Bosch PST 6000 Series Manual

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PST 6000.XXX Thyristor Power Unit
with integrated control function
Technical Information
PST 6000
101
Edition

PST 6000
PST 6000.XXX Thyristor Power Unit
with integrated control function
Technical Information
1070 080 058-101 (2001.04) GB
Reg. no. 16149-03
E2000-2001
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 10.-

Contents V
1070 080 058-101 (2001.04) GB
Contents
Page
1 Safety instructions 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Safety instructions and symbols attached to the product 1-1. . . . . .
1.2 Safety instructions and symbols used in this manual 1-2. . . . . . . . .
1.3 Intended use 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 No admittance for persons fitted with cardiac pacemakers 1-4. . . .
1.5 Qualified personnel 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Installation and assembly 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Electrical connection 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Ensuring EMC of the completely assembled system 1-12. . . . . . . . .
1.9 Operation of the thyristor power units 1-13. . . . . . . . . . . . . . . . . . . . . .
1.10 Retrofits and modifications by the user 1-14. . . . . . . . . . . . . . . . . . . . .
1.11 Maintenance, repair 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.12 Working safely 1-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Setup 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Features 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Modules and components 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Function 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Monitoring 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Notes on Rating 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Commissioning 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Maintenance 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Malfunction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Type overview 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Features 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 PST 6100.XXX L 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 PST 6100.XXX L overview 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Explanation of drawings 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 PST 6100.XXX L front panel 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 Technical data, PST 6100.XXX L 8-4. . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 Dimensioned drawing, PST 6100.XXX L 8-5. . . . . . . . . . . . . . . . . . .
8.6 Electrical connection, PST 6100.XXX L 8-6. . . . . . . . . . . . . . . . . . . .
8.7 Load diagram, PST 6100.XXX L 8-7. . . . . . . . . . . . . . . . . . . . . . . . . .
8.8 Accessories, PST 6100.XXX L 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8.1 Dimensioned drawing, accessories kit 8-8. . . . . . . . . . . . . . . . . . . . .
8.9 Ordering accessories 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
VI
1070 080 058-101 (2001.04) GB
Page
9 PST 6250.XXX L 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 PST 6250.XXX L overview 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Explanation of drawings 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 PST 6250.XXX L front panel 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4 Technical data, PST 6250.XXX L 9-4. . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 Dimensioned drawing, PST 6250.XXX L 9-5. . . . . . . . . . . . . . . . . . .
9.6 Electrical connection, PST 6250.XXX L 9-6. . . . . . . . . . . . . . . . . . . .
9.7 Load diagram, PST 6250.XXX L 9-7. . . . . . . . . . . . . . . . . . . . . . . . . .
9.8 Accessories, PST 6250.XXX L 9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8.1 Dimensioned drawing, accessories kit 9-8. . . . . . . . . . . . . . . . . . . . .
9.9 Ordering accessories 9-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 CE declaration of conformity 10-1. . . . . . . . . . . . . . . . . .
A Annex A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Index A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety instructions 1-1
1070 080 058-101 (2001.04) GB
1 Safety instructions
The products described were developed, manufactured and tested in com-
pliance with the fundamental safety requirements of the EU machine direc-
tive. 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 com-
missioning the products. Store this manual in a place to which all users have
access at any time!
This manual describes the:
DPST 6000 thyristor power units
The functions of the integrated weld timer are described in a separate
manual.
1.1 Safety instructions and symbols attached to the product
Warning of dangerous electrical voltage!
Lug for connecting PE conductor only!

Safety instructions
1-2
1070 080 058-101 (2001.04) GB
1.2 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 per-
sonal 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.
.Note: This symbol is used to draw the user’s attention to special cir-
cumstances.
LThis symbol is used if user activities are required.
Modifications in this manual as compared to a previous edition are marked
by black vertical bars in the margin.

Safety instructions 1-3
1070 080 058-101 (2001.04) GB
1.3 Intended use
PST 6000 thyristor power units are designed for connection of welding trans-
formers.
These thyristor power units are designed for use in
Dresistance welding of metals and
Dare suitable for operation in industrial environments as per DIN EN
50082-2 and 50081-2 on electromagnetic compatibility (EMC).
They are not intended for any other use!
DANGER
Any use other than for the purpose indicated may result in personal
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!
.Note: For operation in residential environments, in trade and commer-
cial 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, stor-
age, erection and installation as well as careful operation.

Safety instructions
1-4
1070 080 058-101 (2001.04) GB
1.4 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!!!
.Note: We recommend that warning sings like the one shown below are
posted at every entrance to manufacturing shops housing resistance-
welding equipment:
No entry for persons with cardiac
pacemakers!
Danger!
DIN 40023