, W1, PE) -- 27 VAC synchronization voltage X12 - - to weld timer -- transfer of the actual current value with...

  • Page 82: Psu Overall Wiring Diagram

    PSU 5000 / PSG 3000 Electrical Instructions for Assembly and Operation connection 11.2 PSU overall wiring diagram U1 V1 W1 Mains: 3 PE 50 / 60 Hz PSU 5XXX.1XX: 400 to 480 VAC+10 % PSU 5XXX.2XX: 480 to 690 VAC+10 % PSU 5200 1070 078 224- -108 11--3...

  • Page 83: Connection Of X1 Interface

    PSU 5000 / PSG 3000 Electrical Instructions for Assembly and Operation connection 11.2.1 Connection of X1 interface X5: 1 to 10 - -> timer unit up to 10 m ≧ 0.75 mm / up to 75 m ≧ 1.50 mm 27 VAC synchronization* (max.

  • Page 84: Connection Of X11 Interface

    PSU 5000 / PSG 3000 Electrical Instructions for Assembly and Operation connection 11.2.3 Connection of X11 interface X11: 1 to 6 - -> transformer 3 x 2 x 0.75 mm shielded LiYCY transformer temperature, must be closed transformer temperature, must be closed current sensor current sensor only with heat control, U...

  • Page 85: Connection Of X21 Interface

    PSU 5000 / PSG 3000 Electrical Instructions for Assembly and Operation connection 11.2.5 Connection of X21 interface X21: 1 to 8 - -> PLC 24 V I/O up to 10 m ≧ 0.75 mm / up to 75 m ≧ 1.50 mm error bit 1, referred to GND , 24 V max.

  • Page 86: Psu Mains Connection And Psg Power Connection For Nominal Operation

    PSU 5000 / PSG 3000 Connection Instructions for Assembly and Operation 11.3 PSU mains connection and PSG power connection for nominal operation All mains connections are led through openings in the PSU 5XXX.1XX: 400 to 480 VAC+10% - - 20%, 50 / 60 Hz housing cover.

  • Page 87: Connection Between Psu And Timer Module

    PSU 5000 / PSG 3000 Connection Instructions for Assembly and Operation 11.4 Connection between PSU and timer module Control option: 5 kHz firing pulses (cf. also Section 8.1) 5) 1) 27 V AC supply (synchronization) 5) 1) 27 V AC supply (synchronization) temperature contact temperature contact ignition +...
  • Page 88 Danger of injury and/or damage to property through missing or inappropriate inter- pretation of fault messages! In connection with a Bosch timer module, the overtemperature contact of the PSU may only be used as a normally--open contact (connector X5, pins 4 and 5).

  • Page 89: Connection Between Psu And Psg

    PSU 5000 / PSG 3000 Connection Instructions for Assembly and Operation 11.5 Connection between PSU and PSG to the electrodes 3 thermostatic switches connected in series white black brown yellow green white current sensor yellow brown Connecting cable: 2 x 2 x 0.75 mm shielded LiYCY The cable and the 12- -pole...
  • Page 90 Instructions for Assembly and Operation 11.6 Protective conductor connection to medium ---frequency transformers BOSCH medium--frequency transformers comply with protection class 1 in accor- dance with DIN VDE 0551 Part 1. For protection class 1, additional protective measures must be applied in accor-...
  • Page 91 PSU 5000 / PSG 3000 Connection Instructions for Assembly and Operation How to recognize a ”defective” (ineffective) MPE protective conductor connection NOTE Transformer Rectifier Electrode gun open Test point Test point Housing max. 1 V 10 A 1.) Subject the protective conductor jumper (MPE) to a visual inspection for dam- ages.
  • Page 92 PSU 5000 / PSG 3000 Connection Instructions for Assembly and Operation Circulating currents Circulating currents are defined as currents which do not flow as desired from the positive pole of the welding equipment through the workpiece and to the negative pole of the welding equipment during the welding process, but rather through the workpiece and then through external ”ground connections”...
  • Page 93 PSU 5000 / PSG 3000 Connection Instructions for Assembly and Operation Case 3 Transformer Rectifier Workpiece Supply line Housing Negative pole grounded via protective conductor jumper (MPE), workpiece grounded, transformer housing has a low--resistance connection to through the welding equipment (practical case). There will be circulating currents through the mains supply line and further- more through the welding equipment.
  • Page 94 PSU 5000 / PSG 3000 Connection Instructions for Assembly and Operation How to measure circulating currents Transformer Rectifier Supply line Workpiece Housing Welding current meter A welding current meter for measuring DC current is required for measuring the circulating currents. (1) Apply measuring belt to positive pole of the electrode gun and fix its position.

  • Page 95: Parallel Connection Of 2 Psg's To Psu 5200

    PSU 5000 / PSG 3000 Connection Instructions for Assembly and Operation 11.7 Parallel connection of 2 PSG’s to PSU 5200 Please note the information given in Section 9.4 ! PSU 5200 3 thermostatic For cable data, please re- switches connected fer to Section 11.5 in series white...
  • Page 96 PSU 5000 / PSG 3000 Connection Instructions for Assembly and Operation VDE 0113 is to be provided (e.g. by earthing the welding gun)! In addition, the transformer is to be marked accordingly (see also dimensioned drawing of the transformer, Section 10.2). Brush leads approx.
  • Page 97 PSU 5000 / PSG 3000 Connection Instructions for Assembly and Operation 1070 078 224- -109 11--18...

  • Page 98: Activation/Deactivation Of The Inverter

    PSU 5000 / PSG 3000 Activation/deactiva- - Instructions for Assembly and Operation tion of the inverter 12 Activation/deactivation of the inverter inverter ready ` Activation of the inverter 1. Apply mains voltage The inverter starts up. After approx. 10 s the DC link circuit is charged to re- ach its maximum voltage, and the green LED ”inverter ready”...
  • Page 99 PSU 5000 / PSG 3000 Activation/deactiva- - Instructions for Assembly and Operation tion of the inverter 1070 078 224- -108 12---2...

  • Page 100: Maintenance

    Replace empty batteries with new ones only! ATTENTION! -- The right to perform repair/maintenance work on the timer compenents is re- served to the BOSCH service department or to repair/maintenance units autho- rized by BOSCH! -- Only use spare parts/replacement parts approved by BOSCH! -- Spent batteries or accumulators must be disposed of as hazardous waste.
  • Page 101 PSU 5000 / PSG 3000 Maintenance Instructions for Assembly and Operation 1070 078 224- -108 13---2...

  • Page 102: Accessories

    Timer module [4] [5] [6] Items [1] through [3] and [7] are not included in the standard delivery! [1] Mating connector, 12--pole, at Bosch timer module PSS2000/E81... (only when equipped with direct--current KSR module) for actual--current value message KSR connector assembly Part no.
  • Page 103 PSU 5000 / PSG 3000 Accessories Instructions for Assembly and Operation Terminal box TH 3050/MC Part--no.: 1070 917 828 suitable for PSG 3050 or PSG 3075 for MC contact connection 135A right- -hand and left- -hand knock- -out panel for Pg29 and MC flanged socket Terminal box TH 3000/PG Part--no.: 1070 917 826...
  • Page 104 MC contact connection 180A right- -hand and left- -hand knock- -out panel for Pg29 and MC flanged socket Advice on request: Robert Bosch GmbH, AT/VWS Phone: ++(49) 6062/78 0 (exchange) Fax: ++(49) 6062 / 78 728 1070 078 224- -108...
  • Page 105 PSU 5000 / PSG 3000 Accessories Instructions for Assembly and Operation 1070 078 224- -108 14--4...

  • Page 106: Storage And Transport

    PSU 5000 / PSG 3000 Storage and Instructions for Assembly and Operation transport 15 Storage and transport ATTENTION! Injuries and bruises may be caused by lifting weights which are too heavy! Depending on the weight of individual modules (for weight data, see Section 5, ”Technical Data”) a suitable device or several persons are required for transporting.
  • Page 107 PSU 5000 / PSG 3000 Storage and transport Instructions for Assembly and Operation 1070 078 224- -108 15---2...

  • Page 108: Ec Declaration Of Conformity

    PSU 5000 / PSG 3000 Declaration of Instructions for Assembly and Operation conformity 16 EC Declaration of Conformity 1070 078 224--- 108 16---1...
  • Page 109 PSU 5000 / PSG 3000 Declaration of conformity Instructions for Assembly and Operation 1070 078 224--- 108 16---2...

  • Page 110: Index

    PSU 5000 / PSG 3000 Index Instructions for Assembly and Operation 17 Index Connection overview, PSU, 11--2 Connections for cooling water, 10--8 Connections PSU (Overview), 11--3 Numbers Connectors, accessories, 14--1 Contact voltage, 11--11 24 V weld time signal, 8--3 Controlling 5 kHz firing pulses, 8--1 by 5 kHz firing pulses, 8--1 by an analog input voltage and 24VDC weld time...
  • Page 111 PSU 5000 / PSG 3000 Index Instructions for Assembly and Operation Operating modes, 6--1 Input signal ”Reset”, 7--2 Operating modes, change--over, 6--4 Input signal ”Stop Current”, 7--2 Operation of the PSU and PSG modules, I -- 8 Installation, 10--10 Operation with current control, 6--1 Insulation breakdown, 11--11 Inverter, 2--2 activation/deactivation, 12--1...
  • Page 112 PSU 5000 / PSG 3000 Index Instructions for Assembly and Operation Technical data, 5--1 Ramp time constant, 9--4 Terminal boxes for PSG, 14--2 Repair, I -- 9 Test procedures, I -- 9, 13--1 Replacement parts, I -- 9, 13--1 Training Reset, input signal, 7--2 Courses, I -- 7 Retrofits, I -- 8...
  • Page 113 PSU 5000 / PSG 3000 Index Instructions for Assembly and Operation 1070 078 224- -109 17--4...
  • Page 114 1070 078 224-109 (98.10) GB · MBA · AT/VWS · Printed in Germany...

This manual is also suitable for:

Psg 3000 seriesPsu 5100 seriesPsu 5300 seriesPsu 5200 seriesPsg 3050.00 aPsg 3050.10 a ... Show all

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