PSI 6000 PSI 6000 Medium-Frequency Inverters with integrated control function Technical Information Edition 101
PSI 6000 PSI 6000 Medium-Frequency Inverters with integrated control function Technical Information 1070 080 059-101 (2001.04) GB Reg. no. 16149-03 E 2000, 2001 This manual is the exclusive property of ROBERT BOSCH GMBH, also in the case of Intellectual Property Right applications. Without their consent it may not be reproduced or given to third parties. Discretionary charge DM 10.
Contents V Contents Page 1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 Safety instructions and symbols attached to the product . . . . . . Safety instructions and symbols used in this manual . . . . . . . . . Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No admittance for persons fitted with cardiac pacemakers . . . . Qualified personnel . . . . . . . .
VI Contents Page 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.7.1 8.8 9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.11.1 9.12 10 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 11 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.11.1 11.12 PSI 6025.XXX L1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Explanation of drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PSI 6025.XXX L1 front panel . . . . . . . . . . . . . . . . . . . . . . . .
Contents VII Page 12 PSI 6500.XXX W1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 Explanation of drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PSI 6500.XXX W1 front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical data, PSI 6500.XXX W1 . . . . . . . . . . . . . . . . . . . . . . . . . Dimensioned drawing, PSI 6500.XXX W1 . . . . . . . . . . . . . . . . . .
VIII Contents Notes: 1070 080 059-101 (2001.
Safety instructions 1 1-1 Safety instructions The products described were developed, manufactured and tested in compliance with the fundamental safety requirements of the EU machine directive. These products normally poses no danger to persons or property if used in accordance with the handling stipulations and safety notes prescribed for their configuration, mounting, and proper operation.
1-2 1.2 Safety instructions Safety instructions and symbols used in this manual DANGEROUS ELECTRICAL VOLTAGE This symbol is used to warn of dangerous electrical voltage. Failure to observe the instructions in this manual in whole or in part may result in personal injury. DANGER This symbol is used wherever insufficient or lacking compliance with instructions may result in personal injury.
Safety instructions 1.3 1-3 Intended use PSI 6000 MF inverters are designed for connection of PSG 3000 welding transformers. These MF inverters are designed for use in D resistance welding of metals and D are suitable for operation in industrial environments as per DIN EN 50082-2 and 50081-2 on electromagnetic compatibility (EMC).
1-4 1.4 Safety instructions No admittance for persons fitted with cardiac pacemakers DANGER WARNING for persons fitted with cardiac pacemakers! To protect persons fitted with cardiac pacemakers, no entry signs should be posted because pacemaker malfunction (missed pulses, total failure), pacemaker program interference or even program destruction is to be expected!!! .
Safety instructions 1.5 1-5 Qualified personnel The requirements as to qualified personnel are based on the requirements profiles 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 Automatisierungstechnik edited by: ZVEI and VDMA Maschinenbau Verlag Postfach 71 08 64 D-60498 Frankfurt.
1-6 1.6 Safety instructions Installation and assembly DANGER Non-workmanlike installation or mounting may lead to personal injury or damage to property. Therefore, it is essential that you take the technical data (environmental conditions) into account for installation or mounting. Installation or mounting must be carried out by skilled personnel only. DANGER Insufficient degree of protection may be life-threatening or cause damage to property! The degree of protection of MF inverters is IP 20.
Safety instructions 1-7 DANGEROUS ELECTRICAL VOLTAGE Before the modules are installed, the respective mounting station must be safely isolated from supply and properly safeguarded to prevent unintentional or unauthorized reclosing. CAUTION Short circuits! When cut-outs are drilled or sawed in switchgear cubicles, metal burr may get into modules already installed there. Or, when cooling water lines are connected, water may leak into the modules installed.
1-8 Safety instructions CAUTION Damage to property through inappropriate or insufficient cooling of the medium-frequency inverters! Water-cooled medium-frequency inverters may only be operated when the cooling water circuit is active! Condensation on water-carrying components must be prevented. Damage to property through insufficient water quality in the cooling water circuit! Deposits in the cooling system may reduce the water flow, thus impairing the performance of the cooling system with time.
Safety instructions 1.7 1-9 Electrical connection DANGEROUS ELECTRICAL VOLTAGE The mains voltage is associated with many dangers! Possible consequences of improper handling include death or most severe injuries (personal injuries) and damage to property. For this reason, the electrical connection must always be made by an electrical expert in compliance with the valid safety regulations, the mains voltage and the maximum current consumption of the individual units of the equipment.
1-10 Safety instructions DANGEROUS ELECTRICAL VOLTAGE Danger of life through insufficient protective conductor system! The medium-frequency inverters must be connected to the protective earthing (PE) circuit of the system. Please ensure that the crosssectional area of cables used for protective conductor wiring is sufficiently large. The electrical continuity of the protective earthing circuit must be verified in accordance with EN 60204 Part 1.
Safety instructions 1-11 CAUTION Connecting lines and signal lines must be laid so as to avoid negative effects on the function of the units through capacitive or inductive interference! Interference is frequently coupled and de-coupled in long cables. Therefore, medium-frequency inverter cables and control cables must be routed separately.
1-12 1.8 Safety instructions System perturbation When operating a medium-frequency 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.
Safety instructions 1-13 1.9 Ensuring EMC of the completely assembled system . Note: The completely assembled system with the welding transformer complies with prEN 50240, the EMC product standard for resistance welding systems, and EN 55011 (October 1997), EMC product family standard class A, group 2, rated current > 100 A. Only for industrial applications. Safe clearance from residential areas y 30 m. Safe clearance to communication systems (wireless, telephone) y 10 m.
1-14 1.
Safety instructions 1-15 1.11 Retrofits and modifications by the user DANGER Retrofits or modifications may have negative effects on the safety of the unit! Product modification may cause death, severe or light personal injury, damage to property or environmental damage. Therefore, please contact us prior to making any modification. This is the only way to determine whether modified components are suitable for use with our products. 1070 080 059-101 (2001.
1-16 1.12 Safety instructions Maintenance, repair DANGEROUS ELECTRICAL VOLTAGE Prior to any maintenance work - unless described otherwise - the system must always be switched off! In the event of necessary measurement or test procedures on the active system, these have to be performed by skilled electrical personnel.
Safety instructions 1-17 1.13 Working safely DANGER During operation of the welding equipment welding splashes are to be expected! They may cause eye injuries or burns.
1-18 1.14 Safety instructions CE conformity CAUTION The CE mark is valid for the medium-frequency inverter only with respect to the Low-Voltage Directive. Concerning EMC, it is always necessary to consider the entire application. The CE mark for MF inverter - welding transformer combinations refers to industrial applications. For other combinations/applications, the certificate must be derived from the above, or a new certificate must be issued, if necessary, by the line designer / user.
Setup 2 Setup 2.
2-2 Setup 2.2 Modules and components The PSI 6000 medium-frequency inverters serve to control the PSG 3000 welding transformers.
Setup 2-3 Welding transformer 6-pulse bridge rectifier with direct current link circuit and transistor inverter U1 V1 W1 U2 V2 PE Medium fre quency inverter Control Power supply Current measurement Temperature message Weld timer (CPU) Stop circuit 24VDC supply type-specific I/O interface external device Quality module Block diagram of a medium-frequency inverter 1070 080 059-101 (2001.
2-4 2.3 Setup Function The medium-frequency welding system (MF welding system) is designed for direct current resistance welding. Its key components are the PSI 6000 medium-frequency inverter and the PSG 3000 MF welding transformer. The figure below shows the basic functional design of the MF welding process.
Setup 2.4 2-5 Monitoring In order to ensure high operational reliability, various monitoring functions are incorporated in the PSI 6000 medium-frequency inverter. There is a thermostatic switch to signal any overload on the PSG 3000 welding transformer and/or the MF thyristor unit to the weld timer. The weld timer will then output a ”Thyristor unit fault” message.
2-6 Setup 2.5 Advantages and benefits of medium-frequency welding The PSI 6000 medium-frequency inverters supply an MF output voltage and DC 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. The medium-frequency welding current is clocked at 1 kHz. The current regulation system is faster and more precise compared to 50 Hz welding.
Setup kA 2-7 splash limit galvanized sheet bare sheet bonding limit ms Welding of different sheet types, conventional 50/60 Hz weld kA * * safe splash limit remaining setting range safe bonding limit * possible variation range with fixed setting Welding of galvanized sheet types with 1 kHz welding process 1070 080 059-101 (2001.
2-8 Setup Notes: 1070 080 059-101 (2001.
Notes on Rating 3 3-1 Notes on Rating The load capability of an MF inverter is always predefined by the type designation indicating the specific maximum welding transformer rating. CAUTION Overloading may cause damage to the MF inverter! Always check the actual load applied on the MF inverter! Any and all warranty excluded in case of damage caused by overload. To check the actual load, use the load diagram.
3-2 3.1 Notes on Rating Load diagrams Various types of semiconductors are used as power breakers in the welding systems. Generally, semiconductors have an almost unlimited life if used in accordance with the specifications. Unfortunately, however, the relatively large semiconductor chips have to sustain mechanical stress due to thermal loads. This mechanical stress may reduce semiconductor life.
Commissioning 4 4-1 Commissioning DANGEROUS ELECTRICAL VOLTAGE Danger 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 off the system and wait for at least 5 minutes until the medium-frequency inverter is de-energized. CAUTION Cooling! Please make sure that there is sufficient cooling capacity.
4-2 Commissioning Notes: 1070 080 059-101 (2001.
Maintenance 5 5-1 Maintenance DANGEROUS ELECTRICAL VOLTAGE All maintenance work must be carried out by skilled electricians in compliance with the valid safety regulations, the mains voltage and the maximum current input values of the individual system components. Prior to connecting an MF inverter, the following must be strictly observed: 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.
5-2 Maintenance DANGEROUS ELECTRICAL VOLTAGE The right to perform repair/maintenance work on the timer components is reserved to the BOSCH service department or to repair/ maintenance units authorized by BOSCH! Only use spare parts/replacement parts approved by BOSCH! Run-down batteries or accumulators must be disposed of according to regulations. D Check connections and terminals of all connecting cables for tight fit at regular intervals. Check all cables for damage.
Malfunction 6 6-1 Malfunction Although the design of the MF inverters is quite rugged, malfunctions may occur 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 the thermal detector, D current parameters set are higher than the maximum current permitted or the monitoring values.
6-2 Malfunction Notes: 1070 080 059-101 (2001.
Type overview 7 Type overview 7.1 Features PSI 6025.XXX L1 D Medium-frequency inverter 0.5 to 7 kA D Air cooling D Integrated control function D Rated voltage 400 to 480 Volt, 50/60 Hz D Rated current 20 A (continuous thermal current) D Preferably for connecting welding transformer D PSG 3025.00 A PSI 6100.
7-2 Type overview PSI 6200.XXX W1 D Medium-frequency inverter 9 to 54 kA D Water cooling D Integrated control function D Rated voltage 400 to 480 Volt, 50/60 Hz D Rated current 220 A (continuous thermal current) D Preferably for connecting welding transformers D PSG 3100.00 A D PSG 3200.00 A D Seam-welding functionality also available PSI 6200.XXX W2 D Medium-frequency inverter 9 to 54 kA D Rated voltage 480 to 690 Volt, 50/60 Hz D Other than that like PSI 6200.XXX W1 PSI 6300.
PSI 6025.XXX L1 8 PSI 6025.XXX L1 8.1 Explanation of drawings The following drawings show the D front plate with modules of the MF inverter D integrated weld timer D slot for the parallel, serial or fieldbus I/O interface D slot prepared for retrofitting a quality module D slot for fieldbus interface for programming (optional) D technical data D dimensions and mounting options D mains connection D connection of the PSG 3000 welding transformer D load diagram D accessories and part numbers .
8-2 8.2 PSI 6025.XXX L1 PSI 6025.XXX L1 front panel [1] [1] [1] U1 [2] [5] [6] [7] V1 D - 64711 Erbach 107 Made in Germany W1 A D R U1 V1 W1 3/PE~ [3] U2 V2 2/~ 2/PE~ − + [8] [1] [9] U2 [4] V2 [1] [1] PSI 6025.
PSI 6025.XXX L1 [7] [8] [9] 1070 080 059-101 (2001.
8-4 8.3 PSI 6025.XXX L1 Technical data, PSI 6025.XXX L1 Type 3-phase MF inverter, module designed for recessed mounting Weld timer integrated I/O interface Slot for parallel, serial or fieldbus interface Quality module Slot prepared for retrofitting Degree of protection IP 20; designed for modular enclosure or for installation in switchgear cabinets with IP 54 Inverter ambient temperature max. 55° C Heat sink air, max.
PSI 6025.XXX L1 8.4 Dimensioned drawing, PSI 6025.XXX L1 Front view Side view, right (as seen from the front) Accessories kit plate for optional mounting Ventilation clearance sealing face, 3 mm flat gasket required Mounting cut-out recommended for mounting on left side panel Plan view 100 mm min. installation clearance at top and bottom of MF inverter! Drawings not true to scale. Dimensions without tolerances: $0.5 Dimensioned drawing, PSI 6025.XXX L1 1070 080 059-101 (2001.
8-6 8.5 PSI 6025.XXX L1 Electrical connection, PSI 6025.XXX L1 Side view, right (as seen from the front) from mains PE U1 V1 W1 all terminals max. 50 mm2 U2 V2 to PSG 3000 welding transformer Electrical connection, PSI 6025.XXX L1 . Note: For the connections of the various control functions, please see the respective manuals ”PSI 6000, Control and I/O Level Description”. 1070 080 059-101 (2001.
PSI 6025.XXX L1 8.6 Load diagram, PSI 6025.XXX L1 . Note: For a general description of load diagrams, see Section 3.1 140 120 100 Iprim (ED) in A 8-7 80 60 40 20 0 1 10 ED in % primary continuous current, air cooling calculated primary peak current, air cooling, ts = 0.1s, 1 000 000 spots Load diagram, PSI 6025.XXX L1 1070 080 059-101 (2001.
8-8 PSI 6025.XXX L1 8.7 Accessories, PSI 6025.XXX L1 8.7.1 Dimensioned drawing, accessories kit greater up to than to to to Dimensions without tolerances Range of nominal for angles (short leg sizes above above length) 1.5 thick radiuses without dimensions = R2 tool Accessories kit, mounting plate Mounting plate dimensions An accessories kit is available for mounting the inverter with its back on the mounting plate. Dimensioned drawing, accessories kit 1070 080 059-101 (2001.
PSI 6025.XXX L1 8-9 D For PSG 3000 welding transformers, see Technical Information, PSG 3000 MF Welding Transformers, part no. 1070 080 087. D For I/O module, see Technical Information, PSI 6000, Control and I/O Level Description. D For insertable profiles for electric connection, see the section on ordering. 1070 080 059-101 (2001.
8-10 8.8 PSI 6025.XXX L1 Ordering, PSI 6025.XXX L1 Designation Part no. PSI 6025.100 L1 medium-frequency inverter 1070 080 997 Not included in shipment: Designation Part no. Insertable profile for pin connectors on small wire sizes, line connection and welding transformer connection 1070 918 779 Accessories kit for PSI 6025.XXX L1 mounting 1070 078 273 SSR 81.
PSI 6100.XXX L1/L2/W1/W2 9 PSI 6100.XXX L1/L2/W1/W2 9.1 PSI 6100.XXX L1/L2/W1/W2 overview D PSI 6100.XXX L1 : D air-cooled D 400 V -20% to 480 V +10%, 50/60 Hz D PSI 6100.XXX L2 : D air-cooled D 480 V -20% to 690 V +10%, 50/60 Hz D PSI 6100.XXX W1 : D water-cooled D 400 V -20% to 480 V +10%, 50/60 Hz D PSI 6100.XXX W2 : D water-cooled D 480 V -20% to 690 V +10%, 50/60 Hz 9.
9-2 9.3 PSI 6100.XXX L1/L2/W1/W2 PSI 6100.XXX L1/L2/W1/W2 front panel [1] [1] [1] U1 [2] [5] [6] [7] V1 D - 64711 Erbach 107 Made in Germany W1 A D R U1 V1 W1 3/PE~ [3] U2 V2 2/~ 2/PE~ − + [8] [1] [9] U2 [4] V2 [1] [1] PSI 6100.
PSI 6100.XXX L1/L2/W1/W2 [7] [8] [9] 1070 080 059-101 (2001.
9-4 9.4 PSI 6100.XXX L1/L2/W1/W2 Technical data, PSI 6100.XXX L1/L2/W1/W2 Type 3-phase MF inverter, module designed for recessed mounting Weld timer integrated I/O interface Slot for parallel, serial or fieldbus interface Quality module Slot prepared for retrofitting Degree of protection IP 20; designed for modular enclosure or for installation in switchgear cabinets with IP 54 Inverter ambient temperature max. 55° C Cooling L1/L2: W1/W2: air, max.
PSI 6100.XXX L1/L2/W1/W2 1070 080 059-101 (2001.04) GB 9-5 Max. cooling losses L1/L2: 360 W W1: 420 W W2: 500 W Switchgear cabinet loss at max. power L1: L2: W1: W2: Weight L1: L2: W1: W2: Mounting position vertical or with its back on mounting plate 170 W 200 W 110 W 140 W approx. 20 kg approx. 21 kg approx. 25 kg approx.
9-6 9.5 PSI 6100.XXX L1/L2/W1/W2 Dimensioned drawing, PSI 6100.XXX L1/L2 Front view Side view, right (as seen from the front) Accessories kit plate for optional mounting Ventilation clearance sealing face, 3 mm flat gasket required Mounting cut-out recommended for mounting on left side panel Plan view 100 mm min. installation clearance at top and bottom of MF inverter! Drawings not true to scale. Dimensions without tolerances: $0.5 Dimensioned drawing, PSI 6100.
PSI 6100.XXX L1/L2/W1/W2 9.6 Dimensioned drawing, PSI 6100.XXX W1/W2 Front view Side view, right (as seen from the front) Accessories kit plate for optional mounting Accessories kit nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.5 sealing face, 3 mm flat gasket required Mounting cut-out recommended for mounting on left side panel Plan view 100 mm min. installation clearance at top and bottom of MF inverter! Drawings not true to scale.
9-8 9.7 PSI 6100.XXX L1/L2/W1/W2 Electrical connection, PSI 6100.XXX L1/L2/W1/W2 Side view, right (as seen from the front) from mains PE U1 V1 W1 all terminals max. 50 mm2 U2 V2 to PSG 3000 welding transformer Electrical connection, PSI 6100.XXX L1/L2/W1/W2 . Note: For the connections of the various control functions, please see the respective manuals ”PSI 6000, Control and I/O Level Description”. 1070 080 059-101 (2001.
PSI 6100.XXX L1/L2/W1/W2 9.8 Cooling water connection, PSI 6100.XXX W1/W2 ÄÄÄ ÄÄÄ ÄÄÄ ÄÄÄ cooling water ÄÄÄ ÄÄÄ cooling water inlet nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.5 ÄÄÄ ÄÄÄ cooling water outlet Cooling water connection, PSI 6100.XXX W1/W2 1070 080 059-101 (2001.
9-10 PSI 6100.XXX L1/L2/W1/W2 The heat sink of the water-cooled MF inverter is connected internally to the protective earth conductor. Maximum water inlet temperature : Water connection : PSI 6000 30° C M 16 x 1.5 external thread (DIN EN 560, nut: DIN 13-6) by the customer Heat sink PSI Hose nozzle washer Union nut M16x1.5 nipple with standard taper bore IAW DIN EN 560, external thread M16x1.5 through hole ∅9+0.5 Cooling water connection 1070 080 059-101 (2001.
PSI 6100.XXX L1/L2/W1/W2 9.9 9-11 Load diagram, PSI 6100.XXX L1/W1 . Note: For a general description of load diagrams, see Section 3.1 500 450 Iprim (ED) in A 400 350 300 250 200 150 100 1 10 ED in % primary continuous current, air or water cooling calculated primary peak current, water cooling, ts = 0.1s, 1 000 000 spots calculated primary peak current, air cooling, ts = 0.1s, 1 000 000 spots Load diagram, PSI 6100.XXX L1/W1 1070 080 059-101 (2001.
9-12 PSI 6100.XXX L1/L2/W1/W2 9.10 Load diagram, PSI 6100.XXX L2/W2 . Note: For a general description of load diagrams, see Section 3.1 600 550 500 Iprim (ED) in A 450 400 350 300 250 200 150 100 1 10 100 ED in % primary continuous current, air or water cooling calculated primary peak current, water cooling, ts = 0.1s, 1 000 000 spots calculated primary peak current, air cooling, ts = 0.1s, 1 000 000 spots Load diagram, PSI 6100.XXX L2/W2 1070 080 059-101 (2001.
PSI 6100.XXX L1/L2/W1/W2 9-13 9.11 Accessories, PSI 6100.XXX L1/L2/W1/W2 9.11.1 Dimensioned drawing, accessories kit tool Dimensioned drawing, accessories kit 1070 080 059-101 (2001.04) GB greater up to than to to to Dimensions without tolerances Range of nominal for angles (short leg sizes above above length) 1.
9-14 PSI 6100.XXX L1/L2/W1/W2 D For PSG 3000 welding transformers, see Technical Information, PSG 3000 MF Welding Transformers, part no. 1070 080 087. D For I/O module, see Technical Information, PSI 6000, Control and I/O Level Description. D For insertable profiles for electric connection, see the section on ordering. 1070 080 059-101 (2001.
PSI 6100.XXX L1/L2/W1/W2 9-15 9.12 Ordering, PSI 6100.XXX L1/L2/W1/W2 Designation Part no. PSI 6100.100 L1 medium-frequency inverter 1070 079 211 PSI 6100.200 L1 medium-frequency inverter 1070 079 359 PSI 6101.321 L2 medium-frequency inverter 1070 079 286 PSI 6100.330 L2 medium-frequency inverter on request PSI 6100.100 W1 medium-frequency inverter 1070 079 210 PSI 6100.100 W2 medium-frequency inverter on request Not included in shipment: Designation Part no.
9-16 PSI 6100.XXX L1/L2/W1/W2 Notes: 1070 080 059-101 (2001.
PSI 6200.XXX W1/W2 10-1 10 PSI 6200.XXX W1/W2 10.1 PSI 6200.XXX W1/W2 overview D PSI 6200.XXX W1: D water-cooled D 400 V -20% to 480 V +10%, 50/60 Hz D PSI 6200.XXX W2: D water-cooled D 480 V -20% to 690 V +10%, 50/60 Hz 10.
10-2 10.3 PSI 6200.XXX W1/W2 PSI 6200.XXX W1/W2 front panel [2] [1] [1] U1 V1 [3] W1 [7] [8] [9] [4] U1 V1 W1 A D R 3/PE~ U2 V2 2/~ D - 64711 Erbach 107 Made in Germany 2/PE~ − + [10] [11] [6] U2 [1] V2 [1] [5] PSI 6200.XXX W1/W2 front panel [1] M6 mounting options D rear panel [2] [3] [4] fan mains supply connection MF inverter symbol 1070 080 059-101 (2001.
PSI 6200.XXX W1/W2 10-3 [6] [7] [8] Cooling water connection nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.5 PSG 3000 welding transformer connection integrated weld timer slot for type-specific I/O interface: D parallel I/O interface D serial I/O interface D fieldbus I/O interface [9] [10] [11] slot for retrofitting a quality module slot for fieldbus interface for programming battery compartment [5] 1070 080 059-101 (2001.
10-4 10.4 PSI 6200.XXX W1/W2 Technical data, PSI 6200.XXX W1/W2 Type 3-phase MF inverter, module designed for recessed mounting Weld timer integrated I/O interface Slot for parallel, serial or fieldbus interface Quality module Slot prepared for retrofitting Degree of protection IP 20; designed for modular enclosure or for installation in switchgear cabinets with IP 54 Inverter ambient temperature max.
PSI 6200.XXX W1/W2 10-5 10.5 Dimensioned drawing, PSI 6200.XXX W1/W2 Front view Side view, right (as seen from the front) Ventilation clearance Ventilation clearance Dimensions without tolerances: $0.5 Dimensioned drawing, PSI 6200.XXX W1/W2 1070 080 059-101 (2001.04) GB for nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.5 100 mm min.
10.6 PSI 6200.XXX W1/W2 Electrical connection, PSI 6200.XXX W1/W2 Front view from mains U1 V1 W1 PE U1 V1 W1 U1 V1 W1 A D R 3/PE~ U2 V2 2/~ 2/PE~ D - 64711 Erbach 107 Made in Germany 10-6 − + [11] U2 all terminals max. 95 mm2 V2 U2 V2 to PSG 3000 welding transformer Electrical connection, PSI 6200.XXX W1/W2 . Note: For the connections of the various control functions, please see the respective manuals ”PSI 6000, Control and I/O Level Description”. 1070 080 059-101 (2001.
PSI 6200.XXX W1/W2 10-7 10.7 Cooling water connection, PSI 6200.XXX W1/W2 Front view U1 V1 W1 U1 V1 W1 A D R 3/PE~ U2 V2 2/~ D - 64711 Erbach 107 Made in Germany 2/PE~ − + [11] ÄÄÄÄÄ ÄÄÄÄÄ ÄÄÄÄÄ cooling water inlet rear side cooling water outlet front side Cooling water connection, PSI 6200.XXX W1/W2 1070 080 059-101 (2001.
10-8 PSI 6200.XXX W1/W2 The heat sink of the water-cooled MF inverter is connected internally to the protective earth conductor. Maximum water inlet temperature : Water connection : PSI 6000 30° C M 16 x 1.5 external thread (DIN EN 560, nut: DIN 13-6) by the customer Heat sink PSI Hose nozzle washer Union nut M16x1.5 nipple with standard taper bore IAW DIN EN 560, external thread M16x1.5 through hole ∅9+0.5 Cooling water connection 1070 080 059-101 (2001.
PSI 6200.XXX W1/W2 10-9 10.8 Load diagram, PSI 6200.XXX W1 . Note: For a general description of load diagrams, see Section 3.1 1600 Iprim (ED) in A 1400 1200 1000 800 600 400 200 1 10 ED in % primary continuous current calculated primary peak current, water cooling, ts = 0.1s, 1 000 000 spots Load diagram, PSI 6200.XXX W1 1070 080 059-101 (2001.
10-10 PSI 6200.XXX W1/W2 10.9 Load diagram, PSI 6200.XXX W2 . Note: For a general description of load diagrams, see Section 3.1 1800 1600 Iprim (ED) in A 1400 1200 1000 800 600 400 200 1 10 100 ED in % primary continuous current calculated primary peak current, water cooling, ts = 0.1s, 1 000 000 spots Load diagram, PSI 6200.XXX W2 1070 080 059-101 (2001.
PSI 6200.XXX W1/W2 10-11 10.10 Accessories, PSI 6200.XXX W1/W2 D For PSG 3000 welding transformers, see Technical Information, PSG 3000 MF Welding Transformers, part no. 1070 080 087. D For I/O module, see Technical Information, PSI 6000, Control and I/O Level Description. 1070 080 059-101 (2001.
10-12 10.11 PSI 6200.XXX W1/W2 Ordering, PSI 6200.XXX W1/W2 Designation Part no. PSI 6200.100 W1 medium-frequency inverter 1070 081 748 PSI 6200.321 W1 medium-frequency inverter 1070 081 749 PSI 6200.100 W2 medium-frequency inverter on request Not included in shipment: Designation Part no. SSR 81.00 current sensor without fixing device, in the form of a toroid coil; 55 mm internal diameter; with 5-pole sleeve terminal 1070 048 099 SSR 81.01-08 current sensor with fixing device; e.g.
PSI 6300.XXX L1/L2/W1/W2 11 PSI 6300.XXX L1/L2/W1/W2 11.1 PSI 6300.XXX L1/L2/W1/W2 overview 11-1 D PSI 6300.XXX L1: D air-cooled D 400 V -20% to 480 V +10%, 50/60 Hz D PSI 6300.XXX L2: D air-cooled D 480 V -20% to 690 V +10%, 50/60 Hz D PSI 6300.XXX W1: D water-cooled D 400 V -20% to 480 V +10%, 50/60 Hz D PSI 6300.XXX W2: D water-cooled D 480 V -20% to 690 V +10%, 50/60 Hz 11.
11-2 11.3 PSI 6300.XXX L1/L2/W1/W2 PSI 6300.XXX L1/L2/W1/W2 front panel [1] [1] [1] U1 [2] [5] [6] [7] V1 D - 64711 Erbach 107 Made in Germany W1 A D R U1 V1 W1 3/PE~ [3] U2 V2 2/~ 2/PE~ − + [8] [1] [9] U2 [4] V2 [1] [1] PSI 6300.
PSI 6300.XXX L1/L2/W1/W2 [7] [8] [9] 1070 080 059-101 (2001.
11-4 11.4 PSI 6300.XXX L1/L2/W1/W2 Technical data, PSI 6300.XXX L1/L2/W1/W2 Type 3-phase MF inverter, module designed for recessed mounting Weld timer integrated I/O interface Slot for parallel, serial or fieldbus interface Quality module Slot prepared for retrofitting Degree of protection IP 20; designed for modular enclosure or for installation in switchgear cabinets with IP 54 Inverter ambient temperature max. 55° C Cooling L1/L2: W1/W2: air, max.
PSI 6300.XXX L1/L2/W1/W2 1070 080 059-101 (2001.04) GB 11-5 Max. ventilating and cooling loss dissipated via external air-cooler L1/L2: 360 W W1: 420 W W2: 500 W Switchgear cabinet loss at max. power L1: L2: W1: W2: Weight L1: L2: W1: W2: Mounting position vertical or with its back on mounting plate 170 W 200 W 110 W 140 W approx. 20 kg approx. 21 kg approx. 25 kg approx.
11-6 11.5 PSI 6300.XXX L1/L2/W1/W2 Dimensioned drawing, PSI 6300.XXX L1/L2 Front view Side view, right (as seen from the front) Accessories kit plate for optional mounting Ventilation clearance sealing face, 3 mm flat gasket required Mounting cut-out recommended for mounting on left side panel Plan view 100 mm min. installation clearance at top and bottom of MF inverter! Drawings not true to scale. Dimensions without tolerances: $0.5 Dimensioned drawing, PSI 6300.
PSI 6300.XXX L1/L2/W1/W2 11.6 Dimensioned drawing, PSI 6300.XXX W1/W2 Front view Side view, right (as seen from the front) Accessories kit plate for optional mounting Accessories kit nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.5 sealing face, 3 mm flat gasket required Mounting cut-out recommended for mounting on left side panel Plan view 100 mm min. installation clearance at top and bottom of MF inverter! Drawings not true to scale.
11-8 11.7 PSI 6300.XXX L1/L2/W1/W2 Electrical connection, PSI 6300.XXX L1/L2/W1/W2 Side view, right (as seen from the front) from mains PE U1 V1 W1 all terminals max. 50 mm2 U2 V2 to PSG 3000 welding transformer Electrical connection, PSI 6300.XXX L1/L2/W1/W2 . Note: For the connections of the various control functions, please see the respective manuals ”PSI 6000, Control and I/O Level Description”. 1070 080 059-101 (2001.
PSI 6300.XXX L1/L2/W1/W2 11.8 Cooling water connection, PSI 6300.XXX W1/W2 ÄÄÄ ÄÄÄ ÄÄÄ ÄÄÄ cooling water ÄÄÄ ÄÄÄ cooling water inlet nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.5 ÄÄÄ ÄÄÄ cooling water outlet Cooling water connection, PSI 6300.XXX W1/W2 1070 080 059-101 (2001.
11-10 PSI 6300.XXX L1/L2/W1/W2 The heat sink of the water-cooled MF inverter is connected internally to the protective earth conductor. Maximum water inlet temperature : Water connection : PSI 6000 30° C M 16 x 1.5 external thread (DIN EN 560, nut: DIN 13-6) by the customer Heat sink PSI Hose nozzle washer Union nut M16x1.5 nipple with standard taper bore IAW DIN EN 560, external thread M16x1.5 through hole ∅9+0.5 Cooling water connection 1070 080 059-101 (2001.
PSI 6300.XXX L1/L2/W1/W2 11-11 11.9 Load diagram, PSI 6300.XXX L1/W1 . Note: For a general description of load diagrams, see Section 3.1 800 700 Iprim (ED) in A 600 500 400 300 200 100 1 10 ED in % primary continuous current, air or water cooling calculated primary peak current, water cooling, ts = 0.1s, 1 000 000 spots calculated primary peak current, air cooling, ts = 0.1s, 1 000 000 spots Load diagram, PSI 6300.XXX L1/W1 1070 080 059-101 (2001.
11-12 PSI 6300.XXX L1/L2/W1/W2 11.10 Load diagram, PSI 6300.XXX L2/W2 . Note: For a general description of load diagrams, see Section 3.1 800 750 700 Iprim (ED) in A 650 600 550 500 450 400 350 300 250 200 150 100 1 10 100 ED in % primary continuous current, air or water cooling calculated primary peak current, water cooling, ts = 0.1s, 1 000 000 spots calculated primary peak current, air cooling, ts = 0.1s, 1 000 000 spots Load diagram, PSI 6300.XXX L2/W2 1070 080 059-101 (2001.
PSI 6300.XXX L1/L2/W1/W2 11-13 11.11 Accessories, PSI 6300.XXX L1/L2/W1/W2 11.11.1 Dimensioned drawing, accessories kit tool Dimensioned drawing, accessories kit 1070 080 059-101 (2001.04) GB greater up to than to to to Dimensions without tolerances Range of nominal for angles sizes (short leg above above length) 1.
11-14 PSI 6300.XXX L1/L2/W1/W2 D For PSG 3000 welding transformers, see Technical Information, PSG 3000 MF Welding Transformers, part no. 1070 080 087. D For I/O module, see Technical Information, PSI 6000, Control and I/O Level Description. D For insertable profiles for electric connection, see the section on ordering. 1070 080 059-101 (2001.
PSI 6300.XXX L1/L2/W1/W2 11-15 11.12 Ordering, PSI 6300.XXX L1/L2/W1/W2 Designation Part no. PSI 6300.100 L1 medium-frequency inverter 1070 081 688 PSI 6300.330 L1 medium-frequency inverter 1070 079 325 PSI 6300.321 L1 medium-frequency inverter 1070 081 689 PSI 6300.330 L2 medium-frequency inverter 1070 079 331 PSI 6300.100 W1 medium-frequency inverter 1070 084 595 PSI 6300.100 W2 medium-frequency inverter on request Not included in shipment: Designation Part no.
11-16 PSI 6300.XXX L1/L2/W1/W2 Notes: 1070 080 059-101 (2001.
PSI 6500.XXX W1 12-1 12 PSI 6500.XXX W1 12.1 Explanation of drawings The following drawings show the D front plate with modules of the MF inverter D integrated weld timer D slot for the parallel, serial or fieldbus I/O interface D slot prepared for retrofitting a quality module D slot for fieldbus interface for programming (optional) D technical data D dimensions and mounting options D mains connection D connection of the PSG 3000 welding transformer D load diagram D accessories and part numbers .
12-2 12.2 PSI 6500.XXX W1 PSI 6500.XXX W1 front panel [2] [1] [3] [6] [7] [8] U1 V1 W1 3/PE~ U2 V2 2/~ A D R 2/PE~ + D - 64711 Erbach 107 Made in Germany − [9] [10] [1] [4] [5] [1] [12] [11] PSI 6500.XXX W1 front panel 1070 080 059-101 (2001.
PSI 6500.XXX W1 12-3 [1] M6 mounting options D rear panel [2] [3] [4] mains supply connection with shrouding cover MF inverter symbol cooling water connection, supply nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.5 cooling water connection, discharge nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.
12-4 12.3 PSI 6500.XXX W1 Technical data, PSI 6500.XXX W1 Type 3-phase MF inverter, module designed for recessed mounting Weld timer integrated I/O interface Slot for parallel, serial or fieldbus interface Quality module Slot prepared for retrofitting Degree of protection IP 20; designed for modular enclosure or for installation in switchgear cabinets with IP 54 Inverter ambient temperature max.
PSI 6500.XXX W1 12-5 12.4 Dimensioned drawing, PSI 6500.XXX W1 396 356.5 194.5 99 Front view 411 600 653 860 Side view, right (as seen from the front) [1] 38 30.75 278 396 110 7.5 638 for M6 Side view, left (as seen from the front) Dimensions without tolerances: $0.5 Dimensioned drawing, PSI 6500.XXX W1 1070 080 059-101 (2001.04) GB 30,75 100 mm min.
12.5 PSI 6500.XXX W1 Electrical connection, PSI 6500.XXX W1 from mains U1 V1 W1 PE Front view U1 V1 W1 3/PE~ U2 V2 2/~ A D R 2/PE~ − + D - 64711 Erbach 107 Made in Germany 12-6 electrical connections: 2 to 4 cables, max. 120 mm2, ea., with cable lugs on M10 bolts U2 V2 to PSG 3000 welding transformer Electrical connection, PSI 6500.XXX W1 . Note: For the connections of the various control functions, please see the respective manuals ”PSI 6000, Control and I/O Level Description”.
PSI 6500.XXX W1 12-7 12.6 Cooling water connection, PSI 6500.XXX W1 Front view U1 V1 W1 3/PE~ U2 V2 2/~ A D R 2/PE~ + D - 64711 Erbach 107 Made in Germany − hose connection for cooling water ÄÄ ÄÄ ÄÄ cooling water supply cooling water discharge Cooling water connection, PSI 6500.XXX W1 1070 080 059-101 (2001.
12-8 PSI 6500.XXX W1 The heat sink of the water-cooled MF inverter is connected internally to the protective earth conductor. Maximum water inlet temperature : Water connection : PSI 6000 30° C M 16 x 1.5 external thread (DIN EN 560, nut: DIN 13-6) by the customer Heat sink PSI Hose nozzle washer Union nut M16x1.5 nipple with standard taper bore IAW DIN EN 560, external thread M16x1.5 through hole ∅9+0.5 Cooling water connection 1070 080 059-101 (2001.
PSI 6500.XXX W1 12-9 12.7 Load diagram, PSI 6500.XXX W1 . Note: For a general description of load diagrams, see Section 3.1 2600 2400 2200 Iprim (ED) in A 2000 1800 1600 1400 1200 1000 800 600 1 10 ED in % primary continuous current calculated primary peak current, ts = 0.1s, 1 000 000 spots Load diagram, PSI 6500.XXX W1 1070 080 059-101 (2001.
12-10 12.8 PSI 6500.XXX W1 Accessories, PSI 6500.XXX W1 D For PSG 3000 welding transformers, see Technical Information, PSG 3000 MF Welding Transformers, part no. 1070 080 087. D For I/O module, see Technical Information, PSI 6000, Control and I/O Level Description. 1070 080 059-101 (2001.
PSI 6500.XXX W1 12-11 12.9 Ordering, PSI 6500.XXX W1 Designation Part no. PSI 6500.XXX W1 medium-frequency inverter 1070 079 302 Not included in shipment: 1070 080 059-101 (2001.04) GB Designation Part no. SSR 81.00 current sensor without fixing device, in the form of a toroid coil; 55 mm internal diameter; with 5-pole sleeve terminal 1070 048 099 SSR 81.01-08 current sensor with fixing device; e.g. for various electrode makes on request Mating connector for SSR 81.
12-12 PSI 6500.XXX W1 Notes: 1070 080 059-101 (2001.
CE declaration of conformity 13-1 13 CE declaration of conformity 1070 080 059-101 (2001.
13-2 CE declaration of conformity Notes: 1070 080 059-101 (2001.
Annex A Annex A.1 Index A Accessories kit, 8-10, 9-15, 11-15 Accessories PSI 6025.XXX L1, 8-8 Accessories PSI 6100.XXX L1/L2/W1/W2, 9-13 Accessories PSI 6200.XXX W1/W2, 10-11 Accessories PSI 6300.XXX L1/L2/W1/W2, 11-13 Accessories PSI 6500.
A-2 Annex Electrical connection PSI 6100.XXX L1/L2/W1/W2, 9-8 M Electrical connection PSI 6200.XXX W1/W2, 10-6 Mains supply, 8-4, 9-4, 10-4, 11-4, 12-4 Electrical connection PSI 6300.XXX L1/L2/W1/W2, 11-8 Maintenance, 1-16, 5-1, 5-2 Electrical connection PSI 6500.XXX W1, 12-6 EMC, 1-13 EMERGENCY-STOP facilities, 1-16, 5-1 F Features, 2-1, 7-1 Field bus module, 2-2 Malfunction, 6-1 Malfunctions, 6-1 Max. output current, 8-4, 9-4, 10-4, 11-4, 12-4 Max.
Annex A-3 PSI 6025.XXX L1, 8-1 Technical data PSI 6100.XXX L1/L2/W1/W2, 9-4 PSI 6025.XXX L1 front panel, 8-2 Technical data PSI 6200.XXX W1/W2, 10-4 PSI 6100.XXX L1/L2/W1/W2, 9-1 Technical data PSI 6300.XXX L1/L2/W1/W2, 11-4 PSI 6100.XXX L1/L2/W1/W2 front panel, 9-2 Technical data PSI 6500.XXX W1, 12-4 PSI 6100.XXX L1/L2/W1/W2 overview, 9-1 Temperature monitoring, 8-4, 9-4, 10-4, 11-4, 12-4 PSI 6200.XXX W1/W2, 10-1 PSI 6200.XXX W1/W2 front panel, 10-2 PSI 6200.XXX W1/W2 overview, 10-1 PSI 6300.
A-4 Annex Notes: 1070 080 059-101 (2001.
A-1 1070 080 059-101 (2001.04) GB · TI WS· AT/VWS · Printed in Germany 1070 080 059-101 (2001.
