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.

PSU 5000 / PSG 3000
Instructions for Assembly and Operation
Safety instructions
I --- 2 1070 078 224---109
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. ATTENTION
3. NOTE
WARNING!
The term WARNING will be used wherever danger is imminent.
The possible consequences may be death or severe injury (personal injury).
ATTENTION!
The term ATTENTION will be used wherever a dangerous situation is possible.
The possible consequences include death, 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.
!
!

PSU 5000 / PSG 3000
Instructions for Assembly and Operation Safety instructions
I --- 3
1070 078 224---109
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.
Dangers, if any, may arise from alternating magnetic fields (critical frequency:
1.6 Hz).
WARNING for operating personnel!
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.
So far, no problems have been reported. Nevertheless, the possible influences are
lower with medium-- frequency welding than with AC welding.
Not permitted for persons with cardiac pacemakers
WARNING for persons with cardiac pacemakers!
Warning signs should be posted for protecting persons with cardiac pacemakers
because the function of these devices may be disturbed (impulse failure, total fail-
ure) and a negative influence on the pacemaker programming or even a total pro-
gram destruction may occur !!!
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
pacemakers!
Danger!
DIN 40023
!
!

PSU 5000 / PSG 3000
Instructions for Assembly and Operation
Safety instructions
I --- 4 1070 078 224---109
Compatibility with residual--current devices to EN 50178
ATTENTION!
Compatibility with residual--current devices to EN 50178:
If a residual--current device is used at the mains side of the inverter to protect per-
sons in the event of direct or indirect contact, a type B device must be used. The
residual--current device must additionally be capable of safely detecting a possible
residual current with a frequency of 1 kHz / 1.2 kHz.
Normal use
The PSU medium--frequency welding inverter in connection with the PSG trans-
former--rectifier unit serves for
`resistance welding of metals
using rectified secondary current at the welding current transformer.
The medium--frequency welding equipment is only suitable for
`industrial applications.
Definition in accordance with: DIN EN 50082--2 of Electromagnetic Compatibility
(EMC).
It is not intended for any other use!
ATTENTION!
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!
!
!

PSU 5000 / PSG 3000
Instructions for Assembly and Operation Safety instructions
I --- 5
1070 078 224---109
Ensuring EMC of the comprehensive system
NOTE
The comprehensive system comprising PSU in connection with PSG 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.
-- only for industrial applications.
-- safe clearance to residential areas ≧30 m.
-- safe clearance to communication systems (wireless, telephone) ≧10 m.
-- cable length of mains feeder (PSU) ≧10 m.
-- interference suppression measures: When switch cabinet doors are open,
radio devices and cell phones may only be used in a safe clearance of ≧2m.
The assessment and certificate of conformity of a competent authority concer-
ning compliance with the fundamental EMC protection is available.
When the MF components are integrated in a Schweisskoffer type GK 100 L MF00,
the Schweisskoffer is awarded the CE label in accordance with the EMC Directive
89/336/EEC. Additional EMC tests of the Schweisskoffer are not necessary.

PSU 5000 / PSG 3000
Instructions for Assembly and Operation
Safety instructions
I --- 6 1070 078 224---109
System perturbation
When operating a welding inverter a harmonic load must be accounted for in the
mains system. This load is caused by the ”B6” rectifier circuit with a smoothing
capacitor.
The following figure shows the typical curve of the mains voltage (top) and the re-
lated mains current (bottom) in one phase during the welding process:
Typical 300 Hz
The 5th, 7th, 11th, 13th, 15th, and 17th harmonic wave are the characteristic har-
monics of the mains current curve.
The harmonic component depends on the welding power.
NOTE
We recommend operating the welding inverter on a separate welding mains sys-
tem. The harmonic content may be considerably reduced, e.g., by using smoothing
reactors with 4% short-- circuit voltage.
There are no requirements as to harmonic loads in industrial applications.
So far, no impact on other devices (PC’s etc.) has been determined.

PSU 5000 / PSG 3000
Instructions for Assembly and Operation Safety instructions
I --- 7
1070 078 224---109
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 inverter (PSU) and the welding
rectifier--transformer (PSG).
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).
!

PSU 5000 / PSG 3000
Instructions for Assembly and Operation
Safety instructions
I --- 8 1070 078 224---109
Operation of the PSU and PSG modules
ATTENTION!
-- 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 X5 of PSU must in-
hibit the connected timer (cf. also Section 11, ”Electrical connection”)!
For interpreting the fault messages also note the information contained in Sec-
tion 7, ”Monitoring and diagnostics”.
-- 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 inappropriate or insufficient cooling of the modu-
les!
Water--cooled PSU and PSG modules may only be operated when the cooling
water circuit is active! Condensation is not permitted on water--carrying compo-
nents. The temperature in the installation room of air--cooled modules must be
within the specified limits.
-- Damage to property through excessive welding current!
The maximum welding current of the combination of PSG and PSU in use must
not be exceeded. No liability is accepted in the event of non--compliance.
The max. admissible welding current of each combination of units is to be deter-
mined from the load diagrams (cf. Section 5.3)!
Retrofits and modifications by the user
The MF welding inverter has been designed and manufactured by us as a safe unit.
WARNING!
Retrofits or modifications may have negative effects on the safety of the unit!
Therefore, please contact us prior to retrofits or modifications to the MF welding
inverter using third--party equipment. This is the only way to determine whether
these parts are suitable for use with our product.
!
!

PSU 5000 / PSG 3000
Instructions for Assembly and Operation Safety instructions
I --- 9
1070 078 224---109
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 electrical voltage!
If the inverter housing is to be opened, switch off the system and wait for at least
5 minutes for the inverter to de--energize.
-- Danger of life through inappropriate EMERGENCY--OFF facilities!
EMERGENCY--OFF facilities must be operative in all modes of the system. Re-
leasing the EMERGENCY--OFF facility must by no means result in an uncon-
trolled restart of the system!
-- Danger of explosion of batteries!
Batteries must not be opened forcefully, recharged, soldered at the cell body or
thrown into fire!
Replace empty batteries with new ones only!
ATTENTION!
-- 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!
-- Spent batteries or accumulators must be disposed of as hazardous waste.
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
NOTE
-- The strong magnetic fields arising in connection with resistance welding may
cause lasting damages to wrist watches, pocket watches, or cards with magne-
tic stripes (e.g. EC cards).
Therefore, you should not carry any such items on you when working in the di-
rect vicinity of the welding equipment.
!
!
!

PSU 5000 / PSG 3000
Instructions for Assembly and Operation
Safety instructions
I --- 1 0 1070 078 224---109
CE conformity
NOTE
The CE label is valid for the individual PSU unit with respect to the Low--Voltage
Directive only.
Concerning EMC, it is always necessary to consider the entire application
(cf. below).
The CE label for the PSS -- PSU -- PSG combination is valid for industrial applica-
tions.
For other combinations/applications, the certificate must be derived from the
above, or a new certificate must be issued, if necessary, by the line designer / user.
(cf. also section 16)

PSU 5000 / PSG 3000
Instructions for Assembly and Operation
Advantages
Benefits
1070 078 224---108 1--1
1 Advantages and benefits of medium--frequency welding
The Bosch medium--frequency welding system uses direct current as the welding
current. As a result, the welding process can be controlled more thoroughly and
faster and becomes more steady. The ”good” welding range becomes larger.
The medium--frequency welding current is clocked at 1 kHz. Current control is defi-
nitely faster and more accurate than with 50 Hz welding systems.
t
50 Hz
t
U
t
I
20 ms
Frequency Inverter out-
put voltage
Welding current
Comparison of 50 Hz and medium--frequency welding
t
1ms
tt
U
1000 Hz
`A direct current flows in the secondary welding circuit of the transformer. As a
result, the inductive resistance of the secondary window loses its influence on
the welding current with different immersion depths of the electrode gun into the
workpiece.
`The weight of the welding transformer is reduced. Due to the higher operating
frequency, the iron content required as well as the volume are reduced while the
performance data is maintained.
`The more steady welding current without any gaps and the possibility of weld
time variation in ms intervals allow for the metered application of energy to the
spot weld and a steady growth of the spot.