Bosch PSU 5000 Series Installation instructions

PSU 5000 / PSG 3000
Instructions for Assembly and Operation
MF Welding Inverters
109
Version

MF Welding Inverters
PSU 5000 / PSG 3000
Instructions for Assembly and Operation
1070 078 224-109 (98.10) GB
DIN ISO 9001
Reg. no. 16149-01/2
E1996, 1997, 1998
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 20.----

PSU 5000 / PSG 3000
Instructions for Assembly and Operation
1070 078 224---109
Possible combinations of
MF welding inverters / welding transformers
PSU 5100.XXX / PSG 3050.00 A
PSU 5100.XXX / PSG 3050.10 A
PSU 5100.XXX / PSG 3075.10 A
PSU 5100.XXX / PSG 3100.00 A
PSU 5300.XXX / PSG 3050.00 A
PSU 5300.XXX / PSG 3050.10 A
PSU 5300.XXX / PSG 3075.10 A
PSU 5300.XXX / PSG 3100.00 A
PSU 5200.XXX / PSG 3200.00 A
PSU 5200.XXX / PSG 3100.00 A
PSU 5200.XXX / 2 x PSG 3100.00 A

PSU 5000 / PSG 3000
Instructions for Assembly and Operation
1070 078 224---109

PSU 5000 / PSG 3000
Instructions for Assembly and Operation Contents
I
1070 078 224--109
Contents
Page
Safety instructions I -- 1..........................................
Explanation of pictographs and symbols I -- 1.....................................
Warning of magnetic fields I -- 3................................................
Not permitted for persons with cardiac pacemakers I -- 3...........................
Compatibility with residual--current devices to EN 50178 I -- 4.......................
Normal use I--4..............................................................
Ensuring EMC of the comprehensive system I -- 5................................
System perturbation I--6......................................................
Qualified personnel I--7.......................................................
Operation of the PSU and PSG modules I -- 8....................................
Retrofits and modifications by the user I -- 8......................................
Maintenance, repair I--9......................................................
Working safely I--9...........................................................
CE conformity I--10...........................................................
1 Advantages and benefits of medium--frequency welding 1--1.......
1.1 Structure of a medium--frequency welding system 1--4............................
2 Schweisskoffer 2--1.............................................
2.1 Inverter 2--2.................................................................
2.2 Driving the inverter 2--2.......................................................
3 Functional description 3--1.......................................
3.1 Functional principle 3--1.......................................................
3.2 Monitoring of the secondary current with Bosch weld timers 3--3....................
3.3 Faults 3--4..................................................................
4 PSU front panel views 4--1.......................................
4.1 Front panel view of PSU 5100 / PSU 5300 4--1...................................
4.2 Front panel view of PSU 5200 4--2.............................................

PSU 5000 / PSG 3000
Instructions for Assembly and Operation
Contents
II 1070 078 224--109
5 Technical data 5--1..............................................
5.1 Technical data of the PSU standard types 5--1...................................
5.1.1 Electrical data 5--1...........................................................
5.1.2 Inverter losses 5--1...........................................................
5.1.3 Mechanical data 5--2.........................................................
5.1.4 Environmental data 5--2.......................................................
5.2 Technical data of the PSG types 5--3...........................................
5.2.1 Electrical data 5--3...........................................................
5.2.2 Mechanical data 5--3.........................................................
5.2.3 Environmental data 5--3.......................................................
5.3 Load diagrams 5--4...........................................................
5.3.1 Performance features of PSU 5100.XXX 5--4
....................................
5.3.2 Performance features of PSU 5300.XXX 5--4
....................................
5.3.3 Performance features of PSU 5200.XXX 5--4
....................................
5.3.4 PSU 5100.XXX / PSU 5300.XXX and PSG 3050.00 A 5--5
.......................
5.3.5 PSU 5100.XXX / PSU 5300.XXX and PSG 3050.10 A 5--6
.......................
5.3.6 PSU 5100.XXX / PSU 5300.XXX and PSG 3075.10 A 5--7
.......................
5.3.7 PSU 5100.XXX / PSG 3100.00 A 5--8
.........................................
5.3.8 PSU 5200.XXX and PSG 3200.00 A 5--9
........................................
5.3.9 PSU 5200.XXX and 2 x PSG 3100.00 A parallel 5--10
..............................
5.3.10 PSU 5200.XXX / PSU 5300.XXX and 1 x PSG 3100.00 A 5--11
....................
5.3.11 Example of PSU 5100.XXX and PSG 3100.00 A 5--12
.............................
5.3.12 Current resistance characteristics 5--14
..........................................
6 Operating modes 6--1............................................
6.1 Current control function 6--1...................................................
6.2 Pulse width mode 6--3........................................................
6.3 Change--over of operating modes 6--4..........................................
6.4 Settings 6--5.................................................................
6.5 Setting instructions 6--6.......................................................
7 Monitoring and diagnostics 7--1..................................
7.1 ”Inverter ready” LED 7--2......................................................
7.2 ”Weld time” LED 7--2.........................................................
7.3 ”Max. pulse width reached” display 7--2.........................................
7.4 X21 pin assignment 7--2......................................................
7.5 Fault numbers at the seven--segment display 7--3................................
7.6 Fault message encoding 7--5..................................................

PSU 5000 / PSG 3000
Instructions for Assembly and Operation Contents
III
1070 078 224--109
8 Controlling the inverter 8--1......................................
8.1 5 kHz firing pulses 8--1.......................................................
8.1.1 Function 8--1................................................................
8.1.2 Displays and pin assignment 8--2..............................................
8.2 24 V weld time signal and analog input voltage 8--3...............................
8.2.1 Function 8--3................................................................
8.2.2 Displays and pin assignment 8--3..............................................
9 Adjustment functions 9--1.......................................
9.1 Change--over of current range 9--2.............................................
9.2 Adjustment of PSU 5100 / PSU 5300 to the welding transformer 9--2................
9.3 Adjustment of PSU 5200 to the welding transformer 9--3..........................
9.4 Diode change--over 9--3.......................................................
9.5 Selection of the control mode 9--3..............................................
9.6 Adjustment to timers with / without KSR module and SSU function 9--4..............
9.7 Ramp time constant 9--4......................................................
9.8 Transformer change--over board 9--5...........................................
10 Dimensions 10--1.................................................
10.1 Dimensions of PSU 10--1......................................................
10.1.1 PSU 5100 / PSU 5300 with water cooling 10--1....................................
10.1.2 PSU 5100 / PSU 5300 with air cooling 10--2......................................
10.1.3 PSU 5200 with water cooling 10--3..............................................
10.2 Dimensions of PSG 10--4......................................................
10.2.1 PSG 3050.00 A and PSG 3050.10 A 10--4.......................................
10.2.2 PSG 3075.10 A 10--5..........................................................
10.2.3 PSG 3100.00 A 10--6..........................................................
10.2.4 PSG 3200.00 A 10--7..........................................................
10.3 Cooling 10--8.................................................................
10.3.1 Water connection to PSU 10--8.................................................
10.3.2 Water connection to PSG 10--9.................................................
10.4 Installation and assembly 10--10.................................................

PSU 5000 / PSG 3000
Instructions for Assembly and Operation
Contents
IV 1070 078 224--109
11 Electrical connection 11--1........................................
11.1 PSU connection overview 11--2.................................................
11.2 PSU overall wiring diagram 11--3................................................
11.2.1 Connection of X1 interface 11--4................................................
11.2.2 Connection of a PSS 2000 to the inverters 11--4...................................
11.2.3 Connection of X11 interface 11--5...............................................
11.2.4 Connection of X12 interface 11--5...............................................
11.2.5 Connection of X21 interface 11--6...............................................
11.2.6 Connection of X22 interface 11--6...............................................
11.3 PSU mains connection and PSG power connection for nominal operation 11--7
........
11.4 Connection between PSU and timer module 11--8
.................................
11.5 Connection between PSU and PSG 11--10
........................................
11.6 Protective conductor connection to medium--frequency transformers 11--11
............
11.7 Parallel connection of 2 PSG’s to PSU 5200 11--16
.................................
12 Activation / deactivation of the inverter 12--1.......................
13 Maintenance 13--1................................................
14 Accessories 14--1................................................
15 Storage and transport 15--1.......................................
16 EC Declaration of Conformity 16--1................................
17 Index 17--1.......................................................

PSU 5000 / PSG 3000
Instructions for Assembly and Operation Safety instructions
I --- 1
1070 078 224---109
Safety instructions
The products described were developed, manufactured and tested in compliance
with the fundamental safety requirements of the EU machine directive.
Nevertheless, there still is some residual risk!
Please read this manual before putting any of the PSU / PSG units into operation
and store it in a place to which all users have access at any time.
Explanation of pictographs and symbols
The following warnings and notes may be attached to the individual hardware
components which are designed to inform the user of certain circumstances.
'Warning of dangerous voltages!
'Components subject to electrostatic induction!
'Disconnect mains plug before opening!
'Bolt for connection of the PE (protective earth)
conductor only!
'For shield conductor only!
NOTE
Note concerning this manual: Black bars on the margin of a page indicate changes
compared to the previous edition.