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Table of Contents
Related Manuals for Bosch L 309 Series
Summary of Contents for Bosch L 309 Series
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Page 1: Technical Information
L 309.150 / L 309.250 Power Supply Module Technical Information Edition... - Page 2 1070 078 131-104 (00.05) GB Reg. no. 16149-03 E 1994-2000 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.
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Page 4: Table Of Contents
Power Supply Module Contents Type L 309 Contents Page Safety instructions ............... . I - 1 Description of pictographs and symbols . - Page 5 Power Supply Module Type L 309 Flexible Automation 1070 078 131-104 (00.05) GB...
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Page 6: Safety Instructions
Power Supply Module Safety instructions Type L 309 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... - Page 7 Power Supply Module Safety instructions Type L 309 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.
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Page 8: Warning Of Magnetic Fields
Power Supply Module Safety instructions Type L 309 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... -
Page 9: Qualified Personnel
Power Supply Module Safety instructions Type L 309 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. -
Page 10: Installation And Assembly
Power Supply Module Safety instructions Type L 309 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. -
Page 11: Electrical Connection
Power Supply Module Safety instructions Type L 309 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. -
Page 12: Operation Of The Power Supply Modules
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. -
Page 13: Maintenance, Repair
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! -
Page 14: Structure
Power Supply Module Structure Type L 309 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”). - Page 15 Power Supply Module Structure Type L 309 Flexible Automation 1070 078 131-104 (00.05) GB...
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Page 16: Technical Data
Power Supply Module Technical data Type L 309 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. - Page 17 Power Supply Module Technical data Type L 309 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).
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Page 18: Dimensions
Power Supply Module Dimensions Type L 309 Dimensions Types L 309.150 and L 309.151 Front view Side view Thyristor con- nection V Connection of phase L2 Connection of phase L1* 100 mm installation clearance above and below the power supply module Drill pattern Top view Tightness of the water... - Page 19 Power Supply Module Dimensions Type L 309 Type L 309.250 Front view Side view PE bolt Thyristor con- nection V Connection of phase L2 Connection of phase L1* 100 mm installation clearance above and below the power supply module Drill pattern Top view Tightness of the water connections can be...
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Page 20: Installation Instructions
Power Supply Module Installation instructions Type L 309 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. - Page 21 Power Supply Module Installation instructions Type L 309 The power supply module is best installed at a housing/switch cabinet wall (fasten- ing bolts M6. The dimensions for the fastening holes are shown in the ”Dimensions” section). Since the cooling water connections are located at the back of the power supply module, cooling water lines in the actual housing/switch cabinet are not nec- essary.
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Page 22: Connection Instructions
Power Supply Module Connection instructions Type L 309 Connection instructions 5.1. Mains and welding transformer connection WARNING! The mains voltage is associated with many dangers! The possible consequences of inappropriate handling include death or most se- vere 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. -
Page 23: Water Connection
Power Supply Module Connection instructions Type L 309 Connect the PE bolt of the power supply module’s base plate with a centralized earthing point. Please ensure a sufficient cable cross-section! Lead mains connection L1* (cf. dimensioned drawings in ”Dimensions” sec- tion) as an auxiliary phase of mains phase L1 to flat connector X3/7 (L1) of the power supply module’s circuit board using a suitable cable (1.5 mm min., short-... -
Page 24: Connection To The Timer Module
Power Supply Module Connection instructions Type L 309 5.3. Connection to the timer module The connection between the L 309 power supply module and the PSS... or PSH ... timer module (PSL, UPR connections) is made via terminal connector X1. The terminal for X1 is included in the delivery. -
Page 25: Mains Voltage Selection
Power Supply Module Connection instructions Type L 309 5.4. Mains voltage selection WARNING! Make sure that the mains voltage is set when the unit is safely isolated from supply! Use suitable insulated tools! If necessary, the customer himself may select the following voltages: Types L 309.150 and L 309.250: 400 V jumper between X3/1 and X3/2 (state as delivered) -
Page 26: Maintenance
Power Supply Module Maintenance Type L 309 Maintenance The power supply module is maintenance-free. However, a faulty connection or mains overvoltages can cause an activation of the protective fuses in the device. If necessary, these can be replaced by the customer himself. Any other defects should be remedied by the manufacturer. - Page 27 Power Supply Module Maintenance Type L 309 1070 078 131-104 (00.05) GB...
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Page 28: Dimensioning Instructions
Power Supply Module Dimensioning instructions Type L 309 Dimensioning instructions In principle, the load capacity of thyristors is predetermined by the type allocation to specified max. welding transformer sizes. CAUTION! The actual load of the thyristor should be checked by the user in each specific case! For this purpose, the load diagram is used. - Page 29 Power Supply Module Dimensioning instructions Type L 309 When the duty cycle has been calculated, the following load diagrams can be used to verify the correct dimensioning of the thyristors: Load diagram of types L 309.150 and L 309.151: Current carrying capacity I [in A] 2500 L 309.150...
- Page 30 Power Supply Module Dimensioning instructions Type L 309 Load diagram of type L 309.250: Current carrying capacity I [in A] 2500 L 309.250 2000 Water cooling 4l/min; 30_C 30 cycles weld time 1500 1000 max. 50% ED [in %] 1070 078 131-104 (00.05) GB...
- Page 31 Power Supply Module Dimensioning instructions Type L 309 1070 078 131-104 (00.05) GB...
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Page 32: Fault Messages
Power Supply Module Fault messages Type L 309 Flexible Automation Fault messages Extensive precautions were taken for protecting the thyristor block. These include, i.a., the following Temperature monitoring A bimetallic switch is located at the thyristor block which transmits a message to the timer unit when temperatures 56 _C are reached. - Page 33 Power Supply Module Fault messages Type L 309 1070 078 131-104 (00.05) GB...
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Page 34: Index
Power Supply Module Index Type L 309 Index Fault messages, 19 Firing component, 1 Fuse F4, 19 Ambient temperature, 3 Fuses, 13 Assembly, I - 5 Installation, I - 5 Block diagram L 309, 1 Installation instructions, 7 Installation of power supply module, 8 Intended use, I - 3 Cardiac pacemakers, I - 3 Connected load, 3... - Page 35 Power Supply Module Index Type L 309 Terminal connector X1, 11 Test procedures, I - 8 Phase L1*, 10 Thyristor off-state voltage, 4 Phase L2, 10 Thyristor power supply, 1 Protection standard, 3 Thyristor, load of the, 15 Protective circuit, 19 Timer module connection, 11 Protective fuses, 13 Training courses, I - 4...
- Page 36 1070 078 131-104 (00.05) GB · TI WS· AT/VWS · Printed in Germany 1070 078 131-104 (00.05) GB...