Bosch Rexroth PSI 6500 Series Manual

R
exroth Indra
C
ontrol V
C
P 20
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
Rexroth PSI 6500.xxx
Master-Slave
1070087059
Edition 02
Te chnical Information

II Electric Drives
and Controls
Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02
Rexroth PSI 6500.xxx
Master-Slave
Technical Information
DOK-PS6000-MasterSlave-FK02-EN-P
The present manual informs about
DFunctionality and
DSpecial features with regard to the electric connection
of the master-slave mode available in the PSI 6500.xxx.
Description Release
Date
Notes
DOK-PS6000-MasterSlave-FK01-EN-P 06.2003
DOK-PS6000-MasterSlave-FK02-EN-P 04.2004
EBosch Rexroth AG, 2003-2004
Copying this document, giving it to others and the use or
communication of the contents thereof without express authority, are
forbidden. Offenders are liable for the payment of damages. All rights
are reserved in the event of the grant of a patent or the registration
of a utility model or design (DIN 34-1).
The data specified above only serve to describe the product. No
statements concerning a certain condition or suitability for a certain
application can be derived from our information. The given
information does not release the user from the obligation of own
judgement and verification. It must be remembered that our products
are subject to a natural process of wear and aging.
Bosch Rexroth AG
Postfach 11 62
D-64701 Erbach
Berliner Straße 25
D-64711 Erbach
Tel.: [phone]
Fax: [phone]
Abt.: BRC - WS/VTR
Title
Type of Documentation
Document Typecode
Purpose of Documentation
Record of Revisions
Copyright
Validity
Published by

Electric Drives
and Controls
IIIBosch Rexroth AGPSI 6500.xxx1070087059 / 02
Table of Contents
Table of Contents
Page
1 Safety Instructions 1-1. . . . . . . . . . . . . . . . . . . . . . .
1.1 Possible Safety Markings on the Product 1-1. . . . . . . . . . . . . . .
1.2 Safety Instructions in this Manual 1-2. . . . . . . . . . . . . . . . . . . . . .
1.3 Intended Use 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Qualified Personnel 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Installation and Assembly 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Electrical Connection 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Operation of the Product 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Retrofits and Modifications by the User 1-10. . . . . . . . . . . . . . . . .
1.9 Maintenance, Repair 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10 Working Safely 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.11 CE mark 1-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Fundamentals on the Master-Slave Mode 2-1. . .
2.1 Function 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 How to Use Current Sensors 2-4. . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Diagnosis 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Electric Connection 3-1. . . . . . . . . . . . . . . . . . . . . .
3.1 Power, Transformer and Temperature Contact 3-1. . . . . . . . . . .
3.2 External Secondary Circuit Current Sensor (X3) 3-2. . . . . . . . .
3.2.1 Reducing the Measurement Signal 3-3. . . . . . . . . . . . . . . . . . .
3.3 Master-Slave Connection (X6, X7) 3-4. . . . . . . . . . . . . . . . . . . . .
4 CE Marking 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Appendix A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Abbreviations A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Index A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV Electric Drives
and Controls
Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02
Table of Contents
Notes:

Electric Drives
and Controls
1-1Bosch Rexroth AGPSI 6500.xxx1070087059 / 02
Safety Instructions
1 Safety Instructions
The products described were developed, manufactured and tested in
compliance with the fundamental safety requirements of the EU machi-
nery directive. These products normally pose no danger to persons or
property if used in accordance with the handling stipulations and safety
notes prescribed for their configuration, mounting, and proper operation.
Nevertheless, there is some residual risk!
Therefore, you should read this manual before installing, connecting or
commissioning the products or programming the welding system.
Store this manual in a place to which all users have access at any time!
The content of this manual refers to
Dthe functionality and
Dthe specific electric connection
of a master-slave combination with PSI 6500.xxx.
You need the present manual as a supplement to the basic docu-
mentation of the product, if you intend the master-slave mode in
your application.
LTherefore, please pay attention to the following documentation as well:
DControl and I/O Level, Technical Information
for PSx 6xxx.100, PSx 6xxx.190 or PSx 6xxx.000
Control and I/O Level, Technical Information
DMedium-Frequency Inverter, Technical Information (1070 080 028)
for PSI 6500.xxx
1.1 Possible Safety Markings on the Product
Warning of dangerous electrical voltage!
Lug for connecting PE conductor only!
Function ground, ground with low parasitic voltage
Connection of shield conductor only

1-2 Electric Drives
and Controls
Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02
Safety Instructions
1.2 Safety Instructions in this Manual
DANGEROUS ELECTRICAL VOLTAGE
This symbol is used to warn of dangerous electrical voltage. The fail-
ure to observe the instructions in this manual in whole or in part may re-
sult in personal injury.
DANGER
This symbol is used wherever insufficient or lacking compliance with in-
structions may result in personal injury.
CAUTION
This symbol is used wherever insufficient or lacking compliance with in-
structions may result in damage to equipment or data files.
.This symbol is used to draw the user’s attention to special circumstan-
ces.
LThis symbol is used if user activities are required.
Modifications in this manual as compared to a previous edition are mar-
ked by black vertical bars in the margin.

Electric Drives
and Controls
1-3Bosch Rexroth AGPSI 6500.xxx1070087059 / 02
Safety Instructions
1.3 Intended Use
The product described
Dserves in connection with a welding transformer and the appropriate
power supply unit for
- resistance welding of metals
and
Dis suitable for operation in industrial environments in accordance with
the following standards:
- EN 50178
- EN 50081-2
- EN 50082-2
- EN 60204-1
In residential environments, in trade and commerce as well as small
enterprises class A equipment may only be used if it does not inad-
missibly interfere with other equipment.
It is not intended for any other use!
DANGER
Any use other than for the purpose indicated may result in perso-
nal injury of the user or third parties or in damage to equipment,
the workpiece to be welded, or environmental damage.
Therefore, our products must never be used for any other than
their respective intended purpose!
.For operation in residential environments, in trade and commercial
applications and small enterprises, an individual permit of the na-
tional authority or test institution is required; in Germany, please
contact the Regulierungsbehörde für Telekommunikation und
Post (RegTP) or its local branch offices.
The faultless, safe functioning of the product requires proper transport,
storage, assembly and installation as well as careful operation.

1-4 Electric Drives
and Controls
Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02
Safety Instructions
1.4 Qualified Personnel
The requirements as to qualified personnel are based on the require-
ment profiles defined by the ZVEI (Zentralverband Elektrotechnik und
Elektronikindustrie - German Electrical and Electronic Manufacturers’
Association) and the VDMA (Verband deutscher Maschinen- und Anla-
genbau - German Engineering Federation) in:
Weiterbildung in der Automatisierungstechnik
edited by: ZVEI and VDMA
Maschinenbau Verlag
Postfach 71 08 64
D-60498 Frankfurt.
This manual is designed for technicians and engineers with special wel-
ding training and skills. They must have a sound knowledge of the soft-
ware and hardware components of the weld timer, the power supply
used, and the welding transformer.
Project engineering, programming, start and operation as well as the
modification of program parameters is reserved to properly trained per-
sonnel! This personnel must be able to judge potential hazards arising
from programming, program changes and in general from the mechani-
cal, electrical, or electronic equipment.
Interventions in the hardware and software of our products, unless des-
cribed otherwise in this manual, are reserved to specialized personnel.
Tampering with the hardware or software, ignoring warning signs atta-
ched to the components, or non-compliance with the warning notes gi-
ven in this manual can result in serious bodily injury or property damage.
Only skilled persons as defined in IEV 826-09-01 (modified) who are fa-
miliar with the contents of this manual may install and service the pro-
ducts described.
Such personnel are
Dthose who, being well trained and experienced in their field and fami-
liar with the relevant standards, are able to analyze the work to be car-
ried out and recognize any hazards.
Dthose who have acquired the same amount of expert knowledge
through years of experience that would normally be acquired through
formal technical training.

Electric Drives
and Controls
1-5Bosch Rexroth AGPSI 6500.xxx1070087059 / 02
Safety Instructions
DANGER!
An exception are persons with cardiac pacemakers!
The strong magnetic fields occurring in resistance welding may
affect the proper functioning of pacemakers. This may be fatal or
cause serious personal injury!
Therefore, persons with pacemakers must stay clear of resistance
welding systems.
We recommend that warning sings as per DIN 40023 are posted at
every entrance to manufacturing shops housing resistance-wel-
ding equipment.
No entry for persons with cardiac
pacemakers!
Danger!
Please note our comprehensive range of training courses. More infor-
mation is available from our training center (Phone: [phone]).

1-6 Electric Drives
and Controls
Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02
Safety Instructions
1.5 Installation and Assembly
DANGEROUS ELECTRICAL VOLTAGE
Danger of life during installation work while systems are switched
on!
Make sure that all plant sections undergoing operations during
the installation are de-energized and sufficiently protected
against accidental reclosing!
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 (environ-
mental conditions) into account for installation or mounting.
Installation or mounting must be carried out by skilled personnel
only.
DANGER
Danger of injury and of damage to property through incorrect in-
stallation!
Devices and, in particular, operating means, must be installed so
as to be properly safeguarded against unintentional operation or
contact.
DANGER
Danger of personal injury and damage to property through inade-
quate fastening!
The place for installing the modules, and their method of faste-
ning, must be suitable for their weight!
DANGER
Injuries and bruises may be caused by lifting weights which are
too heavy or by sharp metal edges!
Due to the heavy weight of individual modules several persons are
required for installation and assembly.
DANGER
The safety and accident prevention regulations as amended shall
be observed!
Wear a protective helmet, safety shoes and gloves!