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Page 1 Bosch Rexroth PSI 6100.105L1 3-Phase Medium Frequency Inverter 2595 In Stock Qty Available: 4 New From Surplus Stock Buy Today! https://www.artisantg.com/91043-1 A l l t r a d e m a r k s , b r a n d n a m e s , a n d b r a n d s a p p e a r i n g h e r e i n a r e t h e p r o p e r t y o f t h e i r r e s p e c t i v e o w n e r s .
Page 2 PSI 6000 PSI 6000 Medium-Frequency Inverters with integrated control function Technical Information Edition Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 3: Technical Information
1070 080 059-101 (2001.04) GB Reg. no. 16149-03 E 2000, 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.
Page 4 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 5: Table Of Contents
Contents Contents Page Safety instructions ......Safety instructions and symbols attached to the product .
Page 6 Contents Page PSI 6025.XXX L1 ......Explanation of drawings ........PSI 6025.XXX L1 front panel .
Page 7 Contents Page PSI 6500.XXX W1 ......12-1 12.1 Explanation of drawings ........12-1 12.2 PSI 6500.XXX W1 front panel...
Page 8 Contents VIII Notes: 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 9: Safety Instructions
Safety instructions 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 poses 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.
Page 10: Safety Instructions And Symbols Used In This Manual
Safety instructions 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.
Page 11: Intended Use
Safety instructions Intended use PSI 6000 MF inverters are designed for connection of PSG 3000 welding transformers. These MF inverters are designed for use in D resistance welding of metals and D are suitable for operation in industrial environments as per DIN EN 50082-2 and 50081-2 on electromagnetic compatibility (EMC).
Page 12: No Admittance For Persons Fitted With Cardiac Pacemakers
Safety instructions 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-...
Page 13: Qualified Personnel
PSI 6000 medium-frequency invert- ers 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.
Page 14: Installation And Assembly
Safety instructions 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.
Page 15 Safety instructions 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.
Page 16 Safety instructions CAUTION Damage to property through inappropriate or insufficient cooling of the medium-frequency inverters! Water-cooled medium-frequency inverters may only be operated when the cooling water circuit is active! Condensation on water-car- rying components 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.
Page 17: Electrical Connection
Safety instructions 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.
Page 18 Safety instructions 1-10 DANGEROUS ELECTRICAL VOLTAGE Danger of life through insufficient protective conductor system! The medium-frequency inverters must be connected to the protec- tive earthing (PE) circuit of the system. Please ensure that the cross- sectional area of cables used for protective conductor wiring is suffi- ciently large.
Page 19 Safety instructions 1-11 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, medium-frequency inverter cables and control cables must be routed separately.
Page 20: System Perturbation
Safety instructions 1-12 System perturbation When operating a medium-frequency inverter a harmonic load must be ac- counted for in the mains system. This load is caused by the ”B6” rectifier cir- cuit with a smoothing capacitor. The following figure shows the typical curve of the mains voltage (top) and the related 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...
Page 21: Ensuring Emc Of The Completely Assembled System
Safety instructions 1-13 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. D Only for industrial applications.
Page 22: Operation Of The Medium-Frequency Inverters
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.
Page 23: Retrofits And Modifications By The User
Safety instructions 1-15 1.11 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.
Page 24: Maintenance, Repair
DANGER The right to perform repair/maintenance work on the components of the medium-frequency inverters is reserved to the BOSCH service department or to repair/maintenance units authorized by BOSCH! CAUTION Only use spare parts approved by BOSCH! 1070 080 059-101 (2001.04) GB...
Page 25: Working Safely
Safety instructions 1-17 1.13 Working safely DANGER During operation of the welding equipment welding splashes are to be expected! They may cause eye injuries or burns. Therefore: D wear protective goggles D wear protective gloves D wear flame-retardant clothes DANGER Danger of injury from sheet metal edges and danger of burns from weld metal! Therefore: - wear protective gloves...
Page 26: Ce Conformity
Safety instructions 1-18 1.14 CE conformity CAUTION The CE mark is valid for the medium-frequency inverter only with re- spect to the Low-Voltage Directive. Concerning EMC, it is always necessary to consider the entire application. The CE mark for MF inverter - welding transformer combinations re- fers to industrial applications.
Page 27: Setup
Setup Setup Features D Integrated control functionality for medium frequency welding D Integrated welding control D Flexible parallel and/or serial I/O interfaces D Fieldbus interfaces for communication D Integrated control and monitoring functions D Control functionality separate from monitoring functionality D Air or water cooled D Less cabling required due to system component integration D Functionality designed for welding quality optimization...
Page 28: Modules And Components
Setup Modules and components The PSI 6000 medium-frequency inverters serve to control the PSG 3000 welding transformers. Integrated features: D the weld timer (central processing unit, CPU) D one slot for the type-specific I/O interface D one slot for the field bus module for programming (optional) D one slot for retrofitting a quality module (optional) PSI 6000 Mains...
Page 29 Setup Welding transformer 6-pulse bridge rectifier with direct current link circuit and transistor in- verter Medium fre quency inverter Power Control supply Current mea- Temperature surement message Weld timer (CPU) Stop circuit external Pressure Shunt trip 24VDC supply device Field bus module type-specific Quality module I/O interface...
Page 30: Function
Setup Function The medium-frequency welding system (MF welding system) is designed for direct current resistance welding. Its key components are the PSI 6000 me- dium-frequency inverter and the PSG 3000 MF welding transformer. The figure below shows the basic functional design of the MF welding pro- cess.
Page 31: Monitoring
D by an input signal for acknowledgement (type-specific) D by an input on the BOS-5000 operator interface D by an input on the Bosch operator terminal (BT) 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 32: Advantages And Benefits Of Medium-Frequency Welding
Setup Advantages and benefits of medium-frequency welding The PSI 6000 medium-frequency inverters supply an MF output voltage and DC 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.
Page 33 Setup splash limit galvanized sheet bare sheet bonding limit Welding of different sheet types, conventional 50/60 Hz weld safe splash limit remaining setting range safe bonding limit * possible variation range with fixed setting Welding of galvanized sheet types with 1 kHz welding process 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ...
Page 34 Setup Notes: 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 35: Notes On Rating
Notes on Rating Notes on Rating The load capability of an MF inverter is always predefined by the type desig- nation indicating the specific maximum welding transformer rating. CAUTION Overloading may cause damage to the MF inverter! Always check the actual load applied on the MF inverter! Any and all warranty excluded in case of damage caused by overload.
Page 36: Load Diagrams
Notes on Rating Load diagrams Various types of semiconductors are used as power breakers in the welding systems. Generally, semiconductors have an almost unlimited life if used in accordance with the specifications. Unfortunately, however, the relatively large semiconductor chips have to sustain mechanical stress due to thermal loads.
Page 37: Commissioning
Commissioning Commissioning DANGEROUS ELECTRICAL VOLTAGE Danger of life in case of contact with live parts! Upon commissioning, the MF inverter is energized! If the medium-frequency inverter housing is to be opened, switch off the system and wait for at least 5 minutes until the medium-fre- quency inverter is de-energized.
Page 38 Commissioning Notes: 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 39: Maintenance
Maintenance Maintenance DANGEROUS ELECTRICAL VOLTAGE All maintenance work must be carried out by skilled electricians in compliance with the valid safety regulations, the mains voltage and the maximum current input values of the individual system compo- nents. Prior to connecting an MF inverter, the following must be strictly observed: D Power OFF.
Page 40 Maintenance DANGEROUS ELECTRICAL VOLTAGE The right to perform repair/maintenance work on the timer compo- nents is reserved to the BOSCH service department or to repair/ maintenance units authorized by BOSCH! Only use spare parts/replacement parts approved by BOSCH! Run-down batteries or accumulators must be disposed of according to regulations.
Page 41: Malfunction
Further information is provided by the diagnostics func- tion, the error message display on the BOS-5000 operator interface, or a message on the BT Bosch operator terminal. DANGEROUS ELECTRICAL VOLTAGE Danger of life in case of contact with live parts!
Page 42 Malfunction Notes: 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 43: Type Overview
Type overview Type overview Features PSI 6025.XXX L1 D Medium-frequency inverter 0.5 to 7 kA D Air cooling D Integrated control function D Rated voltage 400 to 480 Volt, 50/60 Hz D Rated current 20 A (continuous thermal current) D Preferably for connecting welding transformer D PSG 3025.00 A PSI 6100.XXX L1/W1 D Medium-frequency inverter 3 to 20 kA...
Page 44: Psi 6500.Xxx W1
Type overview PSI 6200.XXX W1 D Medium-frequency inverter 9 to 54 kA D Water cooling D Integrated control function D Rated voltage 400 to 480 Volt, 50/60 Hz D Rated current 220 A (continuous thermal current) D Preferably for connecting welding transformers D PSG 3100.00 A D PSG 3200.00 A D Seam-welding functionality also available...
Page 45: Psi 6025.Xxx L1
PSI 6025.XXX L1 PSI 6025.XXX L1 Explanation of drawings The following drawings show the D front plate with modules of the MF inverter D integrated weld timer D slot for the parallel, serial or fieldbus I/O interface D slot prepared for retrofitting a quality module D slot for fieldbus interface for programming (optional) D technical data D dimensions and mounting options...
Page 46: Psi 6025.Xxx L1 Front Panel
PSI 6025.XXX L1 PSI 6025.XXX L1 front panel U1 V1 W1 3/PE~ U2 V2 2/PE~ − PSI 6025.XXX L1 front panel M6 mounting options D rear panel D left side panel (mounting cutout required) mains supply connection MF inverter symbol PSG 3000 welding transformer connection integrated weld timer slot for type-specific I/O interface:...
Page 47 PSI 6025.XXX L1 slot for retrofitting a quality module slot for fieldbus interface for programming battery compartment 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 48: Technical Data, Psi 6025.Xxx L1
PSI 6025.XXX L1 Technical data, PSI 6025.XXX L1 Type 3-phase MF inverter, module designed for recessed mounting Weld timer integrated I/O interface Slot for parallel, serial or fieldbus interface Quality module Slot prepared for retrofitting Degree of protection IP 20; designed for modular enclosure or for installation in switchgear cabinets with IP 54 Inverter ambient temperature max.
Page 49: Dimensioned Drawing, Psi 6025.Xxx L1
PSI 6025.XXX L1 Dimensioned drawing, PSI 6025.XXX L1 Side view, right Front view (as seen from the front) Accessories kit Ventilation clearance plate for optional mounting sealing face, 3 mm flat gasket required Mounting cut-out recommended for Plan view 100 mm min. installation clear- mounting on left side panel ance at top and bottom of MF inverter!
Page 50: Electrical Connection, Psi 6025.Xxx L1
PSI 6025.XXX L1 Electrical connection, PSI 6025.XXX L1 Side view, right (as seen from the front) from mains all terminals max. 50 mm to PSG 3000 welding transformer Electrical connection, PSI 6025.XXX L1 Note: For the connections of the various control functions, please see the respective manuals ”PSI 6000, Control and I/O Level Description”.
Page 51: Load Diagram, Psi 6025.Xxx L1
PSI 6025.XXX L1 Load diagram, PSI 6025.XXX L1 Note: For a general description of load diagrams, see Section 3.1 ED in % primary continuous current, air cooling calculated primary peak current, air cooling, t = 0.1s, 1 000 000 spots Load diagram, PSI 6025.XXX L1 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ...
Page 52: Accessories, Psi 6025.Xxx L1
PSI 6025.XXX L1 Accessories, PSI 6025.XXX L1 8.7.1 Dimensioned drawing, accessories kit An accessories kit is available for mounting the inverter with its back on the mounting plate. 1.5 thick radiuses without dimensions = R2 tool Dimensioned drawing, accessories kit 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ...
Page 53 PSI 6025.XXX L1 D For PSG 3000 welding transformers, see Technical Information, PSG 3000 MF Welding Transformers, part no. 1070 080 087. D For I/O module, see Technical Information, PSI 6000, Control and I/O Level Description. D For insertable profiles for electric connection, see the section on order- ing.
Page 54: Ordering, Psi 6025.Xxx L1
PSI 6025.XXX L1 8-10 Ordering, PSI 6025.XXX L1 Designation Part no. PSI 6025.100 L1 medium-frequency inverter 1070 080 997 Not included in shipment: Designation Part no. Insertable profile for pin connectors on small wire sizes, line 1070 918 779 connection and welding transformer connection Accessories kit for PSI 6025.XXX L1 mounting 1070 078 273 SSR 81.00 current sensor without fixing device,...
Page 55: Psi 6100.Xxx L1/L2/W1/W2
PSI 6100.XXX L1/L2/W1/W2 PSI 6100.XXX L1/L2/W1/W2 PSI 6100.XXX L1/L2/W1/W2 overview D PSI 6100.XXX L1 : D air-cooled D 400 V -20% to 480 V +10%, 50/60 Hz D PSI 6100.XXX L2 : D air-cooled D 480 V -20% to 690 V +10%, 50/60 Hz D PSI 6100.XXX W1 : D water-cooled D 400 V -20% to 480 V +10%, 50/60 Hz...
Page 56: Psi 6100.Xxx L1/L2/W1/W2 Front Panel
PSI 6100.XXX L1/L2/W1/W2 PSI 6100.XXX L1/L2/W1/W2 front panel U1 V1 W1 3/PE~ U2 V2 2/PE~ − PSI 6100.XXX L1/L2/W1/W2 front panel M6 mounting options D rear panel D left side panel (mounting cutout required) mains supply connection MF inverter symbol PSG 3000 welding transformer connection integrated weld timer slot for type-specific I/O interface:...
Page 57 PSI 6100.XXX L1/L2/W1/W2 slot for retrofitting a quality module slot for fieldbus interface for programming battery compartment 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 58: Technical Data, Psi 6100
IP 54 Inverter ambient temperature max. 55° C Cooling L1/L2: air, max. 45° C with Bosch fan cowl, temperature- controlled through inverter W1/W2: water, 4 l/min; max. 30° C Temperature monitoring integrated Storage temperature -25°...
Page 59 PSI 6100.XXX L1/L2/W1/W2 Max. cooling losses L1/L2: 360 W 420 W 500 W Switchgear cabinet loss at max. power 170 W 200 W 110 W 140 W Weight approx. 20 kg approx. 21 kg approx. 25 kg approx. 26 kg Mounting position vertical or with its back on mounting plate...
Page 60: Dimensioned Drawing, Psi 6100.Xxx L1/L2
PSI 6100.XXX L1/L2/W1/W2 Dimensioned drawing, PSI 6100.XXX L1/L2 Front view Side view, right (as seen from the front) Accessories kit Ventilation clearance plate for optional mounting sealing face, 3 mm flat gasket required Mounting cut-out recommended for Plan view mounting on left side panel 100 mm min.
Page 61 PSI 6100.XXX L1/L2/W1/W2 Dimensioned drawing, PSI 6100.XXX W1/W2 Front view Side view, right (as seen from the front) Accessories kit Accessories kit plate for optional mounting nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.5 sealing face, 3 mm flat gasket required Mounting cut-out recommended for...
Page 62: Electrical Connection, Psi 6100
PSI 6100.XXX L1/L2/W1/W2 Electrical connection, PSI 6100.XXX L1/L2/W1/W2 Side view, right (as seen from the front) from mains all terminals max. 50 mm to PSG 3000 welding transformer Electrical connection, PSI 6100.XXX L1/L2/W1/W2 Note: For the connections of the various control functions, please see the respective manuals ”PSI 6000, Control and I/O Level Description”.
Page 63: Cooling Water Connection, Psi 6100
PSI 6100.XXX L1/L2/W1/W2 Cooling water connection, PSI 6100.XXX W1/W2 Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä cooling water nipple (brass) Ä Ä Ä with standard taper cooling water inlet bore IAW Ä Ä Ä DIN EN 560, external thread M16x1.5 Ä...
Page 64 PSI 6100.XXX L1/L2/W1/W2 9-10 The heat sink of the water-cooled MF inverter is connected internally to the protective earth conductor. Maximum water inlet temperature : 30° C Water connection M 16 x 1.5 external thread (DIN EN 560, nut: DIN 13-6) PSI 6000 by the customer Heat sink...
Page 65: Load Diagram, Psi 6100.Xxx L1/W1
PSI 6100.XXX L1/L2/W1/W2 9-11 Load diagram, PSI 6100.XXX L1/W1 Note: For a general description of load diagrams, see Section 3.1 ED in % primary continuous current, air or water cooling calculated primary peak current, water cooling, t = 0.1s, 1 000 000 spots calculated primary peak current, air cooling, t = 0.1s, 1 000 000 spots Load diagram, PSI 6100.XXX L1/W1...
Page 66 PSI 6100.XXX L1/L2/W1/W2 9-12 9.10 Load diagram, PSI 6100.XXX L2/W2 Note: For a general description of load diagrams, see Section 3.1 ED in % primary continuous current, air or water cooling calculated primary peak current, water cooling, t = 0.1s, 1 000 000 spots calculated primary peak current, air cooling, t = 0.1s, 1 000 000 spots Load diagram, PSI 6100.XXX L2/W2...
Page 67: Accessories, Psi 6100
PSI 6100.XXX L1/L2/W1/W2 9-13 9.11 Accessories, PSI 6100.XXX L1/L2/W1/W2 9.11.1 Dimensioned drawing, accessories kit An accessories kit is available for mounting the inverter with its back on the mounting plate. 1.5 thick radiuses without dimensions = R2 tool Dimensioned drawing, accessories kit 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ...
Page 68 PSI 6100.XXX L1/L2/W1/W2 9-14 D For PSG 3000 welding transformers, see Technical Information, PSG 3000 MF Welding Transformers, part no. 1070 080 087. D For I/O module, see Technical Information, PSI 6000, Control and I/O Level Description. D For insertable profiles for electric connection, see the section on order- ing.
Page 69: Ordering, Psi 6100
PSI 6100.XXX L1/L2/W1/W2 9-15 9.12 Ordering, PSI 6100.XXX L1/L2/W1/W2 Designation Part no. PSI 6100.100 L1 medium-frequency inverter 1070 079 211 PSI 6100.200 L1 medium-frequency inverter 1070 079 359 PSI 6101.321 L2 medium-frequency inverter 1070 079 286 PSI 6100.330 L2 medium-frequency inverter on request PSI 6100.100 W1 medium-frequency inverter 1070 079 210...
Page 70 PSI 6100.XXX L1/L2/W1/W2 9-16 Notes: 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 71: Psi 6200.Xxx W1/W2
PSI 6200.XXX W1/W2 10-1 PSI 6200.XXX W1/W2 10.1 PSI 6200.XXX W1/W2 overview D PSI 6200.XXX W1: D water-cooled D 400 V -20% to 480 V +10%, 50/60 Hz D PSI 6200.XXX W2: D water-cooled D 480 V -20% to 690 V +10%, 50/60 Hz 10.2 Explanation of drawings The following drawings show the...
Page 72: Psi 6200.Xxx W1/W2 Front Panel
PSI 6200.XXX W1/W2 10-2 10.3 PSI 6200.XXX W1/W2 front panel U1 V1 W1 3/PE~ U2 V2 2/PE~ − [10] [11] PSI 6200.XXX W1/W2 front panel M6 mounting options D rear panel mains supply connection MF inverter symbol 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ...
Page 73 PSI 6200.XXX W1/W2 10-3 Cooling water connection nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.5 PSG 3000 welding transformer connection integrated weld timer slot for type-specific I/O interface: D parallel I/O interface D serial I/O interface D fieldbus I/O interface slot for retrofitting a quality module [10]...
Page 74: Technical Data, Psi 6200
PSI 6200.XXX W1/W2 10-4 10.4 Technical data, PSI 6200.XXX W1/W2 Type 3-phase MF inverter, module designed for recessed mounting Weld timer integrated I/O interface Slot for parallel, serial or fieldbus interface Quality module Slot prepared for retrofitting Degree of protection IP 20;...
Page 75: Dimensioned Drawing, Psi 6200.Xxx W1/W2
PSI 6200.XXX W1/W2 10-5 10.5 Dimensioned drawing, PSI 6200.XXX W1/W2 Side view, right Front view (as seen from the front) Ventilation clearance nipple (brass) with standard Ventilation clearance taper bore IAW DIN EN 560, external thread M16x1.5 100 mm min. installation clear- ance at top and bottom of MF Dimensions without tolerances: $0.5 inverter!
Page 76: Electrical Connection, Psi 6200.Xxx W1/W2
PSI 6200.XXX W1/W2 10-6 10.6 Electrical connection, PSI 6200.XXX W1/W2 Front view from mains V1 W1 U1 V1 W1 3/PE~ U2 V2 2/PE~ − [11] all terminals max. 95 mm to PSG 3000 welding transformer Electrical connection, PSI 6200.XXX W1/W2 Note: For the connections of the various control functions, please see the respective manuals ”PSI 6000, Control and I/O Level Description”.
Page 77: Cooling Water Connection, Psi 6200.Xxx W1/W2
PSI 6200.XXX W1/W2 10-7 10.7 Cooling water connection, PSI 6200.XXX W1/W2 Front view U1 V1 W1 3/PE~ U2 V2 2/PE~ − [11] Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä cooling water inlet cooling water outlet rear side front side...
Page 78 PSI 6200.XXX W1/W2 10-8 The heat sink of the water-cooled MF inverter is connected internally to the protective earth conductor. Maximum water inlet temperature : 30° C Water connection M 16 x 1.5 external thread (DIN EN 560, nut: DIN 13-6) PSI 6000 by the customer Heat sink...
Page 79: Load Diagram, Psi 6200.Xxx W1
PSI 6200.XXX W1/W2 10-9 10.8 Load diagram, PSI 6200.XXX W1 Note: For a general description of load diagrams, see Section 3.1 1600 1400 1200 1000 ED in % primary continuous current calculated primary peak current, water cooling, t = 0.1s, 1 000 000 spots Load diagram, PSI 6200.XXX W1 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ...
Page 80: Load Diagram, Psi 6200.Xxx W2
PSI 6200.XXX W1/W2 10-10 10.9 Load diagram, PSI 6200.XXX W2 Note: For a general description of load diagrams, see Section 3.1 1800 1600 1400 1200 1000 ED in % primary continuous current calculated primary peak current, water cooling, t = 0.1s, 1 000 000 spots Load diagram, PSI 6200.XXX W2 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ...
Page 81: Accessories, Psi 6200.Xxx W1/W2
PSI 6200.XXX W1/W2 10-11 10.10 Accessories, PSI 6200.XXX W1/W2 D For PSG 3000 welding transformers, see Technical Information, PSG 3000 MF Welding Transformers, part no. 1070 080 087. D For I/O module, see Technical Information, PSI 6000, Control and I/O Level Description. 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ...
Page 82: Ordering, Psi 6200.Xxx W1/W2
PSI 6200.XXX W1/W2 10-12 10.11 Ordering, PSI 6200.XXX W1/W2 Designation Part no. PSI 6200.100 W1 medium-frequency inverter 1070 081 748 PSI 6200.321 W1 medium-frequency inverter 1070 081 749 PSI 6200.100 W2 medium-frequency inverter on request Not included in shipment: Designation Part no.
Page 83: Psi 6300.Xxx L1/L2/W1/W2
PSI 6300.XXX L1/L2/W1/W2 11-1 PSI 6300.XXX L1/L2/W1/W2 11.1 PSI 6300.XXX L1/L2/W1/W2 overview D PSI 6300.XXX L1: D air-cooled D 400 V -20% to 480 V +10%, 50/60 Hz D PSI 6300.XXX L2: D air-cooled D 480 V -20% to 690 V +10%, 50/60 Hz D PSI 6300.XXX W1: D water-cooled D 400 V -20% to 480 V +10%, 50/60 Hz...
Page 84: Psi 6300.Xxx L1/L2/W1/W2 Front Panel
PSI 6300.XXX L1/L2/W1/W2 11-2 11.3 PSI 6300.XXX L1/L2/W1/W2 front panel U1 V1 W1 3/PE~ U2 V2 2/PE~ − PSI 6300.XXX L1/L2/W1/W2 front panel M6 mounting options D rear panel D left side panel (mounting cutout required) mains supply connection MF inverter symbol PSG 3000 welding transformer connection integrated weld timer slot for type-specific I/O interface:...
Page 85 PSI 6300.XXX L1/L2/W1/W2 11-3 slot for retrofitting a quality module slot for fieldbus interface for programming battery compartment 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 86: Technical Data, Psi 6300
IP 54 Inverter ambient temperature max. 55° C Cooling L1/L2: air, max. 45° C with Bosch fan cowl, temperature- controlled through inverter W1/W2: water, 4 l/min; max. 30° C Temperature monitoring integrated Storage temperature -25°...
Page 87 PSI 6300.XXX L1/L2/W1/W2 11-5 Max. ventilating and cooling loss L1/L2: 360 W external air-cooler 420 W dissipated via 500 W Switchgear cabinet loss at max. power 170 W 200 W 110 W 140 W Weight approx. 20 kg approx. 21 kg approx.
Page 88: Dimensioned Drawing, Psi 6300.Xxx L1/L2
PSI 6300.XXX L1/L2/W1/W2 11-6 11.5 Dimensioned drawing, PSI 6300.XXX L1/L2 Side view, right Front view (as seen from the front) Ventilation Accessories kit clearance plate for optional mounting sealing face, 3 mm flat gasket required Plan view Mounting cut-out recommended for 100 mm min.
Page 89 PSI 6300.XXX L1/L2/W1/W2 11-7 11.6 Dimensioned drawing, PSI 6300.XXX W1/W2 Side view, right Front view (as seen from the front) Accessories kit Accessories kit plate for optional mounting nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.5 sealing face, 3 mm flat gasket required...
Page 90: Electrical Connection, Psi 6300.Xxx L1/L2/W1/W2
PSI 6300.XXX L1/L2/W1/W2 11-8 11.7 Electrical connection, PSI 6300.XXX L1/L2/W1/W2 Side view, right (as seen from the front) from mains all terminals max. 50 mm to PSG 3000 welding transformer Electrical connection, PSI 6300.XXX L1/L2/W1/W2 Note: For the connections of the various control functions, please see the respective manuals ”PSI 6000, Control and I/O Level Description”.
Page 91: Cooling Water Connection, Psi 6300
PSI 6300.XXX L1/L2/W1/W2 11-9 11.8 Cooling water connection, PSI 6300.XXX W1/W2 Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä cooling water nipple (brass) Ä Ä Ä with standard taper cooling water inlet bore IAW Ä Ä Ä DIN EN 560, external thread M16x1.5 Ä...
Page 92 PSI 6300.XXX L1/L2/W1/W2 11-10 The heat sink of the water-cooled MF inverter is connected internally to the protective earth conductor. Maximum water inlet temperature : 30° C Water connection M 16 x 1.5 external thread (DIN EN 560, nut: DIN 13-6) PSI 6000 by the customer Heat sink...
Page 93: Load Diagram, Psi 6300.Xxx L1/W1
PSI 6300.XXX L1/L2/W1/W2 11-11 11.9 Load diagram, PSI 6300.XXX L1/W1 Note: For a general description of load diagrams, see Section 3.1 ED in % primary continuous current, air or water cooling calculated primary peak current, water cooling, t = 0.1s, 1 000 000 spots calculated primary peak current, air cooling, t = 0.1s, 1 000 000 spots Load diagram, PSI 6300.XXX L1/W1...
Page 94 PSI 6300.XXX L1/L2/W1/W2 11-12 11.10 Load diagram, PSI 6300.XXX L2/W2 Note: For a general description of load diagrams, see Section 3.1 ED in % primary continuous current, air or water cooling calculated primary peak current, water cooling, t = 0.1s, 1 000 000 spots calculated primary peak current, air cooling, t = 0.1s, 1 000 000 spots Load diagram, PSI 6300.XXX L2/W2...
Page 95: Accessories, Psi 6300.Xxx L1/L2/W1/W2
PSI 6300.XXX L1/L2/W1/W2 11-13 11.11 Accessories, PSI 6300.XXX L1/L2/W1/W2 11.11.1 Dimensioned drawing, accessories kit An accessories kit is available for mounting the inverter with its back on the mounting plate. 1.5 thick radiuses without dimensions = R2 tool Dimensioned drawing, accessories kit 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ...
Page 96 PSI 6300.XXX L1/L2/W1/W2 11-14 D For PSG 3000 welding transformers, see Technical Information, PSG 3000 MF Welding Transformers, part no. 1070 080 087. D For I/O module, see Technical Information, PSI 6000, Control and I/O Level Description. D For insertable profiles for electric connection, see the section on order- ing.
Page 97: Ordering, Psi 6300.Xxx L1/L2/W1/W2
PSI 6300.XXX L1/L2/W1/W2 11-15 11.12 Ordering, PSI 6300.XXX L1/L2/W1/W2 Designation Part no. PSI 6300.100 L1 medium-frequency inverter 1070 081 688 PSI 6300.330 L1 medium-frequency inverter 1070 079 325 PSI 6300.321 L1 medium-frequency inverter 1070 081 689 PSI 6300.330 L2 medium-frequency inverter 1070 079 331 PSI 6300.100 W1 medium-frequency inverter 1070 084 595...
Page 98 PSI 6300.XXX L1/L2/W1/W2 11-16 Notes: 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 99 PSI 6500.XXX W1 12-1 PSI 6500.XXX W1 12.1 Explanation of drawings The following drawings show the D front plate with modules of the MF inverter D integrated weld timer D slot for the parallel, serial or fieldbus I/O interface D slot prepared for retrofitting a quality module D slot for fieldbus interface for programming (optional) D technical data D dimensions and mounting options...
Page 100: Psi 6500.Xxx W1 Front Panel
PSI 6500.XXX W1 12-2 12.2 PSI 6500.XXX W1 front panel [6] [7] [8] U1 V1 W1 3/PE~ U2 V2 2/PE~ − [10] [12] [11] PSI 6500.XXX W1 front panel 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 101 PSI 6500.XXX W1 12-3 M6 mounting options D rear panel mains supply connection with shrouding cover MF inverter symbol cooling water connection, supply nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.5 cooling water connection, discharge nipple (brass) with standard taper bore IAW DIN EN 560, external thread M16x1.5 integrated weld timer...
Page 102: Technical Data, Psi 6500.Xxx W1
PSI 6500.XXX W1 12-4 12.3 Technical data, PSI 6500.XXX W1 Type 3-phase MF inverter, module designed for recessed mounting Weld timer integrated I/O interface Slot for parallel, serial or fieldbus interface Quality module Slot prepared for retrofitting Degree of protection IP 20;...
Page 103: Dimensioned Drawing, Psi 6500.Xxx W1
PSI 6500.XXX W1 12-5 12.4 Dimensioned drawing, PSI 6500.XXX W1 Side view, right (as seen from the front) Front view 356.5 194.5 30.75 for M6 nipple (brass) with stan- dard taper bore IAW DIN EN 560, 30,75 external thread M16x1.5 Side view, left Rear view (as seen from the front)
Page 104: Electrical Connection, Psi 6500.Xxx W1
PSI 6500.XXX W1 12-6 12.5 Electrical connection, PSI 6500.XXX W1 from mains V1 W1 Front view U1 V1 W1 3/PE~ U2 V2 2/PE~ − electrical connections: 2 to 4 cables, max. 120 mm , ea., with cable lugs on M10 bolts to PSG 3000 welding transformer Electrical connection, PSI 6500.XXX W1...
Page 105: Cooling Water Connection, Psi 6500.Xxx W1
PSI 6500.XXX W1 12-7 12.6 Cooling water connection, PSI 6500.XXX W1 Front view U1 V1 W1 3/PE~ U2 V2 2/PE~ − hose connection for cooling water Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä cooling water cooling water discharge supply...
Page 106 PSI 6500.XXX W1 12-8 The heat sink of the water-cooled MF inverter is connected internally to the protective earth conductor. Maximum water inlet temperature : 30° C Water connection M 16 x 1.5 external thread (DIN EN 560, nut: DIN 13-6) PSI 6000 by the customer Heat sink...
Page 107: Load Diagram, Psi 6500.Xxx W1
PSI 6500.XXX W1 12-9 12.7 Load diagram, PSI 6500.XXX W1 Note: For a general description of load diagrams, see Section 3.1 2600 2400 2200 2000 1800 1600 1400 1200 1000 ED in % primary continuous current calculated primary peak current, t = 0.1s, 1 000 000 spots Load diagram, PSI 6500.XXX W1 1070 080 059-101 (2001.04) GB...
Page 108: Accessories, Psi 6500.Xxx W1
PSI 6500.XXX W1 12-10 12.8 Accessories, PSI 6500.XXX W1 D For PSG 3000 welding transformers, see Technical Information, PSG 3000 MF Welding Transformers, part no. 1070 080 087. D For I/O module, see Technical Information, PSI 6000, Control and I/O Level Description. 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ...
Page 109: Ordering, Psi 6500.Xxx W1
PSI 6500.XXX W1 12-11 12.9 Ordering, PSI 6500.XXX W1 Designation Part no. PSI 6500.XXX W1 medium-frequency inverter 1070 079 302 Not included in shipment: Designation Part no. SSR 81.00 current sensor without fixing device, 1070 048 099 in the form of a toroid coil; 55 mm internal diameter;...
Page 110 PSI 6500.XXX W1 12-12 Notes: 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 111: Ce Declaration Of Conformity
CE declaration of conformity 13-1 CE declaration of conformity 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 112 CE declaration of conformity 13-2 Notes: 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 113 Annex Annex Index Cooling, 9-4, 10-4, 11-4, 12-4 Cooling water, 1-8 Accessories kit, 8-10, 9-15, 11-15 Chlorides, 1-8 Degree of hardness, 1-8 Accessories PSI 6025.XXX L1, 8-8 Insoluble substances, 1-8 Accessories PSI 6100.XXX L1/L2/W1/W2, 9-13 Nitrates, 1-8 pH value, 1-8 Accessories PSI 6200.XXX W1/W2, 10-11 Sulfates, 1-8 Accessories PSI 6300.XXX L1/L2/W1/W2, 11-13...
Page 114 Annex Electrical connection PSI 6100.XXX L1/L2/W1/W2, Mains supply, 8-4, 9-4, 10-4, 11-4, 12-4 Electrical connection PSI 6200.XXX W1/W2, 10-6 Maintenance, 1-16, 5-1, 5-2 Electrical connection PSI 6300.XXX L1/L2/W1/W2, 11-8 Malfunction, 6-1 Electrical connection PSI 6500.XXX W1, 12-6 Malfunctions, 6-1 EMC, 1-13 Max.
Page 115 Annex PSI 6025.XXX L1, 8-1 Technical data PSI 6100.XXX L1/L2/W1/W2, 9-4 PSI 6025.XXX L1 front panel, 8-2 Technical data PSI 6200.XXX W1/W2, 10-4 PSI 6100.XXX L1/L2/W1/W2, 9-1 Technical data PSI 6300.XXX L1/L2/W1/W2, 11-4 PSI 6100.XXX L1/L2/W1/W2 front panel, 9-2 Technical data PSI 6500.XXX W1, 12-4 PSI 6100.XXX L1/L2/W1/W2 overview, 9-1 Temperature monitoring, 8-4, 9-4, 10-4, 11-4, 12-4...
Page 116: Annex
Annex Notes: 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Page 117 1070 080 059-101 (2001.04) GB · TI WS· AT/VWS · Printed in Germany 1070 080 059-101 (2001.04) GB Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

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