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

Safety instructions 1-5
1070 080 058-101 (2001.04) GB
1.5 Qualified personnel
The requirements as to qualified personnel are based on the requirements
profiles as defined by the ZVEI (Zentralverband Elektrotechnik und Elek-
tronikindustrie - German Electrical and Electronic Manufacturers’ Associ-
ation) 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.
This manual is designed for technicians and engineers with special welding
training and skills. They must have a sound knowledge of the hardware com-
ponents of the weld control system, the PST 6000 thyristor power units and
the welding transformers.
Interventions in the hardware and software of our products, unless de-
scribed otherwise in this manual, are reserved to specialized Bosch person-
nel.
Tampering with the hardware or software, ignoring warning signs attached to
the components, or non-compliance with the warning notes given in this
manual can result in serious bodily injury or property damage.
Only skilled persons as defined in IEV 826-09-01 who are familiar with the
contents of this manual may install and service the products described.
Such personnel are
Dthose who, being well trained and experienced in their field and familiar
with the relevant standards, are able to analyze the work to be carried 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 tech-
nical training.
DANGER!
An exception are persons with cardiac pacemakers!
The strong magnetic fields occurring in resistance welding may af-
fect 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 ev-
ery entrance to manufacturing shops housing resistance-welding
equipment.
Please note our comprehensive range of training courses. More information
is available from our training center (Phone: +49 / 6062 / 78-258).

Safety instructions
1-6
1070 080 058-101 (2001.04) GB
1.6 Installation and assembly
DANGER
Non-workmanlike installation or mounting may lead to personal in-
jury 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
Insufficient degree of protection may be life-threatening or cause
damage to property!
The degree of protection of thyristor power units is IP 20. They must
be installed in switchgear cubicles providing a degree of protection
of no less than IP 54.
DANGER
Danger of injury and of damage to property through incorrect instal-
lation!
Devices and, in particular, operating means, must be installed so as
to be properly safeguarded against unintentional operation or con-
tact.
DANGER
Risk of injury from sharp-edged sheet metal!
Wear protective gloves!
DANGER
Danger of personal injury and damage to property through inade-
quate fastening!
The place for installing the thyristor power units, and their method
of fastening, must be suitable for their weight!
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.
Wear safety shoes and safety gloves!

Safety instructions 1-7
1070 080 058-101 (2001.04) GB
DANGEROUS ELECTRICAL VOLTAGE
Before the modules are installed, the respective mounting station
must be safely isolated from supply and properly safeguarded to pre-
vent 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 thyristor power
units 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-compliance.
CAUTION
Heat accumulation!
Thyristor power units must be mounted with a minimum clearance
of 100 mm on top and at the bottom. Without this minimum clearance,
heat may accumulate and cause power unit failure.
CAUTION
In the case of aircooled thyristor power units, the temperature inside
the housing must stay within the specified range. Thyristor power
units must always be operated under forcedair cooling conditions.
Convection cooling will not be sufficient!
CAUTION
Leaks in the cooling water circuit may cause consequential damage!
Cooling water leaks may damage adjacent components. Therefore,
when mounting water-cooled modules, always ensure that other de-
vices in the switchgear cabinet are well protected against leaking
cooling water.

Safety instructions
1-8
1070 080 058-101 (2001.04) GB
CAUTION
Damage to property through inappropriate or insufficient cooling of
the thyristor power units!
Water-cooled thyristor power units may only be operated when the
cooling water circuit is active! Condensation on water-carrying com-
ponents 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 im-
pairing the performance of the cooling system with time.
Therefore, you should ensure that your cooling water has the follow-
ing properties:
DpH value :7to 8.5
DDegree of hardness Dmax :10 German degrees
(1 German degree = 1.25 British degrees = 1.05 US degrees =
1.8 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.
LMake sure that all contact surfaces are bright, i.e. free of paint, plastic coat-
ing or dirt/oxidation.
LMount the device in a vertical position.

Safety instructions 1-9
1070 080 058-101 (2001.04) GB
1.7 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 electri-
cal expert in compliance with the valid safety regulations, the mains
voltage and the maximum current consumption of the individual
units of the equipment.
The mains voltage must match the nominal voltage given on the
nameplate of the product!
The equipment must be appropriately fused on the supply side!
Prior to connecting a thyristor power unit, the following must be
strictly observed:
DPower OFF.
DProvide a safeguard to prevent unintentional reclosing.
DVerify that the system is safely isolated from supply and
de-energized.
DConnect to earth and short circuit.
DCover up or safeguard all live parts.
DANGEROUS ELECTRICAL VOLTAGE
Handling live parts at mains voltage may result in death, severe
bodily injury or considerable damage to property unless appropriate
precautions are taken.
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 indi-
vidual units of the equipment.
Incorrect mains voltage may render the system dangerous or cause
electrical component failure!
Therefore, please ensure the following:
DThe mains voltage must match the nominal voltage given on the
nameplate of the product!
DMains voltage fluctuation or variation from the nominal voltage
must be within the specified tolerance range (see Technical Data).
DThe equipment must be appropriately fused on the mains side!
DProper and well insulated tools must be used for handling electric
connections!

Safety instructions
1-10
1070 080 058-101 (2001.04) GB
DANGEROUS ELECTRICAL VOLTAGE
Danger of life through insufficient protective conductor system!
The thyristor power units must be connected to the protective earth-
ing (PE) circuit of the system. Please ensure that the cross-sectional
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.
DANGEROUS ELECTRICAL VOLTAGE
Thyristor power units may be operated in earth neutral systems only.
Protective grounding is the only protective measure permitted as per
EN 50 178 (DIN VDE 0160)!
DANGEROUS ELECTRICAL VOLTAGE
Operation in unbalanced networks (only one network phase
grounded) is not permitted.
.Note: It is recommended that the whole welding system be operated
within a separate welding power network.
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 induc-
tive interference!
Interference is frequently coupled and de-coupled in long cables.
Therefore, thyristor power unit cables and control cables must be
routed separately. The influence of interfering cables on cables sus-
ceptible to interference can be minimized by keeping the following
distances:
D> 100 mm if cables are run in parallel for < 10 m,
D> 250 mm if cables are run in parallel for > 10 m.
The thyristor power unit should be mounted close to the welding
systems so as to avoid cable lengths of more than 25 m.
CAUTION
Connection cables may come off and apply dangerous voltage to
system components!
It is crucial that cables are properly fixed.

Safety instructions 1-11
1070 080 058-101 (2001.04) GB
LPE connection : Connect to a central earth point. Make sure that cable
cross-sectional areas are sufficiently large!
LAll conductor cross-sections must be large enough for the loads to be con-
nected.
LU1 connection :Connect to L1 system phase.
LV1 connection : Connect to L2 system phase.
LU2 and V2 welding transformer outputs : Connect to welding trans-
former.

Safety instructions
1-12
1070 080 058-101 (2001.04) GB
1.8 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.
DOnly for industrial applications.
DSafe clearance from residential areas y30 m.
DSafe clearance to communication systems (wireless, telephone) y10 m.
DCable length of mains feeder y10 m.
DInterference suppression measures: When switchgear cabinet doors are
open, operation of radio devices or cell phones is permitted only beyond
a safe clearance of y2 m.

Safety instructions 1-13
1070 080 058-101 (2001.04) GB
1.9 Operation of the thyristor power units
DANGER
Danger of personal injury and damage to property if devices are op-
erated before they have been properly installed!
The devices are designed to be installed in housings or switchgear
cabinets and must not be operated unless properly installed and
switchgear cabinet doors are closed!
DANGER
Danger of personal injury and damage to property through missing
or false interpretation of fault messages!
Therefore, closing of the temperature contact (thermostatic switch,
break contact) must inhibit the connected timer!
As regards fault analysis, see also the section on ”Malfunction”.
DANGER
Danger of bruises through electrode movement!
All users, line designers, welding machine manufacturers and weld-
ing gun producers 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.
The risk of bruises can be considerably reduced by means of, e.g.,
two-handed start, guard rails, light barriers etc.
CAUTION
Damage to property through insufficient cooling of the modules!
Ensure that the modules are properly cooled during operation. Con-
densation on water-carrying components must be prevented. In the
case of air-cooled thyristor power units, the temperature inside the
mounting station must remain in the specified range. In the case of
water-cooled thyristor power units, the maximum permitted cooling-
water temperature must not be exceeded.
CAUTION
Damage to property through excessive welding current!
The maximum welding current depends on the thyristor unit and the
welding transformer in use. It must not be exceeded.
Therefore, the user must check the load in each case. See also the
section on ”Load diagrams”.
Any and all warranty excluded in case of non-compliance.

Safety instructions
1-14
1070 080 058-101 (2001.04) GB
1.10 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.