Bosch L 309 Series Manual

Power Supply Module
Technical Information
L 309.150 / L 309.250
104
Edition

L 309.150 / L 309.250
Power Supply Module
Technical Information
1070 078 131-104 (00.05) GB
Reg. no. 16149-03
E1994-2000
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 5.--

Contents
Type L 309
Power Supply Module
1070 078 131-104 (00.05) GB
Contents
Page
Safety instructions I - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description of pictographs and symbols I - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning of magnetic fields I - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intended use I - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualified personnel I - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage I - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and assembly I - 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical connection I - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation of the power supply modules I - 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retrofits and modifications by the user I - 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance, repair I - 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Working safely I - 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Structure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Technical data 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Dimensions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types L 309.150 and L 309.151 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type L 309.250 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Installation instructions 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Connection instructions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1. Mains and welding transformer connection 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2. Water connection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3. Connection to the timer module 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4. Mains voltage selection 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Dimensioning instructions 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Fault messages 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Index 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FlexibleAutomation
Type L 309
Power Supply Module
1070 078 131-104 (00.05) GB

Safety instructions
Type L 309
Power Supply Module
I−1
1070 078 131-104 (00.05) GB
Safety instructions
The product described here has been developed, manufactured and tested in com-
pliance with the fundamental safety requirements of the EC machinery directive.
Nevertheless, there is some residual risk!
Therefore, you should read this manual before installing, connecting or commis-
sioning the product, and store it in a place to which all users have access at any
time!
Description of pictographs and symbols
The following warnings and notes may be attached to the actual timer compo-
nents which are designed to inform the user on certain features:
’Warning of dangerous voltages!
’Components subject to electrostatic induction!
’Disconnect mains plug before opening!
’Bolt exclusively designed for PE (protective earth)
conductor!
’Only for shield conductor connection!

Safety instructions Type L 309
Power Supply Module
I−2 1070 078 131-104 (00.05) GB
There is a certain hierarchy of warnings in this manual. The warnings are
printed in bold letters and marked by a warning sign at the margin.
The hierarchy of the warnings is as follows:
1. WARNING
2. CAUTION
3. NOTE
WARNING!
The term WARNING will be used wherever danger is imminent.
The possible consequences may be death or severe injury (personal injury).
CAUTION!
The term CAUTION will be used wherever a dangerous situation is possible.
The possible consequences include severe or light injury (personal injury), damage
to property or environmental hazards.
NOTE
The term NOTE will be used for making recommendations on the use.
Non-compliance with these recommendations may result in damage to property,
e.g. to the machine or the workpiece.
!
!

Safety instructions
Type L 309
Power Supply Module
I−3
1070 078 131-104 (00.05) GB
Warning of magnetic fields
In the environment of resistance welding systems magnetic field strengths have to
be expected which usually are below the limits specified in VDE 0848 Part 4; in
cases of doubt, the field strength must be measured.
WARNING!
The function of cardiac pacemakers may be disturbed!
The possible consequences include death or severe bodily injuries of persons with
cardiac pacemakers! These persons have to avoid the welding system.
We recommend posting a warning of the type shown below at all entrances to fac-
tory halls containing resistance welding equipment:
No entry for persons with cardiac pace-
makers!
Danger!
DIN 40023
CAUTION!
When using manual welding guns, the limit values may be exceeded for the ex-
tremities. In this case, additional work protection measures must be taken.
Intended use
The power supply module is used for controlling the welding transformer.
The power supply modules in connection with suitable welding transformers and
the PSS.../PSH... timer modules serve for
‘resistance welding of metals and are suitable for operation only
‘in industrial environments
in accordance with DIN EN 50082-2 and 50081-2 concerning electromagnetic
compatibility (EMC).
The timers are not intended for any other use!
CAUTION!
The use for purposes other than the intended use may result in personal damage to
the user or third persons or damage to the equipment, the workpiece to be welded
or environmental hazards.
Therefore, our products should only be used for their intended purpose!
!
!
!

Safety instructions Type L 309
Power Supply Module
I−4 1070 078 131-104 (00.05) GB
Qualified personnel
This manual is designed for welding technicians and engineers with special training
and specific knowledge of the welding technology. They require profound knowl-
edge of the hardware components of the timer, the thyristor power supply unit
(L309) and the welding transformer.
The term qualified personnel refers to
- engineering personnel familiar with the safety standards of the electrical and
automation technology.
- commissioning personnel entitled to commission, earth and label electrical cir-
cuits and equipment/systems in compliance with the standards of safety
technology.
- operating personnel who have been instructed in operating installations in re-
sistance welding technology and who know the contents of the present docu-
mentation as far as operation is concerned.
WARNING!
An exception are persons with cardiac pacemakers!
Due to the strong magnetic fields arising from resistance welding, the function of
cardiac pacemakers may be disturbed. This may cause the death or considerable
health damages to the persons concerned!
Therefore, these persons should avoid the welding system.
Please note our comprehensive range of training courses. More information is
available from our training center (Phone: ++49 (0) 6062 / 78258).
Storage
NOTE
Danger of damage caused by frost!
When storing water-cooled modules below the freezing point, the heat sink could
get cracked by frozen water.
Therefore, the heat sink must be drained prior to storage. Please also note the ma-
ximum temperature range for storage given in the ”Technical Data” section.
!

Safety instructions
Type L 309
Power Supply Module
I−5
1070 078 131-104 (00.05) GB
Installation and assembly
CAUTION!
- Danger of life and of damage to property through insufficient protection class!
The protection class of the power supply modules is IP 00. The modules must
be installed in a switch cabinet which must at least comply with protection class
IP 54 (cf. also ”Technical Data” Section).
- Danger of injury and of damage to property through incorrect installation!
The units, and especially the operating elements, must be installed so as to be
sufficiently protected against unintentional operation or contact.
- Danger of injury and of damage to property when operating the units outside a
switch cabinet!
The units are designed to be installed in housings or switch cabinets and may
only be operated in such housings or cabinets with the door closed!
- Danger of injury at sharp metal edges!
You should therefore wear protective gloves.
- Danger of damage to property through short-circuits!
When drilling or sawing out openings within switch cabinets, metal burr may get
inside modules that have already been installed. It is also possible that water
may emerge during the installation of the cooling water lines and may enter the
modules.
The possibility of short-circuits and a destruction of the units cannot be entirely
ruled out.
Therefore, the modules should be well partitioned prior to any additional work!
No liability is accepted in the event of non-compliance.
- Damages to property through leaks in the cooling water circuit!
A leak in the cooling water circuit may cause damages to adjacent components
through emerging cooling water. Therefore you should install the power supply
modules so as to sufficiently protect other units in the switch cabinet against
leaking cooling water.
NOTE
- 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!
- A clearance of min. 100 mm must be available above and below the power sup-
ply modules modules. Lower clearances induce the danger of heat accumula-
tions which may result in a failure of the unit.
!

Safety instructions Type L 309
Power Supply Module
I−6 1070 078 131-104 (00.05) GB
Electrical connection
The power supply modules are connected to the supplying mains.
WARNING!
- The mains voltage is associated with many dangers!
The possible consequences of inappropriate 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.
The mains voltage must be identical with the nominal voltage given on the
nameplate of the product!
Appropriate electrical fusing equipment must be available on the mains side!
- Danger of life through electrical voltage!
Changing the system voltage of the power supply module, if necessary, may
only be performed when the system is de-energized. In any case, suitable insu-
lated tools should be used for this purpose.
- Danger of life through electrical voltage!
The power supply modules must be connected to the protective earthing (PE)
circuit of the system. Please ensure that a sufficient conductor cross-section is
used for wiring the protective conductor. The electrical continuity of the protec-
tive earthing circuit must be verified in accordance with EN 60204 Part 1.
NOTE
We recommend operating the complete welding system on a separate welding
grid. For smaller welding powers, smoothing reactors may be used to achieve cer-
tain improvements.
!

Safety instructions
Type L 309
Power Supply Module
I−7
1070 078 131-104 (00.05) GB
Operation of the power supply modules
CAUTION!
- Danger of injury and of damage to property when operating the units outside a
switch cabinet!
The units are designed to be installed in housings or switch cabinets and may
only be operated in such housings or cabinets with the door closed!
- Danger of injury and of damage to property through missing or false interpreta-
tion of fault messages!
Therefore, closing of the temperature contact connected to X1 (thermostatic
switch) of the modules must inhibit the connected timer! For interpreting the
fault messages also note the information contained in the ”Fault messages”
Section.
- Danger of bruises through electrode movement!
All users, line designers, welding machine manufacturers and welding gun pro-
ducers 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.
NOTE
- Damage to property through insufficient cooling of the modules!
The power supply modules must not be operated unless the cooling water cir-
cuit is active!
- Damage to property through excessive welding current!
The maximum admissible welding current depends on the thyristors of the
power supply modules and must not be exceeded.
Therefore, the thyristor load must be verified in each individual case by the user.
For more information, please refer to the ”Dimensioning instructions” Section.
No liability is accepted in the event of non-compliance.
Retrofits and modifications by the user
The power supply units have been designed and manufactured by us as safe units.
WARNING!
Modifications may have negative effects on the safety of the unit!
The possible consequences include death, severe or light injury (personal injury),
damage to property and environmental hazards.
Therefore, please contact us prior to modifications. This is the only way to deter-
mine whether modified parts are suitable for use with our product.
!
!

Safety instructions Type L 309
Power Supply Module
I−8 1070 078 131-104 (00.05) GB
Maintenance, repair
WARNING!
- Danger of life through 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 proce-
dures on the active system, the applicable safety and accident prevention regu-
lations must be strictly observed. In any case, suitable insulated tools must be
used!
- Danger of life through inappropriate EMERGENCY-STOP facilities!
EMERGENCY-STOP facilities must be operative in all modes of the system.
Releasing the EMERGENCY-STOP facility must by no means result in an un-
controlled restart of the system!
CAUTION!
- The right to perform repair/maintenance work on the timer compenents is re-
served to the BOSCH service department or to repair/maintenance units autho-
rized by BOSCH!
- Only use spare parts/replacement parts approved by BOSCH!
Working safely
WARNING!
- During operation of the welding equipment welding splashes are to be ex-
pected! The consequence may be injuries to the eyes or burns.
Therefore:
‘wear protective goggles
‘wear protective gloves
‘wear flame-retardant clothes
- Danger of injury at sheet metal edges and danger of getting burnt at the parts to
be welded!
Therefore:
‘wear protective gloves
!
!
!

Type L 309
Power Supply Module Structure
1
1070 078 131-104 (00.05) GB
1. Structure
The L 309 power supply modules serve to operate a welding transformer with max.
150 kVA or 250 kVA. Three types are available, L 309.150, L 309.151 and
L 309.250 with different mains voltages and power data (see Section 2., ”Technical
Data”).
The L 309 power supply module contains the firing component as well as the thyris-
tor power supply for triggering the welding transformer. The firing component is
triggered by the weld timer. It transmits firing pulses to the thyristor power supply.
The integrated power supply unit generates the 27 V A.C. and 24 V D.C. synchro-
nization voltage for the weld timer.
The primary voltage of the welding transformer is measured and transmitted to the
weld timer for evaluation and control (UPR).
If the welding transformer or the thyristor power supply is overloaded, a thermo-
static switch is released, thus stopping the weld timer which will output a fault mes-
sage.
L1
L2
=
~
V
L2L1*
UPR1 UPR2
Weld timer
24 V D.C. 27 V A.C. Firing
5 kHz
Temperature
message
Welding transformer
27VA.C.
feedback
L 309
Power
Supply
Module
Block diagram: L 309 Power Supply Module
power supply
mains transformer firing trans-
former
measuring
transformer

FlexibleAutomation
Type L 309
Power Supply Module
Structure
21070 078 131-104 (00.05) GB

Type L 309
Power Supply Module Technical data
3
1070 078 131-104 (00.05) GB
2. Technical data
Type of construction: 2-phase thyristor A.C. power controller as
built-in module in open construction
Protection standard: IP 00; designed for installation in housing or
switch cabinet with IP54
Ambient temperature: max. 60 °C with prescribed cooling, referred to
the room of the installation
Storage temperature: -25 °C to +70 °C,
heat sink must have been drained!
Mains voltage connection: Types L 309.150 and L 309.250:
400 V; 415-440 V; 500-550 V
50 - 60 Hz
(set to 400 V when delivered)
Type L 309.151:
400 V; 460-480 V; 575 V
50 - 60 Hz
(set to 460-480 V when delivered)
Admissible voltage variations: +15%, -20%
Synchronization and supply for timer modules type PSH, PSS: 27 V A.C.
voltage generation: (fused with M 1.25 A at F1);
for triggering of inputs: 24 V D.C.
(fused with M 2.5 A at F2)
Percentage duty cycle (ED): independent from the possible thyristor
switching currents, limited by built-in de-ex-
citation resistor.
up to 400 V: 100 % duty cycle
up to 440 V: 75 % duty cycle
up to 480 V: 70 % duty cycle
up to 575 V: 50 % duty cycle
integration time:  1 minute
Connected load: Types L 309.150 and L 309.151:
for welding transformers up to approx.
150 kVA (with 400 V).
Type L 309.250:
for welding transformers up to approx.
250 kVA (with 400 V).
Max. admissible switching currents depend
on the duty cycle and the weld time, see load
diagram in Section ”Dimensioning
instructions”.

Type L 309
Power Supply Module
Technical data
41070 078 131-104 (00.05) GB
Thyristor off-state voltage: 2000 V
Overvoltage protection: by MOV (metal-oxide varistor)
Electrical connection: Mains connection L1* as auxiliary phase with
6.3 mm flat connector.
Mains connection L2 with bolt
M8 (Types L 309.150/151) or
M10 (L 309.250).
Welding transformer connection V with bolt
M10
Connection to timer unit: via 12-pin plug-in connector
Cooling: Water cooling without internal piping.
Water inlet temperature: max. 30 °C
Water throughput:  4 liters/min.
Differential inlet-outlet:  1 bar at 4 liters/min.
Cooling thermostatically controlled
Water connection: Inlet / outlet: R 3/8”, 37°female taper
Fault messages: Thermostatic switch signal, floating relay con-
tact; it is evaluated by the timer which outputs
the fault message: ”Overtemperature - power
supply fault”
Monitoring: Feedback transformer. Primary voltage of the
welding transformer is reduced to 24 V A.C.
Display: Incoming firing pulses are indicated by yellow
LED - 5 kHz firing

Type L 309
Power Supply Module Dimensions
5
1070 078 131-104 (00.05) GB
3. Dimensions
Types L 309.150 and L 309.151
L1
PE bolt
100 mm installation clearance
above and below the power
supply module
Front view Side view
Top view
Drill pattern
Thyristor con-
nection V
Connection of
phase L2
Connection of
phase L1*
Tightness of the water
connections can be
achieved by using a
22 x 3.5 O-ring.
Coolingwaterconnection with37°femaletaper
0.5 0.5
0.5
0.5
0.5

Dimensions Type L 309
Power Supply Module
61070 078 131-104 (00.05) GB
Type L 309.250
.
.
. 0.5
0.5
0.5
0.5
PE bolt
100 mm installation clearance
above and below the power
supply module
Front view Side view
Top view
Drill pattern
Thyristor con-
nection V
Connection of
phase L2
Connection of
phase L1*
Tightness of the water
connections can be
achieved by using a
22 x 3.5 O-ring.
Coolingwaterconnection with37°femaletaper

Type L 309
Power Supply Module Installationinstructions
7
1070 078 131-104 (00.05) GB
4. Installation instructions
WARNING!
- Danger of life through mains voltage!
Therefore, the space designed for installation must be disconnected from the
supply and sufficiently protected against accidental or unauthorized reclosing
prior to installation.
CAUTION!
- Danger of life and of damage to property through insufficient protection class!
The protection class of the power supply modules is IP 00. The modules must
be installed in a switch cabinet which must at least comply with protection class
IP 54 (cf. also ”Technical Data” Section).
- Danger of injury and of damage to property through incorrect installation!
The units, and especially the operating elements, must be installed so as to be
sufficiently protected against unintentional operation or contact.
- Danger of injury and of damage to property when operating the units outside a
switch cabinet!
The units are designed to be installed in housings or switch cabinets and may
only be operated in such housings or cabinets with the door closed!
- Danger of injury at sharp metal edges!
You should therefore wear protective gloves.
- Danger of damage to property through short-circuits!
When drilling or sawing out openings within switch cabinets, metal burr may get
inside modules that have already been installed. It is also possible that water
may emerge during the installation of the cooling water lines and may enter the
modules.
The possibility of short-circuits and a destruction of the units cannot be entirely
ruled out.
Therefore, the modules should be well partitioned prior to any additional work!
No liability is accepted in the event of non-compliance.
- Damages to property through leaks in the cooling water circuit!
A leak in the cooling water circuit may cause damages to adjacent components
through emerging cooling water. Therefore you should install water-cooled mo-
dules so as to sufficiently protect other units in the switch cabinet against lea-
king cooling water.
NOTE
- 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!
- A clearance of min. 100 mm must be available above and below the power sup-
ply modules. If these clearances are not maintained, there is a risk of heat accu-
mulation which may lead to a failure of the unit.
!
!