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!

Electric Drives
and Controls
1-7Bosch Rexroth AGPSI 6500.xxx1070087059 / 02
Safety Instructions
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. The possibility of short circuits occurring
in the process or even the destruction of the devices cannot be
entirely ruled out.
Therefore, guard any existing modules well before you install a
new module! Any and all warranty excluded in case of non-com-
pliance.
CAUTION
Heat accumulation! Modules must be mounted with a minimum
clearance of 100 mm on top and at the bottom. Without this mini-
mum clearance, heat may accumulate and cause inverter failure.
CAUTION
Leaks in the cooling water circuit may cause consequential da-
mage! Cooling water leaks may damage adjacent components.
Therefore, when mounting water-cooled modules, always ensure
that other devices in the switchgear cabinet are well protected
against leaking cooling water.
CAUTION
Damage to property through insufficient water quality in the pos-
sibly required cooling water circuit! Deposits in the cooling sy-
stem 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 properties:
DpH value :7to 8.5
DDegree of hardness Dmax :10 German degrees =
12.5 British degrees =
10.5 US degrees =
18 French degrees)
DChlorides :max. 20 mg/l
DNitrates : max. 10 mg/l
DSulfates :max. 100 mg/l
DInsoluble substances :max. 250 mg/l
Tap water usually meets these requirements. However, an algicide
should be added.
LFor information about dimensions and installation accessories of the
product as a whole as well as information about the cooling system,
please refer to the manuals of the power supply units (see page 1-1).

1-8 Electric Drives
and Controls
Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02
Safety Instructions
1.6 Electrical Connection
DANGEROUS ELECTRICAL VOLTAGE
The line voltage causes considerable risks!
Improper handling may result in death, personal injury or material
damage.
For that reason, the electric connection may only be established
by an electrician.
The applicable safety regulations as well as the nominal and limit
values of all parts of the plant or system must be taken into consi-
deration.
DANGER
Danger of life through inappropriate EMERGENCY-STOP facili-
ties!
EMERGENCY-STOP facilities must be operative in all modes of the
system. Releasing the EMERGENCY-STOP facility must by no
means result in an uncontrolled restart of the system! First check
the EMERGENCY-STOP circuit, then switch the unit on!
DANGER
Error messages that fail to be evaluated or are evaluated impro-
perly may cause personal injury and material damage!
For instance, switching of a transformer temperature contact
(thermal switch, normally closed contact) must result in blo#king
of the connected control.
CAUTION
Connecting lines and signal lines must be laid so as to avoid nega-
tive effects on the function of the units through capacitive or in-
ductive interference!Interference is frequently coupled and de-
coupled in long cables.
Therefore, power and control cables must be routed separately.
The influence of interfering cables on cables susceptible to inter-
ference can be minimized by keeping the following distances:
> 100 mm if cables are run in parallel for < 10 m,
> 250 mm if cables are run in parallel for > 10 m.
The product should be mounted close to the welding systems so
as to avoid cable lengths of more than 25 m.
LIn addition, please comply with all safety regulations regarding electrical
connections and the EMC of the system as a whole in the manuals of the
power supply units (see page 1-1).

Electric Drives
and Controls
1-9Bosch Rexroth AGPSI 6500.xxx1070087059 / 02
Safety Instructions
1.7 Operation of the Product
DANGER
In the environment of resistance welding systems, magnetic field
strengths have to be expected which are above the limit values
specified in VDE 0848 Part 4.
This applies, above all, to the master-slave mode, because it per-
mits parallel connection of several units to increase the welding
capacity. Especially if manual guns are used, the limit values for
extremities may be exceeded.
In cases of doubt, you should measure the field strength and take
additional measures to ensure safety and health at work. Please
comply with regulation BGV B11 of the German Berufsgenossen-
schaft (professional association) ”Unfallverhütungsvorschrift
elektromagnetische Felder”.
DANGER
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!
DANGER
Danger of personal injury and damage to property if devices are
operated before they have been properly installed!
The devices are designed to be installed in housings or switch-
gear cabinets and must not be operated unless properly installed
and switchgear cabinet doors are closed!

1-10 Electric Drives
and Controls
Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02
Safety Instructions
DANGER
Danger of bruises through electrode movement!
All users, line designers, welding machine manufacturers and
welding gun producers are obliged to connect output signals
which initiate the electrode movement so that the applicable sa-
fety regulations are complied with.
For example, by means of ”Two-handed start”, fences, light bar-
riers etc. the risk of bruises can be considerably reduced.
CAUTION
Overheating through inappropriate or insufficient cooling.
The temperature inside the housing must stay within the specified
range.
Aircooled medium-frequency inverters must always be operated
under forcedair cooling conditions. Convection cooling will not
be sufficient!
Water-cooled medium-frequency inverters may only be operated
when the cooling water circuit is active! Condensation on water-
carrying components must be prevented.
1.8 Retrofits and Modifications by the User
DANGER
Modifications to the product may have negative effects on the
safety of the unit!
The possible consequences include death, severe or light injury
(personal injury), damage to property or environmental hazards.
Therefore, please contact us prior to making any modifications.
This is the only way to determine whether changes can be made
without any problems.

Electric Drives
and Controls
1-11Bosch Rexroth AGPSI 6500.xxx1070087059 / 02
Safety Instructions
1.9 Maintenance, Repair
DANGEROUS ELECTRICAL VOLTAGE
Prior to any maintenance work - unless described otherwise - the
system must always be switched off and sufficiently secured!
In the event of necessary measurement or test procedures on the
active system, these have to be performed by skilled electrical per-
sonnel.
DANGER
Lithium batteries can cause skin burns or explode in case of im-
proper handling!
Therefore, do not forcefully open batteries, do not attempt to
charge or heat up batteries over 1005C!
CAUTION
Please use only spare parts approved by us!
Use only original replacement batteries! In any case, spent batte-
ries and accumulators should be disposed of as hazardous waste!
CAUTION
Danger to the module!
All ESD protection measures must be observed when using the
module! Prevent electrostatic discharges!
The following protective measures must be observed for modules and
components sensitive to electrostatic discharge (ESD)!
DPersonnel responsible for storage, transport, and handling must have
training in ESD protection.
DESD-sensitive components must be stored and transported in the
prescribed protective packaging.
DESD-sensitive components may only be handled at special ESD-
workplaces.
DPersonnel, working surfaces, as well as all equipment and tools
which may come into contact with ESD-sensitive components must
have the same potential (e.g. by grounding).
DWear an approved grounding bracelet. The grounding bracelet must
be connected with the working surface through a cable with an inte-
grated 1 MWresistor.
DESD-sensitive components may by no means come into contact with
chargeable objects, including most plastic materials.

1-12 Electric Drives
and Controls
Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02
Safety Instructions
1.10 Working Safely
DANGER
If the start signal is present in the event of an error reset (acknowl-
edgement), the control immediately starts the program run! Haz-
ardous machine movements may be the result!
Therefore, before fault reset, you should make sure that there are
no persons in the danger zone of the welding equipment!
DANGER
During operation of the welding equipment welding splashes are
to be expected! They may cause eye injuries or burns. Therefore:
- wear protective goggles
- wear protective gloves
- wear flame-retardant clothes
DANGER
Danger of injury from sheet metal edges and danger of burns from
weld metal!
Therefore: - wear protective gloves
CAUTION
The strong magnetic fields occurring in the resistance welding
process may cause permanent damage to wrist watches, pocket
watches, or cards with magnetic stripes (e.g. EC cards).
Therefore, you should not carry any such items on you when wor-
king in the immediate vicinity of the welding equipment.

Electric Drives
and Controls
1-13Bosch Rexroth AGPSI 6500.xxx1070087059 / 02
Safety Instructions
1.11 CE mark
CAUTION
The CE mark for thyristor unit - welding transformer combinations
(see section 4) refers to industrial applications.
For other combinations/applications, the certificate must be deri-
ved from the above, or a new certificate must be issued, if neces-
sary, by the line designer / user.
The product described corresponds to an application variant
which cannot comply with the regulations for terminals, machines
or plants. For that reason, the product may only be used as descri-
bed.
The electrical and mechanical safety and the environmental ef-
fects (foreign bodies, moisture) must be evaluated on the installed
final product.
When installed, the product may have different EMC properties.
For that reason, it is appropriate that the manufacturer of the final
product tests the EMC properties of the final product (terminals,
machines, plants).

1-14 Electric Drives
and Controls
Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02
Safety Instructions
Notes:

Electric Drives
and Controls
2-1Bosch Rexroth AGPSI 6500.xxx1070087059 / 02
Fundamentals on the Master-Slave Mode
2 Fundamentals on the Master-Slave Mode
The types PSI 6500.xxx of the PS 6000 series are provided with the “ma-
ster-slave mode” functionality.
Features of the master-slave mode:
DSynchronization of up to 3 PSI 6500.xxx of the same type, for increa-
sing the welding capacity. In this process, welding currents of max.
360 kA can be achieved with transformers with a transmission of n =
50.
DAutomatic control of all slaves by the master.
DAn “error reset” at the master (via the user interface or by means of
the Reset button on the front panel) also causes an automatic “error
reset” at the slaves.
DHence, assemblies for I/O and programming connection are only re-
quired for the master, if necessary for the application.
DEasy parameterization. Only one unit in the network is parameterized
via the user interface (as master with 1 or 2 slaves).
Units that are coupled to the master via the master-slave connection
cable are automatically parameterized as slaves and accept all rele-
vant parameters from the master (e.g. transformer parameters, etc.).
DIdentical basic hardware for master and slave.
Examples: attainable welding peak currents
Ap-
plica
-
Type:
PSI
Max. inverter
output current
PSG number per
unit (transformer
Max. secondary peak
t it
Max. possible welding
peak current with
plica
-
tion
PSI
6500.xxx
output current
per unit
unit (transformer
transmission)
yp
current per unit 1 slave 2 slaves
Weld .190 1 kA
1x12-V trans-
former
(n = 38)
38 kA
(permanent current:
max. 25 kA)
approx.
76 kA
approx.
114 kA
Weld .190 1 kA 1x9-V transformer
(n = 50)
50 kA
(permanent current:
max. 33 kA)
approx.
100 kA
approx.
150 kA
Projec-
tion or
spot
.000
.100 2.4 kA 3 x PSG 3200 (n = 38)
91 kA
(with a secondary resistance
of 85 µohms)
approx.
180 kA
approx.
270 kA
Projec-
tion or
spot
.000
.100 2.4 kA 4 x PSG 3100 (n = 50)
120 kA
(with a secondary resistance
of 28 µohms)
approx.
240 kA
approx.
360 kA
.For dimensions, line connection, cooling or welding capacities of
the individual units, please refer to the manual of the power section
used (see page 1-1).

2-2 Electric Drives
and Controls
Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02
Fundamentals on the Master-Slave Mode
CAUTION
There may be malfunctions and damage!
Improper installation, incorrect connection or maloperation may
cause unexpected or wrong unit reactions and may, thus, result in
hazardous situations at the welding system.
For that reason, all instruction in the various manuals must be ob-
served!
2.1 Function
The entire master-slave combination is exclusively controlled via the
master.
As is the case with an application without “master-slave mode”, it is only
the master that communicates with the higher-order PLC or the robot via
its I/O assembly (e.g. I/O DISK1) and that is coupled to a higher-order
control/programming unit via a programming bus interface (e.g. PROFI-
BUS), if necessary.
The slaves are connected sequentially to the master via 9-pin connec-
tion lines.
These are used by the master to activate the power sections of the sla-
ves synchronously with its own power section and to reset error states, if
occurring in the individual slaves, after they have been eliminated.
The slaves use the connection lines, for instance, to signal “ready” and
the particular actual value of the primary current to the master.
Each individual unit activates a single welding transformer or (via the pri-
mary-side parallel circuit) several welding transformers (with identical
electric data!).
The secondary-side parallel circuit of all transformers provides the pos-
sibility of increasing the welding capacity accordingly.