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Medium-Frequency Welding Transformers Technical

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1. Block diagram PSG 3100 00 P 1 Primary side e U welding transformer gt U2 medium frequency inverter e V welding transformer gt V2 medium frequency inverter 2 MPE neutral earth conductor A DANGEROUS ELECTRICAL VOLTAGE If the MPE protective conductor jumper is to be removed another protective measure to EN 50063 must be installed In this case the ground connection between the transformer neutral and the earthing bolt must be crossed out in an indelible manner 3 Primary winding and rectifier block temperature monitoring T1 T4 Turck FSD 4 4 0 5 Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY e 11 thermal release rectifier block 80 C e T4 thermal release welding transformer primary side 150 C 4 Secondary side connection of electrodes 1070 080 087 101 2001 04 GB BOSCH PSG 3100 00 X 12 11 12 11 Block diagram PSG 3100 00 S T2 3 Terminating ena T Mos 3 4 5 Block diagram PSG 3100 00 S 1 Primary side e U welding transformer gt U2 medium frequency inverter e V welding transformer gt V2 medium frequency inverter 2 MPE neutral earth conductor A DANGEROUS ELECTRICAL VOLTAGE If the MPE protective conductor jumper is to be removed another protective measure t
2. housing Circulating currents occur Negative pole grounded via protective conductor jumper MPE workpiece not grounded several electrode guns with their negative poles also grounded are employed simultaneously There will be circulating currents through the neighboring electrode guns Additional circulating currents will occur if also the workpiece is grounded cf Case 3 1070 080 087 101 2001 04 GB BOSCH Protective conductor connection 3 5 3 1 3 How to measure circulating currents supply line U welding transformer rectifier workpiece housing welding current meter Circulating currents A DC welding current meter is required for measuring circulating currents 1 Apply belted measuring cable to the positive pole of the weld gun and fix it in position Close the weld gun without a workpiece being used apply welding current with MF inverter in closed loop current control mode Measure and record welding current 1r 2 Close the weld gun on a workpiece close neighboring gun if any Case 4 apply welding current with current conditions as under 1 above Measure and record welding current Ip If the current values are different the presence of circulating currents has to be assumed The amount of the circulating current is calculated as liaj I1 circulating current 3 1 4 Rem
3. 3 1 How to recognize a defective ineffective MPE protective conductor connection 0 cece eee eee eee 3 2 What are circulating currents a 3 3 When do circulating currents occur 2 222er 3 3 How to measure circulating currents 3 5 Remedying circulating currents een 3 5 Residual current protective resistor 3 6 Installation of a residual current protective resistor 3 8 Ordering protective resistors aa 3 10 Connection uga a sawa a mk GG AG 4 1 PSG 3XXX XX X to inverter ooocccccccc eee 4 1 Parallel connection of PSG 3XXX XXX aan 4 2 Malntenante u 5 1 Accessories ura AA 6 1 Electrical connection ocooorcccrrrrr eee eee 6 1 Primary connection of welding transformer 6 2 Terminal box TH 3000 Pg 00 c eee eee eee ee 6 2 Terminal box TH 3050 MC aaa 6 3 Terminal box TH 3100 MC aa 6 4 Ordering PSG accessories aaa 6 5 VI Contents 10 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10 10 11 10 12 10 13 10 14 Load diagrams AA Rating example cece eee Type overview 2eara rana naman PSG 3025 00 Aa AN AA KAN NAG AS Technical data PSG 3025 00 A 0 sasa Dimensioned drawing PSG 3025 00 A Cooling water connection PSG 3025 00 A Block diagram PS
4. 400 300 200 100 D E 2 4 6 8 1012 1416 18 20 22 24 26 28 30 32 34 36 38 4042 44 46 48 50 52 54 kA Current resistance characteristic PSG 3075 10 X 1070 080 087 101 2001 04 GB 11 10 PSG 3075 10 A PSG 3075 10 P 11 10 Ordering PSG 3075 10 A Designation Part no PSG 3075 10 A welding transformer 1070 079 152 with current sensor in secondary circuit with higher diode rating 11 11 Ordering PSG 3075 10 P Designation Part no PSG 3075 10 P welding transformer 1070 079 346 without current sensor in secondary circuit with higher diode rating with MC 135 plug receptacle 1070 080 087 101 2001 04 GB BOSCH PSG 3100 00X 12 1 12 PSG 3100 00 X 12 1 Technical data PSG 3100 00 A e with current transformer in secondary circuit Medium frequency transformer rectifier unit Sy 100 kVA at X 50 Primary voltage Un 500 V Max primary continuous current I4p 116A Secondary current range lon 3 to 36 kA Continuous direct current ly 5 8 kA 100 duty cycle ED Cable cross section U2 V2 gt U V 235mm Frequency f 1000 Hz Transformer ratio U 50 1 No load direct voltage Ugio 9 3V Continuous d c forward current rat
5. Color RAL 7005 grey Cooling water volume min 61 min Cooling water temperature max 30 C Cooling water pressure drop max 0 6 bar Primary circuit monitoring max 150 C Rectifier block monitoring max 80 C 1070 080 087 101 2001 04 GB BOSCH PSG 3075 10 A PSG 3075 10P 11 3 11 3 Dimensioned drawing PSG 3075 10 A Touch guard required for primary connection For connection cover type and order data cf attached sheet no SKT 0058 4x M8 10 deep on all sides 2x 6H 8 deep on all sides ligac o a terra Connection M 3 Be Br Current Contact surface Contact surface Contact surface transformer TA ai Connection lines i 150 mm long T M Dimensions without tolerances are subject to mean deviations to DIN 7168 291 Cooling water inlet G 1 4 Y 7 0 374 Cooling water outlet G 1 4 pe x z Nameplate pag rectifier 12 deep 1064 LL 10 314 abi Connection T ng 17083 Thermal release M5 4x 10 deep Technical alterations reserved Dimensioned drawing PSG 3075 10 A Note Connecting pins for primary side supplied loosely Designation 4 straight pins ISO 8735 06 x 12 supplied loosely 3 contact pins MC135 Y 06 supplied loosely 1070 080 087 101 2001 04 GB 11 4 PSG 3075 10 A PSG 3075 10 P 11 4 Dimensioned drawing PSG 307
6. sonal injury or in part may result in personal injury CAUTION This symbol is used wherever insufficient or lacking compliance with in structions may result in damage to equipment or data files DANGER A This symbol is used wherever failure to observe the instructions in whole Note This symbol is used to draw the user s attention to special cir cumstances This symbol is used if user activities are required Modifications in this manual as compared to a previous edition are marked by black vertical bars in the margin 1070 080 087 101 2001 04 GB BOSCH 1 2 Intended use Safety instructions 1 3 The welding transformer is controlled by the medium frequency inverter These welding transformers are designed for use in e resistance welding of metals and e are suitable for operation in industrial environments as per DIN EN 50082 2 and 50081 2 on electromagnetic compatibility EMC They are not intended for any other use DANGER Any use other than for the purpose indicated may result in personal injury of the user or third parties or in damage to equipment the workpiece to be welded or environmental damage Therefore our products must never be used for any other than their respective intended purpose 1070 080 087 101 2001 04 GB For operation in residential environments in trade and commercial ap plications and small enterprises an individual permit of the national authority
7. 2 terminal box flange connectors and connecting sockets available as accessories 1070 080 087 101 2001 04 GB 6 2 Accessories BOSCH 6 2 Primary connection of welding transformer There are two options for the primary connection of the MF welding trans former e Provide terminals V U and the ground terminal with cable clamps and screw them onto the respective contact pieces A suitable transformer terminal box is the TH 3000 terminal box with cable gland Pg connection heavy gauge screwed conduit connection see diagram below e Welding transformers are delivered with three plug contacts ea which can be screwed into the contact tubes They provide plug in connection for the welding transformer primary For information on the matching female connectors and suitable trans former terminal boxes please see the following descriptions 6 2 1 Terminal box TH 3000 Pg Suitable for all PSG 3000 transformer types except for PSG 3025 00 A and PSG 3XXX XX P variants with primary connection through cable gland Pg connection right hand and left hand knock out panel for Pg29 and MC flanged socket Terminal box TH 3000 PG 1070 080 087 101 2001 04 GB BOSCH Accessories 6 3 6 2 2 Terminal box TH 3050 MC Suitable for PSG 3050 XX X or PSG 3075 XX X except for PSG 3XXX XX P variants for MC 135 multi contact connection right hand and left hand knock out panel for Pg29 and MC flanged socket
8. Protective resistor short connecting leads 1070 081 822 Protective resistor long connecting leads 1070 083 996 1070 080 087 101 2001 04 GB BOSCH Connection 4 1 4 Connection 4 1 PSG 3XXX XX X to inverter to electrodes not available with all transformer types NN 7 ua to inverter 3 thermostatic switches con m nected in series screened cable for inverter connection not included in the delivery to power output of inverter type of attachment depends on transformer type PSG 3XXX XX X connection to inverter 1070 080 087 101 2001 04 GB 4 2 Connection BOSCH 4 2 Parallel connection of PSG 3XXX XX X two PSG 3100 XX X connected to PSI 6200 XXX two PSG 3200 XX X connected to PSI 6500 XXX e four PSG 3100 XX X connected to PSI 6500 XXX connected accordingly as shown for 2 transformers in the diagram be low screened cable for o o inverter MAA not available with all even nme transformer types A BA white 5 brown current sensor A to inverter black NG NG yellow 3 thermostatic switches con W nected in series screened cable for me zu inverter AH connection not PSG 3XXX MPE included in the delivery O O not available with all transformer types white brown current sensor O black o yellow 3 thermostatic switches con nected in ser
9. Terminal box TH 3050 MC Flange connector suitable for PSG 3050 XX X or PSG 3075 XX X for MC 135 multi contact connection contact pins on welding transformer welding transformer terminal box flange connector individual parts screwed on contact pins right angle J ET TE shrink on sleeve sleeve tag Flange connector 1070 080 087 101 2001 04 GB 6 4 Accessories BOSCH 6 2 3 Terminal box TH 3100 MC Suitable for PSG 3100 00 X except for PSG 3XXX XX P variants for MC 180 multi contact connection right hand and left hand knock out panel for Pg29 and MC flanged socket Terminal box TH 3100 MC Flange connector suitable for PSG 3100 00 X for MC 180 multi contact con nection contact pins on welding transformer welding transformer terminal box flange connector individual parts screwed on contact pins right angle a straight shrink on sleeve shrink on sleeve Lg Flange connector 1070 080 087 101 2001 04 GB BOSCH Accessories 6 5 6 3 Ordering PSG accessories 1070 080 087 101 2001 04 GB Not included in the delivery of MF welding transformers Designation Terminal box TH 3000 PG suitable for all PSG 3000 welding transformers except for PSG 3025 00 A and PSG 3XXX XX P variants Part no 1070 917 826 Terminal box TH 3050 MC suitable for PSG 3050 XX X or PSG 3075 XX X for multi contact connection
10. attached sheet no inlet G 1 4 outlet G 1 4 SKT 0058 c Nameplates_ MB 6x 1250 15 deep 4 x M8 10 deep on all sides Connection T Thermal release 2x 6H 8 deep on all sides __ Thermal release Rectifier Earthing sign e M5 4x 10 deep Connection lines Connection M 150 mm long T M Current transformer View X Contact surfaces Y mp Dimensions without tolerances are subject to mean deviations to DIN 7168 Dimensioned drawing PSG 3200 00 A Note Connecting pins for primary side supplied loosely Designation 4 straight pins ISO 8735 Y 06 x 12 supplied loosely 1070 080 087 101 2001 04 GB BOSCH PSG 3200 00A 13 3 13 3 Cooling water connection PSG 3200 00 A Maximum supply water temperature 30 C WE water inlet WA water outlet Water connection internal thread G 1 4 for example see sketch gt by the customer Hose washer internal 6 3 VA A a i 5 El j z i Hose nozzle Double screw neck DIN EN 560 6 3 Union nut DIN EN 560 G 1 4 G 3 8 RH Rear part G 3 8 DIN EN 560 G 3 8 Cooling water connection PSG 3200 00 A 1070 080 087 101 2001 04 GB 13 4 PSG 3200 00 A BOSCH 13 4 Block diagram PSG 3200 00 A 3 Terminating T2 connecto
11. e Medium frequency welding transformer 12 kVA e Welding current range 0 25 to 6 kA e Integrated temperature monitoring PSG 3050 00 A e Medium frequency welding transformer 56 kVA e Welding current range 3 to 20 kA e Integrated current sensor and temperature monitoring PSG 3050 10 A e Medium frequency welding transformer 56 kVA Welding current range 3 to 20 kA Integrated current sensor and temperature monitoring Higher diode rating than PSG 3050 00 A PSG 3050 10 S e Medium frequency welding transformer 56 kVA Welding current range 3 to 20 kA Integrated current sensor and temperature monitoring Connection for secondary voltage monitoring Higher diode rating than PSG 3050 00 A PSG 3075 10 A e Medium frequency welding transformer 75 kVA Welding current range 3 to 20 kA Integrated current sensor and temperature monitoring Higher diode rating than PSG 3075 00 A PSG 3075 10 P e Medium frequency welding transformer 75 kVA Welding current range 3 to 20 kA Integrated temperature monitoring For primary current regulation without current sensor Higher diode rating than PSG 3075 00 A 8 1 8 2 Type overview PSG 3100 00 A e Medium frequency welding transformer 100 kVA e Welding current range 3 to 36 kA e Integrated current sensor and temperature monitoring PSG 3100 00 P e Medium frequency welding transformer 100 kVA e Welding current range 3 to 36 kA e Integrated temperature monitoring e For p
12. Power OFF e Provide a safeguard to prevent unintentional reclosing e Verify that the system is safely isolated from supply and de energized e Connect to earth and short circuit e Cover up or safeguard all live parts 1070 080 087 101 2001 04 GB 1 10 Safety instructions BOSCH 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 inverter cables and control cables must be routed sepa rately The influence of interfering cables on cables susceptible to interfer ence can be minimized by keeping the following distances e gt 100 mm if cables are run in parallel for lt 10 m e 5 250 mm if cables are run in parallel for gt 10 m CAUTION Connection cables may come off and apply dangerous voltage to system components It is crucial that cables are properly fixed k PE connection Connect to a central earth point Make sure that cable cross sectional areas are sufficiently large U connection Connect to U2 on MF inverter V connection Connect to V2 on MF inverter Primary side connection For some welding transformers the degree of protection of the primary terminal is IP 00 Additional protection against accidental contact is required see Section 9 2 All conductor cross sections must be large enough for
13. V2 medium frequency inverter MPE neutral earth conductor A DANGEROUS ELECTRICAL VOLTAGE If the MPE protective conductor jumper is to be removed another protective measure to EN 50063 must be installed In this case the ground connection between the transformer neutral and the earthing bolt must be crossed out in an indelible manner 3 4 5 Primary winding and rectifier block temperature monitoring T1 T2 Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY e Ti thermal release rectifier block 80 C e T2 thermal release welding transformer primary side 150 C Connection M current transformer secondary side Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY e white brown e measuring voltage Um 150 mV kA 2 5 at ohmic resistance of 1kQ Secondary side connection of electrodes 1070 080 087 101 2001 04 GB BOSCH PSG 3075 10 A PSG 3075 10 P 11 7 11 7 Block diagram PSG 3075 10 P Block diagram PSG 3075 10 P 1 Primary side e U welding transformer gt U2 medium frequency inverter e V welding transformer gt V2 medium frequency inverter 2 MPE neutral earth conductor A DANGEROUS ELECTRICAL VOLTAGE If the MPE protective conductor jumper is to be removed another protective measure to EN 50063 must be installed In this case the ground connection bet
14. a il EN dulo3ial o eee Na Connection T ba M5 Thermal release er 4 x M8 10 deep on all sides Thermal release on amp x Rectifier we ved poe T p ZJ 2x 6H 8 deep on all sides 4 HE a M6 6X J 8 deep ae 3 OOO ANG formen mi Connection M A 32 Connection lines mal i Contact surface y kia f 150 mm long for T S and Current L NAGANA ang ag ae tM x transformer A View x Dimensions without tolerances are subject to mean deviations to DIN 7168 Dimensioned drawing PSG 3050 00 A and PSG 3050 10 A Note Connecting pins for primary side supplied loosely Designation 4 straight pins ISO 8735 Y 06 x 12 3 contact pins MC135 Y 06 supplied loosely supplied loosely 1070 080 087 101 2001 04 GB PSG 3050 00 A PSG 3050 10 A PSG 3050 10S 10 5 10 5 Dimensioned drawing PSG 3050 10 S Touch guard required for primary connection For connection cover type and order data cf attached sheet no SKT 0058 Cooling water inlet G 1 4 Cooling water outlet G 1 4 Nameplate rectifier M8 6x 12 deep Connection T Thermal release 4x M8 10 deep on all sides 2x 6H 8 deep on all sides 1 Connection S Sec circuit i monitoring M6 3x _ 8 deep Connection M Current Contact surface Contact surface Contact surface
15. current transformer in secondary circuit e with higher diode rating Medium frequency transformer rectifier unit Sn 56 kVA at X 50 Primary voltage Un 500 V Max primary continuous current I4p 60A Secondary current range lon 3 0 to 20 kA Continuous direct current ly 4 2 kA 100 duty cycle ED Cable cross section U2 V2 gt U V 216mm Frequency f 1000 Hz Transformer ratio U 70 1 No load direct voltage Ugio 6 3 V Continuous d c forward current rating Pgio 26 2 kW 100 duty cycle ED Max rated surge forward current lrsiy 50 kA 10 ms Ty max 180 C Max direct current ly max cf load diagram Transformer degree of protection IP65 Primary connection zone degree of protection IP00 Welding transformer insulation class F Weight 14 5 kg Color RAL 5015 blue Cooling water volume min 61 min Cooling water temperature max 30 C Cooling water pressure drop max 0 6 bar Primary circuit monitoring max 150 C Rectifier block monitoring max 80 C 1070 080 087 101 2001 04 GB PSG 3050 00 A PSG 3050 10 A PSG 3050 10S 10 3 10 3 Technical data PSG 3050 10 S e with current transformer in secondary circuit e with higher diode rating e with connection for secondary voltage monitoring Medium frequency transformer rectifier unit Sn 56 kVA at X 50 P
16. for the loads to be connected 1070 080 087 101 2001 04 GB BOSCH Safety instructions 1 11 1 7 System perturbation 1070 080 087 101 2001 04 GB When operating a welding system 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 related mains current bottom in one phase during the welding process 300 200 100 100 200 300 10 Pa ee O a AB hac faces 100 r gt here nenn Ear DO bido AETA NG PUNA IG UA P Tie B0n 5535 IDA 93H 100m 105m LiDr The 5th 7th 11th 13th 15th and 17th harmonic wave are the characteristic harmonics of the mains current curve The harmonic component depends on the welding power The harmonic content may be considerably reduced e g by using smoothing reactors with 4 short circuit voltage 1 12 Safety instructions BOSCH 1 8 Ensuring EMC of the completely assembled system The completely assembled system 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 gt 100 A Only for industrial applications Safe clearance from residential areas 30 m Safe clearance to communication systems wireless telephone 10 m Cable length of mains fee
17. link circuit PSI 6000 F 6 pulse bridge Transistor inverter mains rectifier e A e3 power supply PSG 3000 Welding trans former Weld timer Rectifier Block diagram of a medium frequency inverter system A Primary voltage UPRIM Primary voltage f 1 kHz setting range u 2 high current Isec 1 low current Primary voltage and secondary current in an MF welding system 1070 080 087 101 2001 04 GB BOSCH Protective conductor connection 3 1 3 Protective conductor connection The BOSCH PSG 3000 MF transformers comply with protection class 1 in accordance with DIN VDE 0551 Part 1 Additional protective measures as per EN 50063 DIN VDE 0545 Part 1 must be taken for protection class 1 devices to provide protection against inadmissibly high touch voltage in case of an insulation breakdown between primary and secondary circuits The implementation of these measures is the responsibility of the machine system manufacturer operator DANGEROUS ELECTRICAL VOLTAGE If these protective measures are not applied or if they are ineffective touching the secondary connections the welding gun or the work piece is associated with danger of life and limb Welding transformers are delivered with a detachable protective condu
18. plug 1070 080 087 101 2001 04 GB 12 16 PSG 3100 00 X BOSCH Notes 1070 080 087 101 2001 04 GB BOSCH 13 PSG 3200 00 A 13 1 Technical data PSG 3200 00 A 1070 080 087 101 2001 04 GB PSG 3200 00 A 13 1 Medium frequency transformer rectifier unit Sy 200 kVA at X 50 Primary voltage Un 500 V Max primary continuous current I4p 171A Secondary current range lon 6 0 to 40 kA Continuous direct current Ig 6 5 kA 100 duty cycle ED Cable cross section U2 V2 gt U V 95mm2 Frequency f 1000 Hz Transformer ratio U 38 1 No load direct voltage Ugio 13 0V Continuous d c forward current rating Pgio 85 0 kW 100 duty cycle ED Max rated surge forward current IFsm 120 kA 10 ms Tyj max 180 C Max direct current ly max cf load diagram Transformer degree of protection IP65 Primary connection zone degree of protection IPOO Welding transformer insulation class F Weight 39 5 kg Color RAL 8001 brown Cooling water volume min 101 min Cooling water temperature max 30 C Cooling water pressure drop max 2 0 bar Primary circuit monitoring max 150 C Rectifier block monitoring max 80 C 13 2 PSG 3200 00 A BOSCH 13 2 Dimensioned drawing PSG 3200 00 A Touch guard required for primary connection Cooling water Cooling water For connection cover type and order data cf
19. the resistance welding pro cess may cause permanent damage to wrist watches pocket watches or cards with magnetic stripes e g EC cards Therefore you should not carry any such items on you when working in the immediate vicinity of the welding equipment 1070 080 087 101 2001 04 GB BOSCH 1 13 CE conformity Safety instructions 1 17 8 CAUTION The CE mark is valid for the welding transformer with respect to the Low Voltage Directive 72 23 EEC and the standards EN 60204 Part 1 and EN 50063 cf Declaration of Conformity Concerning EMC it is always necessary to consider the entire application The CE mark for MF inverter welding transformer combinations is valid for industrial applications For other combinations applications the certificate must be derived from the above or a new certificate must be issued if necessary This is a responsibility of the line designer user 1070 080 087 101 2001 04 GB 1 18 Safety instructions BOSCH Notes 1070 080 087 101 2001 04 GB BOSCH Setup 2 1 2 Setup 2 1 Features e Primary circuit temperature monitoring e Rectifier block temperature monitoring e Integrated diodes in secondary e Some types with integrated current transformer in secondary e External protective conductor jumper e Degree of protection transformer block IP65 rectifier block IPOO primary terminal compartment IPOO or IP 54 depending on type terminal box of higher d
20. then through external ground connec tions and the protective conductor jumper MPE to the negative pole 3 1 2 When do circulating currents occur Case 1 welding transformer rectifier U Suppe ine workpiece Vo Pe housing No circulating currents Negative pole grounded through protective conductor jumper MPE work piece not grounded ideal arrangement No circulating currents can occur Case 2 welding transformer rectifier U supply line Circulating currents occur Negative pole grounded via protective conductor jumper MPE workpiece grounded welding transformer housing insulated from 2 There will be circulating currents through the mains supply line 1070 080 087 101 2001 04 GB 3 4 Protective conductor connection BOSCH Case 3 welding transformer rectifier U supply line workpiece housing Circulating currents occur Case 4 Negative pole grounded via protective conductor jumper MPE workpiece grounded welding transformer housing has a low resistance connection to through the welding equipment practical case There will be circulating currents through the mains supply line and furthermore through the welding equipment welding transformer rectifier supply line U
21. transformer View X 332 Connection lines 150 mm long for T S and M mae echnical alterations reserved Dimensions without tolerances are subject to mean deviations to DIN 7168 Dimensioned drawing PSG 3050 10 S Note Connecting pins for primary side supplied loosely Designation 4 straight pins ISO 8735 06 x 12 supplied loosely 3 contact pins MC135 06 supplied loosely 1070 080 087 101 2001 04 GB 10 6 PSG 3050 00 A PSG 3050 10 A PSG 3050 10 S BOSCH 10 6 Cooling water connection PSG 3050 XX X Maximum supply water temperature 30 C WE water inlet WA water outlet Water connection internal thread G 1 4 for example see sketch gt by the customer Hose washer internal 6 3 VA A z A 5 El i Hose nozzle Double screw neck DIN EN 560 6 3 Union nut DIN EN 560 G 1 4 G 3 8 RH Rear part G 3 8 DIN EN 560 G 3 8 Cooling water connection PSG 3050 00 A PSG 3050 10 A PSG 3050 10 S 1070 080 087 101 2001 04 GB PSG 3050 00 A PSG 3050 10 A PSG 3050 10S 10 7 10 7 Block diagram PSG 3050 00 A and PSG 3050 10 A T2 Terminating T4 3 connector external 3 4 Block diagram PSG 3050 00 A and PSG 3050 10 A 1 Primary side e U welding transformer gt U2 medium frequency inverter e V welding transformer gt V2 me
22. 0 00 P Note Connecting pins for primary side supplied loosely Designation 4 straight pins ISO 8735 Y 06 x 12 supplied loosely 1070 080 087 101 2001 04 GB BOSCH PSG 3100 00X 12 7 12 7 Dimensioned drawing PSG 3100 00 C Cooling water Cooling water inlet G 1 4 outlet G 1 4 Touch guard required for primary connection For connection cover type and order data cf attached sheet no SKT 0058 Information sign Earthing sign M8 8x 15 deep 4 x M8 10 deep on all sides _ M5 4x 15 deep Connection M Current transformer Zr 32 Connection lines Contact surfaces Y 150 mm long T M Dimensions without tolerances are subject to mean deviations to DIN 7168 View X Dimensioned drawing PSG 3100 00 C Note Connecting pins for primary side supplied loosely Designation 4 straight pins ISO 8735 Y 06 x 12 supplied loosely 3 contact pins MC135 Y 06 supplied loosely 1070 080 087 101 2001 04 GB 12 8 PSG 3100 00 X BOSCH 12 8 Cooling water connection PSG 3100 00 X Maximum supply water temperature 30 C WE water inlet WA water outlet Water connection internal thread G 1 4 for example see sketch gt by the customer Hose washer internal 6 3 VA A z A 5 El i Hose nozzle Double screw neck DIN EN 560 6 3 Union nut DIN EN 560 G 1 4 G 3 8 RH Rear pa
23. 0 087 101 2001 04 GB 10 12 PSG 3050 00 A PSG 3050 10 A PSG 3050 10 S 10 12 Ordering PSG 3050 00 A Designation Part no PSG 3050 00 A welding transformer 1070 063 560 with current sensor in secondary circuit 10 13 Ordering PSG 3050 10 A Designation Part no PSG 3050 10 A welding transformer 1070 073 063 with current sensor in secondary circuit with higher diode rating 10 14 Ordering PSG PSG 3050 10 S Designation Part no PSG 3050 10 S welding transformer 1070 084 152 with current sensor in secondary circuit with higher diode rating with connection for secondary voltage monitoring 1070 080 087 101 2001 04 GB BOSCH PSG 3075 10 A PSG 3075 10P 11 1 11 PSG 3075 10 A PSG 3075 10 P 11 1 Technical data PSG 3075 10 A e with current transformer in secondary circuit e with higher diode rating Medium frequency transformer rectifier unit Sy 75 kVA at X 50 Primary voltage Un 500 V Max primary continuous current I4p 76A Secondary current range lon 3 0 to 20 kA Continuous direct current ly 4 2 kA 100 duty cycle ED Cable cross section U2 V2 gt U V 216mm Frequency f 1000 Hz Transformer ratio U 55 1 No load direct voltage Ugio 8 4 V Continuous d c forward current rating Pgio 35 0 kW 100 duty cycle ED Max rated surge forward current IE5m 50 kA 10 ms Ty max 180 C Max direc
24. 075 10 P aaa BOSCH 1070 080 087 101 2001 04 GB BOSCH 1070 080 087 101 2001 04 GB Contents Vil Page PSG 3100 00 X 2 dak tien aces KA kA AA 12 1 Technical data PSG 3100 00 A cc cece eee 12 1 Technical data PSG 3100 00 P cc cee eee 12 2 Technical data PSG 3100 00 S 0 cece eee 12 3 Technical data PSG 3100 00 C cee ee 12 4 Dimensioned drawing PSG 3100 00 A PSG 3100 00 S 12 5 Dimensioned drawing PSG 3100 00 P 4 12 6 Dimensioned drawing PSG 3100 00C 12 7 Cooling water connection PSG 3100 00 X 12 8 Block diagram PSG 3100 00 A PSG 3100 00 C 12 9 Block diagram PSG 3100 00 P 0c cece eens 12 10 Block diagram PSG 3100 00S 0c cece es 12 11 Load diagram 1 x PSG 3100 00 X cece eee ee 12 12 Load diagram 2 x PSG 3100 00 X connected in parallel 12 13 Current resistance characteristic 1 x PSG 3100 00 X 12 14 Current resistance characteristic 2 x PSG 3100 00 X connected in parallel 12 14 Ordering PSG 3100 00 A cece eens 12 15 Ordering PSG 3100 00 P cece eens 12 15 Ordering PSG 3100 00 S cece eee 12 15 Ordering PSG 3100 00 kee eee 12 15 PSG 3200 00 A cee eee 13 1 Technical data PSG 3200 00 A 00 13 1 Dimensioned drawing PSG 3200 00 A 13 2 Cooling w
25. 1 16 Z Zone of protection 3 7 A 4 Annex BOSCH Notes 1070 080 087 101 2001 04 GB 1070 080 087 101 2001 04 GB TI ws AT VWS Printed in Germany
26. 36 38 4042 44 kA Current resistance characteristic 1 x PSG 3100 00 X 12 15 Current resistance characteristic 2 x PSG 3100 00 X connected in parallel R pa 900 800 700 2 PSG 3100 00 X connected in parallel 600 500 400 300 200 100 50 2 4 6 8 1012 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 KA Current resistance characteristic 2 x PSG 3100 00 X connected in parallel 1070 080 087 101 2001 04 GB BOSCH PSG 3100 00 X 12 15 12 16 Ordering PSG 3100 00 A Designation Part no PSG 3100 00 A welding transformer 1070 063 764 with current sensor in secondary circuit 12 17 Ordering PSG 3100 00 P Designation Part no PSG 3100 00 P welding transformer 1070 079 347 without current sensor in secondary circuit complete MC assembly for primary current measuring 12 18 Ordering PSG 3100 00 S Designation Part no PSG 3100 00 S welding transformer 1070 084 153 with current sensor in secondary circuit with secondary voltage monitoring 12 19 Ordering PSG 3100 00 C Designation Part no PSG 3100 00 C welding transformer 1070 084 427 with current sensor in secondary circuit designed for MC 135
27. 5 10 A 11 5 Cooling water connection PSG 3075 10 P 11 5 Cooling water connection PSG 3100 00 X 12 8 Cooling water connection PSG 3200 00 A 13 3 Crossover currents 3 1 Current resistance characteristic 1 x PSG 3100 00 X 12 14 Current resistance characteristic 2 x PSG 3100 00 X connected in parallel 12 14 Current resistance characteristic PSG 3050 XX X 10 11 Current resistance characteristic PSG 3075 10 X 11 9 Current resistance characteristic PSG 3200 00 A 13 6 Current operated e l c b system 3 5 3 7 Current operated g f c i system See Current op erated e l c b system D Declaration of conformity 14 1 Dimensioned drawing PSG 3050 10 A 10 4 Dimensioned drawing PSG 3050 10 S 10 5 Dimensioned drawing PSG 3075 10 A 11 3 Dimensioned drawing PSG 3075 10 P 11 4 Dimensioned drawing PSG 3100 00 A 12 5 Dimensioned drawing PSG 3100 00 C 12 7 Dimensioned drawing PSG 3100 00 P 12 6 Dimensioned drawing PSG 3100 00 S 12 5 Dimensioned drawing PSG 3200 00 A 13 2 A 2 Annex Direct current link circuit 2 4 Direct protective conductor connection 3 1 3 5 Duty cycle ED 7 1 7 3 E Electrical connection 1 8 EMC 1 12 EMERGENCY STOP facilities 1 15 5 1 F Features 2 1 Function 2 3 G Ground connection 3 3 Installation 1 6 Insulation breakdown 3 1 Integration time 7 1 Intended use 1 3 L Load diagram 1 x PSG 3100 00 X 12 12 Load diagram 2 x PSG 3100 00 X c
28. 5 10 P Cooling water inlet G 1 4 Cooling water outlet G 1 4 Nameplate rectifier 12 deep Connection T Thermal release 4 x M8 10 deep on all sides 2x0 6H 8 deep on all sides o 2 o NG ao Es 2D Contact surface TURCK FSD 1 7 4 4 0 5 flange con ES a nector not included nn ad in the delivery Dimensions without tolerances are subject to mean deviations to DIN 7168 Dimensioned drawing PSG 3075 10 P 1070 080 087 101 2001 04 GB BOSCH PSG 3075 10 A PSG 3075 10P 11 5 11 5 Cooling water connection PSG 3075 10 A PSG 3075 10 P Maximum supply water temperature 30 C WE water inlet WA water outlet Water connection internal thread G 1 4 for example see sketch gt by the customer Hose washer internal 6 3 VA A a i 5 El j z i Hose nozzle Double screw neck DIN EN 560 6 3 Union nut DIN EN 560 G 1 4 G 3 8 RH Rear part G 3 8 DIN EN 560 G 3 8 Cooling water connection PSG 3075 10 A PSG 3075 10 P 1070 080 087 101 2001 04 GB 11 6 PSG 3075 10 A PSG 3075 10 P 11 6 Block diagram PSG 3075 10 A T2 Terminating T1 3 connector 3 external 4 Block diagram PSG 3075 10 A 1 2 Primary side e U welding transformer gt U2 medium frequency inverter e V welding transformer gt
29. G 3025 00 A cc cece eee Load diagram PSG 3025 00 A eee eee ee Ordering PSG 3025 00 A 2 aaa PSG 3050 00 A PSG 3050 10 A PSG 3050 10S Technical data PSG 3050 00 A cece eens Technical data PSG 3050 10 A a Technical data PSG 3050 10 S aa Dimensioned drawing PSG 3050 00 A and PSG 3050 10A Dimensioned drawing PSG 3050 10S Cooling water connection PSG 3050 XXX Block diagram PSG 3050 00 A and PSG 3050 10 A Block diagram PSG 3050 10S eee eee Load diagram PSG 3050 00 A aaa aan Load diagram PSG 3050 10 A PSG 3050 10 S Current resistance characteristic PSG 3050 XXX Ordering PSG 3050 00 A 0 aaa Ordering PSG 3050 10 A 2 aaa Ordering PSG PSG 3050 10S cece eee eee PSG 3075 10 A PSG 3075 10P Technical data PSG 3075 10 A aaa Technical data PSG 3075 10 P a Dimensioned drawing PSG 3075 10 A Dimensioned drawing PSG 3075 10 P Cooling water connection PSG 3075 10 A PSG 3075 10P Block diagram PSG 3075 10 A aaa Block diagram PSG 3075 10P aan Load diagram PSG 3075 10 A PSG 3075 10 P Current resistance characteristic PSG 3075 10X Ordering PSG 3075 10 A aaa Ordering PSG 3
30. MC 135 25 except for PSG 3XXX XX P variants 1070 917 828 Flange connector MC 135 25 for multi contact connection on PSG 3000 suitable for PSG 3050 XX X or PSG 3075 XX X on request Terminal box TH 3100 MC suitable for PSG 3100 for multi contact connection MC 180 50 except for PSG 3XXX XX P variants 1070 917 827 Flange connector MC 180 50 for multi contact connection on PSG 3000 suitable for PSG 3100 on request Cable for PSG sensors 2 x 2 x 0 75 mm screened LiYCY 1070 913 494 6 6 Accessories BOSCH Notes 1070 080 087 101 2001 04 GB BOSCH Load diagrams 7 1 7 Load diagrams A DANGER Danger of damage to property through inadmissibly high welding current Therefore read the load diagrams to see whether the maximum wel ding current of your application is within the permitted range The modules should only be operated with appropriate cooling 1070 080 087 101 2001 04 GB The load diagrams define the maximum admissible welding current of the PSG unit depending on the duty cycle ED The maximum admissible welding current depends not only on the duty cy cle of the rectifier diodes but also on the duty cycle of the PSG 3000 trans former used All load diagrams are based on the thermal transient recovery times inte gration time of the rectifier diodes 2 seconds and the transformers 60 se conds These data together with some application specific data
31. O Diode related limitation at 5 weld time periods be utilized Load diagram PSG 3050 00 A 1070 080 087 101 2001 04 GB 10 10 PSG 3050 00 A PSG 3050 10 A PSG 3050 10 S BOSCH 10 10 Load diagram PSG 3050 10 A PSG 3050 10 S ty ot diode integration time 2 s g Isec kA Iprim A 1 0 10 0 100 0 duty cycle ED 4 Transformer related limitation The load curves represent absolute limit A Diode related limitation at 50 weld time periods values To ensure the reliability in contin O Diode related limitation at 20 weld time periods uous operation we recommend that no X Diode related limitation at 10 weld time periods more than 80 of the max load capacity O Diode related limitation at 5 weld time periods be utilized Load diagram PSG 3050 10 A PSG 3050 10 S 1070 080 087 101 2001 04 GB PSG 3050 00 A PSG 3050 10 A PSG 3050 10S 10 11 10 11 Current resistance characteristic PSG 3050 XX X R U 900 800 700 600 500 400 300 200 100 2 4 6 8 1012 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 KA Current resistance characteristic PSG 3050 XX X 1070 08
32. PSG 3000 Medium Frequency Welding Transformers Technical Information 101 PSG 3000 Medium Frequency Welding Transformers Technical Information 1070 080 087 101 2001 04 GB Reg no 16149 03 O 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 Discretionary charge DM 10 BOSCH Contents h h h dl mob mob dl dl mob cb dl sob sob mah 222200 NX000A0mnN onto 2 1 2 2 1070 080 087 101 2001 04 GB Contents Vv Page Safety instructions aa 1 1 Safety instructions and symbols used in this manual 1 2 Intended USO coi 22222 a ara ek eas 1 3 No admittance for persons fitted with cardiac pacemakers 1 4 Qualified personnel 0c cece eee 1 5 Installation and assembly 0 cece eee 1 6 Electrical connection 0 cece eee ees 1 8 System perturbation 0 eee eee eee 1 11 Ensuring EMC of the completely assembled system 1 12 Operation of the welding transformers 1 13 Retrofits and modifications by the user 1 14 Maintenance repair c eee eee 1 15 Working safely 1 0 2 0 ccs 1 16 CE conformity 0 0 cece eee eee 1 17 BEIDE ince 2 1 Features cri Mee ieee a nie 2 1 FUNCION 4 di is 2 3 Protective conductor connection
33. Weight 24 4 kg Color RAL 1004 yellow Cooling water volume min 101 min Cooling water temperature max 30 C Cooling water pressure drop max 2 5 bar Primary circuit monitoring max 150 C Rectifier block monitoring max 80 C 1070 080 087 101 2001 04 GB BOSCH 12 3 Technical data PSG 3100 00 S 1070 080 087 101 2001 04 GB PSG 3100 00 X 12 3 e with current transformer in secondary circuit e with connection for secondary voltage monitoring Medium frequency transformer rectifier unit Sy 100 kVA at X 50 Primary voltage Un 500 V Max primary continuous current I4p 116A Secondary current range lon 3 to 36 kA Continuous direct current ly 5 8 kA 100 duty cycle ED Cable cross section U2 V2 gt U V gt 35mm Frequency f 1000 Hz Transformer ratio U 50 1 No load direct voltage Ugio 9 0V Continuous d c forward current rating Pgio 52 2 kW 100 duty cycle ED Max rated surge forward current IFsm 120 kA 10 ms Tyj max 180 C Max direct current ly max cf load diagram Transformer degree of protection IP65 Primary connection zone degree of protection IPOO Welding transformer insulation class F Weight 24 4 kg Color RAL 1004 yellow Cooling water volume min 101 min Cooling water temperature max 30 C Cooling water pressure drop max 2 5 bar Primary circuit m
34. all contact surfaces are bright i e free of paint plastic coat ing or dirt oxidation 1 8 Safety instructions BOSCH 1 6 Electrical connection DANGEROUS ELECTRICAL VOLTAGE The primary voltage of the welding transformer 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 The mains voltage must match the nominal voltage given on the nameplate of the product DANGEROUS ELECTRICAL VOLTAGE Working with system voltage may result in death severe bodily in jury or considerable damage to property unless the appropriate pre cautionary measures are taken Therefore you should carefully read the safety instructions at the be ginning of this manual where you will find a description of a number of features to be strictly observed The system voltage is associated with considerable 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 cons
35. as per DIN 40023 are posted at ev ery entrance to manufacturing shops housing resistance welding equipment 1070 080 087 101 2001 04 GB Please note our comprehensive range of training courses More information is available from our training center Phone 49 6062 78 258 1 6 Safety instructions BOSCH 15 Installation and assembly A 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 DANGER Danger of injury and of damage to property through incorrect instal lation Devices and in particular operating means must be installed so as to be properly safeguarded against unintentional operation or con tact DANGER Danger of personal injury and damage to property through inade quate fastening The place for installing the welding transformers and their method of fastening must be suitable for their weight Injuries and bruises may be caused by lifting weights which are too heavy or by sharp metal edges Due to the heavy weight of individual modules several persons are required for installation and assembly Wear safety shoes and safety gloves gt 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 c
36. ater connection PSG 3200 00A 13 3 Block diagram PSG 3200 00 A 0 aaa 13 4 Load diagram PSG 3200 00 A 2 aaa 13 5 Current resistance characteristic PSG 3200 00A 13 6 Ordering PSG 3200 00 A ccc ccc eens 13 7 Declaration of Conformity 14 1 ANNEX u a A 1 INN ne an a an a TA NANA DNA ae nr Geen aes es A 1 vill Contents BOSCH Notes 1070 080 087 101 2001 04 GB BOSCH Safety instructions 1 1 1 Safety instructions 1070 080 087 101 2001 04 GB 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 pose 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 Nevertheless there is some residual risk Therefore you should read this manual before installing connecting or com missioning the products Store this manual in a place to which all users have access at any time This manual describes the e PSG 3000 medium frequency welding transformers 1 2 Safety instructions BOSCH 1 1 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
37. ble to trans formers with one secondary winding for muiti spot welding as used in the automobile industry Kenngr en f r Widerstandsschwei einrichtungen Widerstands Schwei transformatoren Transformateurs pour machines a souder par resistance sp cifications gene rales applicables a tous les transformateurs Lorsch aye 1997 1070 080 087 101 2001 04 GB 14 2 Declaration of Conformity BOSCH Notes 1070 080 087 101 2001 04 GB BOSCH A Annex A 1 Index Numbers 6 pulse bridge rectifier 2 4 A Accessories 6 1 Assembly 1 6 Block diagram PSG 3025 00 A 9 3 Block diagram PSG 3050 00 A 10 7 Block diagram PSG 3050 10 A 10 7 Block diagram PSG 3050 10 S 10 8 Block diagram PSG 3075 10 A 11 6 Block diagram PSG 3075 10 P 11 7 Block diagram PSG 3100 00 A 12 9 Block diagram PSG 3100 00 C 12 9 Block diagram PSG 3100 00 P 12 10 Block diagram PSG 3100 00 S 12 11 Block diagram PSG 3200 00 A 13 4 C Cables 6 1 CE conformity 1 17 Circulating currents 3 1 3 3 Connection 4 1 Parallel connection of PSG 4 2 PE 1 10 Primary side 1 10 Protective conductor 3 1 U 1 10 V 1 10 Cooling water 1 7 Chlorides 1 7 Degree of hardness 1 7 1070 080 087 101 2001 04 GB Annex A 1 Insoluble substances 1 7 Nitrates 1 7 pH value 1 7 Sulfates 1 7 Cooling water connection PSG 3025 00 A 9 2 Cooling water connection PSG 3050 XX X 10 6 Cooling water connection PSG 307
38. ctor jumper MPE connected between the MF transformer secondary negative pole and the protective conductor terminal This is in compliance with the protective measure of a direct protective conductor connection as per Sec tion 5 1 4 1 EN 50063 If another protective measure to EN 50063 is implemented instead of a direct protective conductor connection the protective conductor jumper MPE must be removed The removal of the protective conductor jumper MPE must be indicated on the label provided on the transformer in a permanent way As an additional measure for devices of protection class 1 the MF trans former housings have non detachable connections to the transformer pro tective conductor terminals DANGEROUS ELECTRICAL VOLTAGE Under certain circumstances circulating currents called cross over currents as per EN 50063 may flow through the MPE protective conductor connection Any such circulating currents must be prevented at all events be cause they may interrupt the protective conductor continuity through the protective conductor jumper MPE Interrupting the protective conductor connection will render the pro tective measure of a direct protective conductor connection inef fective Therefore in the case of an insulation breakdown there is danger of life 1070 080 087 101 2001 04 GB BOSCH 3 2 Protective conductor connection How to recognize a defective ineffective MPE protec
39. d Welding system layout plan 1070 080 087 101 2001 04 GB Setup 2 3 BOSCH 2 2 Function 1070 080 087 101 2001 04 GB Medium frequency welding technology allows efficient energy conversion using lightweight transformers Due to the higher operating frequency both the iron content and the size of the transformers can be reduced without af fecting performance The figure below shows the difference between welding equipment with 1 phase AC and medium frequency DC 50 60 Hz single phase alternating current 50 60 Hz R mM Timer Thyristor Welding Welding unit transformer apparatus 1 kHz medium frequency direct current Timer MF inverter Transformer Welding rectifier apparatus Schematic block diagram of 1 phase AC and MF DC welding systems The 50 60 Hz mains AC is first rectified by a bridge rectifier B6 connection The direct current thus generated connects a transistorized H bridge alter natingly to the welding transformer with a frequency of 1 kHz The welding current is rectified in the welding transformer secondary Welding current amperage is controlled by adjusting the pulse width The welding current is measured by a current sensor incorporated in the secon dary circuit of the PSG 3000 welding transformer 2 4 Setup BOSCH Direct current
40. d electrical inspections must be conducted periodically on residu al current protective resistors installed Recommended inspection intervals no more than 6 months CAUTION In order to comply with EN 50063 MF welding systems equipped with re sidual current protective devices for personnel protection require a re sidual current protective resistor to be installed on the welding transformer with the protective conductor jumper MPE jumper removed cf Sec tion 5 1 4 3 EN 50063 Technical data Resistance 1 kQ 10 Pulse power tuned to use in combination with residual current protective device see above Degree of protection electrical connections IPOO resistor IP65 Dimensions see diagram BOSCH R1KO0 4W 1070 081 822 101 BOSCH R1KO 4W 1070 083 996 101 S a al 158 0 Residual current protective resistor 1070 080 087 101 2001 04 GB BOSCH Protective conductor connection 3 7 residual current protective resistor current trans transformer line switch former MF inverter i V Y V W undervoltage re lease housing e l c b Zu zone of protection current operated e l c b system rectifier workpiece Current operated e l c b system to Section 5 1 4 3 EN 50063 The zone of protection against indirect contact includes all c
41. der 10 m Interference suppression measures When switchgear cabinet doors are open operation of radio devices or cell phones is permitted only beyond a safe clearance of 2 m e The assessment and certificate of conformity of a competent authority concerning compliance with the fundamental EMC protection is avail able 1070 080 087 101 2001 04 GB BOSCH Safety instructions 1 13 1 9 Operation of the welding transformers DANGER Danger of personal injury and damage to property through missing or false interpretation of fault messages Therefore closing of the temperature contact thermostatic switch break contact of the welding transformer must inhibit the connected timer DANGER Danger of bruises through electrode movement 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 CAUTION Damage to property through insufficient cooling Ensure proper cooling during operation The maximum permitted cooling water temperature must not be exceeded Condensation on water carrying components must be prevented CAUTION Damage to property through excessive welding current Th
42. disconnect the system from supply and wait at least 5 minutes before you open the housing so as to ensure that the MF inverter is de energized 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 uncontrolled restart of the system A DANGEROUS ELECTRICAL VOLTAGE The right to perform repair maintenance work on the components is reserved to the BOSCH service department or to repair maintenance units authorized by BOSCH Only use spare parts replacement parts approved by BOSCH 1070 080 087 101 2001 04 GB 5 2 Maintenance BOSCH e Check the cooling water circuit for leaks at regular intervals e Add an algicide to the cooling water e Check connections and terminals of all connecting cables for tight fit at regular intervals Check all cables for damage DANGEROUS ELECTRICAL VOLTAGE A Check whether the current operated e l c b system the residual current protective resistor is in proper service condition at least every 6 months 1070 080 087 101 2001 04 GB BOSCH Accessories 6 1 6 Accessories 6 1 Electrical connection PSI 6000 BOSCH D 64711 Erbach 107 Made in Germany Heat sink BOSCH e PSG 3000 Electrical connection 1 screened sensor cable LiYCY2 x 2 x 0 75 mm available as an accessory
43. dium frequency inverter 2 MPE neutral earth conductor A DANGEROUS ELECTRICAL VOLTAGE If the MPE protective conductor jumper is to be removed another protective measure to EN 50063 must be installed In this case the ground connection between the transformer neutral and the earthing bolt must be crossed out in an indelible manner 1070 080 087 101 2001 04 GB 3 Primary winding and rectifier block temperature monitoring T1 T2 Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY e 711 thermal release rectifier block 80 C e T2 thermal release welding transformer primary side 150 C 4 Connection M current transformer secondary side Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY e white brown e measuring voltage Um 150 mV kA 2 5 at ohmic resistance of 1kQ 5 Secondary side connection of electrodes 10 8 PSG 3050 00 A PSG 3050 10 A PSG 3050 10 S BOSCH 10 8 Block diagram PSG 3050 10 S T2 Terminating Ti 3 connector external 3 4 5 Block diagram PSG 3050 10 S 1 2 Primary side e U welding transformer gt U2 medium frequency inverter e V welding transformer gt V2 medium frequency inverter MPE neutral earth conductor A DANGEROUS ELECTRICAL VOLTAGE If th e MPE protective conductor jumper is to be removed another protective measure
44. e maximum welding current depends on the medium frequency inverter and the welding transformer in use It must not be exceeded Therefore the user must check the load in each case Any and all warranty excluded in case of non compliance 1070 080 087 101 2001 04 GB 1 14 Safety instructions BOSCH 1 10 Retrofits and modifications by the user DANGER A 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 This is the only way to determine whether modified components are suitable for use with our products 1070 080 087 101 2001 04 GB BOSCH 1 11 Maintenance repair Safety instructions 1 15 DANGEROUS 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 procedures on the ac tive system these have to be performed by skilled electrical person nel In any case suitable insulated tools must be used DANGEROUS ELECTRICAL VOLTAGE If you need to open the primary connection disconnect the system from supply and wait at least 5 minutes after disconnecting the in verter supply before you open the housing so as to ensure that the MF inverter is de energized DANGER Danger of life throu
45. edying circulating currents 1070 080 087 101 2001 04 GB If circulating currents cannot be avoided by the protective measure of a di rect protective conductor connection other protective measures to EN 50063 must be installed by the machine plant manufacturer operator For example protective measures such as current operated e l c b sys tems or voltage operated e l c b systems cf EN 50063 Sections 5 1 4 3 and 5 1 4 4 may be installed for medium frequency systems However please read the manufacturer s specifications carefully and check whether devices to be used for the measures described above are suitable for MF system operation with a DC link circuit and at a frequency of 1000 Hz The manufacturer s specifications must be verified accordingly The applica ble standards are to be observed 3 6 3 2 Protective conductor connection BOSCH Residual current protective resistor DANGEROUS ELECTRICAL VOLTAGE A residual current protective resistor may be used only as prescribed in combination with a residual current protective device with a rated residual current of 5 30 mA as per EN 60947 2 in TN or TT systems of up to 690 V for installation on a welding transformer cf EN 50063 No warranty Supplier excludes any and all liability for any other than the permitted use including without being limited to any use in combination with any residual current protective device unfit for the intended purpose Visual an
46. egree of protection required with IPOO PSG 3100 00 A similar design PSG 3100 00 P e3100 00E PSG 3200 00 A PSG 3100 00 C PSG 3050 00 A similar design PSG 3050 10 A PSG 3050 10 S PSG 3075 10 A similar design PSG 3075 10 P PSG 3025 00 Medium frequency welding transformers The welding transformers must be connected to a Bosch MF inverter with an output frequency of 1 kHz Rectifier block and primary winding temperatures are monitored and their values transmitted Any error message occurring must invariably block the gate control 1070 080 087 101 2001 04 GB 2 2 Setup BOSCH PSI 6000 w Ae TO DA 0000008 0000000 e I Slot for Q module E E a Local PC e x ll e programming 2 3 BOS 5000 e logging 3 Off e diagnostics 5 m e fault display 2 T ji i a V24 Pan E E E I 3 Host PC e programming e logging diagnostics 3 e fault display 3 Field bus for progr option kej lol ls o a 5 0000 lel 10000 PSG 3000 welding transformer Pressure control valve x x Solenoid valve dh O IS NE u Q ta 80 C Y O T2 O T1 Temperature monitoring connection Current sensor toroi
47. et no SKT 0058 Cooling water Cooling water inlet G 1 4 i outlet G 1 4 Information sign Earthing sign Nameplates M8 8x 15 deep M5 4x 10 deep Connection T 4 x M8 10 deep on all sides Thermal release M8 3x 10 deep 2x9 6H 8 deep on all sides M5 4x 15 deep Connection M ee i Connection lines Current transformer Contact surfaces Y 1 150 mm long T M View x Dimensions without tolerances are subject to mean deviations to DIN 7168 Dimensioned drawing PSG 3100 00 A PSG 3100 00 S Note Connecting pins for primary side supplied loosely Designation 4 straight pins ISO 8735 Y 06 x 12 supplied loosely 3 contact pins MC180 Y 08 supplied loosely 1070 080 087 101 2001 04 GB 12 6 PSG 3100 00 X BOSCH 12 6 Dimensioned drawing PSG 3100 00 P 05 227 49 190 BA Information sign de er TI ln Nameplates M8 8x 15 deep Connection T 4 x M8 10 deep on all sides Thermal release TURCK 2x 6H 8 desp on all sides FSD 4 4 0 5 Thermal release Rectifier flange connector TURCK FSD 4 4 0 5 flange con View x Contact surfaces Y ade nector not included A ee in the delivery Dimensions without tolerances are subject to mean deviations to DIN 7168 Dimensioned drawing PSG 310
48. g is sufficiently large The electrical continuity of the protective earthing circuit must be verified in accordance with EN 60204 Part 1 cf Section 3 1 DANGEROUS ELECTRICAL VOLTAGE Protective conductor jumper MPE The protective earth for the negative pole of the PSG 3000 can be in terrupted by opening the protective earth conductor jumper at the PSG 3000 In order to protect the operating personnel against dan gerous electrical voltages in the event of a break down of the trans former primary side to the secondary side in this case a suitable protective measure pursuant to EN 50 063 is to be provided In addi tion the transformer is to be marked accordingly DANGEROUS ELECTRICAL VOLTAGE Insufficient degree of protection may be life threatening or cause damage to property Depending on the type the protection class of the welding trans former primary terminal is IP 00 or IP 54 To prevent accidental contact the primary terminal must be equipped with a touch guard An additional terminal box of a higher class of protection must be used for connecting the welding transformers DANGEROUS ELECTRICAL VOLTAGE The electrical connection must always be made by an electrical ex pert in compliance with the valid safety regulations the mains volt age and the maximum current consumption of the individual units of the equipment Prior to connecting an MF inverter the following must be strictly observed e
49. gh inappropriate EMERGENCY STOP facilities EMERGENCY STOP facilities must be operative and accessible in all modes of the system Releasing the EMERGENCY STOP facility must by no means result in an uncontrolled restart of the system First check the EMERGENCY STOP circuit then switch the unit on DANGER The right to perform repair maintenance work on the weld timer com ponents is reserved to the BOSCH service department or to repair maintenance units authorized by BOSCH gt gt gt CAUTION Only use spare parts approved by BOSCH 1070 080 087 101 2001 04 GB 1 16 Safety instructions 1 12 Working safely BOSCH A DANGER During operation of the welding equipment welding splashes are to be expected They may cause eye injuries or burns Therefore e wear protective goggles e wear protective gloves e wear flame retardant clothes DANGER Danger of injury from sheet metal edges and danger of burns from weld metal Therefore wear protective gloves A A DANGER In the environment of resistance welding systems magnetic field strengths have to be expected which are above the limit values spe cified in VDE 0848 Part 4 Especially if manual guns are used the limit values for extremities may be exceeded If in doubt measure the field strength and take additional measures to ensure safety and health at work CAUTION The strong magnetic fields occurring in
50. gram Transformer degree of protection IP65 Primary connection zone degree of protection IP54 Welding transformer insulation class F Weight 9 3 kg Color RAL 5015 blue Cooling water volume min 1 1 min Cooling water temperature max 30 C Cooling water pressure drop max 0 6 bar Primary circuit monitoring max 140 C Rectifier block monitoring max 80 C 9 2 PSG 3025 00 A BOSCH 9 2 Dimensioned drawing PSG 3025 00 A Earthingsign _ Nameplate Cooling water connection E thread M12x1 ph protective neu POGI tral conductor M6 Al ground con ductor housing bolted PG11 connection supply and bolted PG9 4 x M8 10 deep on all sides connection temperature View X w o cover monitoring supplied for view of level 2 with pro assembly tective neutral conduc CAES Dimensions without tolerances are subject to mean deviations to DIN 7168 AA en Dimensioned drawing PSG 3025 00 A 9 3 Cooling water connection PSG 3025 00 A Maximum supply water temperature 30 C WE water inlet WA water outlet Water connection hose with 6 3 mm internal diameter Type Parker Push lock 831 4 WP2 4 1070 080 087 101 2001 04 GB BOSCH PSG 3025 00A 9 3 9 4 Block diagram PSG 3025 00 A 1 V Jumper 2 Jumper 1 2 Jumper 2 1 U Block diag
51. ies PSG 3XXX to power output of inverter a MPE PSG 3XXX XX X parallel connection to inverters 1070 080 087 101 2001 04 GB BOSCH 5 Maintenance Maintenance 5 1 A DANGEROUS ELECTRICAL VOLTAGE Maintenance work must always be carried out 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 Prior to connecting an MF inverter the following must be strictly observed Power OFF Provide a safeguard to prevent unintentional reclosing Verify that the system is safely isolated from supply and de energized Connect to earth and short circuit Cover up or safeguard all live parts DANGEROUS ELECTRICAL VOLTAGE Prior to any maintenance work unless described otherwise the system must always be switched off If the system was active shortly before wait until the system is totally de energized before starting the maintenance work e g because of charged capacitors etc The system must always be safeguarded against unintentional reclosing while maintenance work is per formed In the event of necessary measurement or test procedures at the ac tive system the applicable safety and accident prevention regula tions must be strictly observed In any case suitable insulated tools must be used If you need to open the MF inverter housing
52. ing Pgio 53 9 kW 100 duty cycle ED Max rated surge forward current Irsm 120 kA 10 ms Tyj max 180 C Max direct current ly max cf load diagram Transformer degree of protection IP65 Primary connection zone degree of protection IPOO Welding transformer insulation class F Weight 24 4 kg Color RAL 1004 yellow Cooling water volume min 101 min Cooling water temperature max 30 C Cooling water pressure drop max 2 5 bar Primary circuit monitoring max 150 C Rectifier block monitoring max 80 C 1070 080 087 101 2001 04 GB 12 2 PSG 3100 00 X BOSCH 12 2 Technical data PSG 3100 00 P e without current transformer in secondary circuit e with MC 135 plug receptacle Medium frequency transformer rectifier unit Sy 100 kVA at X 50 Primary voltage Un 500 V Max primary continuous current I4p 116A Secondary current range lon 3 to 36 kA Continuous direct current ly 5 8 kA 100 duty cycle ED Cable cross section U2 V2 gt U V 35mm Frequency f 1000 Hz Transformer ratio U 50 1 No load direct voltage Ugio 9 0V Continuous d c forward current rating Pgio 52 2 kW 100 duty cycle ED Max rated surge forward current lrsiy 120 kA 10 ms Tyj max 180 C Max direct current ly max cf load diagram Transformer degree of protection IP65 Primary connection zone degree of protection IP54 Welding transformer insulation class F
53. minal 3 1 1070 080 087 101 2001 04 GB BOSCH Protective measures 3 1 Protective resistor 3 10 PSG 3025 00 A 9 1 PSG 3050 00 A 10 1 PSG 3050 10 A 10 1 PSG 3050 10 S 10 1 PSG 3075 10 A 11 1 PSG 3075 10 P 11 1 PSG 3100 00 X 12 1 PSG 3200 00 A 13 1 PSG technical data 9 1 Q Qualified personnel 1 5 R Rating example 7 2 Repair 1 15 5 1 Replacement parts 5 1 Residual current protective resistor 3 6 Retrofits 1 14 S Safety instructions 1 1 1 2 Secondary current 2 4 Secondary voltage monitoring 10 3 10 8 12 3 12 11 Setup 2 1 Spare parts 1 15 5 1 Symbols 1 2 System perturbation 1 11 T Technical data PSG 3025 00 A 9 1 Technical data PSG 3050 00 A 10 1 Technical data PSG 3050 10 A 10 2 Technical data PSG 3050 10 S 10 3 Technical data PSG 3075 10 A 11 1 Technical data PSG 3075 10 P 11 2 Technical data PSG 3100 00 A 12 1 1070 080 087 101 2001 04 GB Annex Technical data PSG 3100 00 C 12 4 Technical data PSG 3100 00 P 12 2 Technical data PSG 3100 00 S 12 3 Technical data PSG 3200 00 A 13 1 Temperature monitoring 2 1 Terminal box TH 3000 Pg 6 2 TH 3050 MC 6 3 TH 3100 MC 6 4 Test procedures 1 15 5 1 Touch voltage 3 1 Training courses 1 5 Transient recovery times 7 1 Transistor inverter 2 4 Type overview 8 1 V Voltage operated e l c b system 3 5 W Welding current maximum 1 13 Welding splashes 1 16 Working safely
54. mitation at 5 weld time periods Example of load diagram e 2 Write down your welding parameters Sample data 20 sequences per minute 1 sequence 60s 20 3s 150 overall weld cycles incl all non weld times i e SQZ OFF CT WLD HOLD and all idle times 150 overall weld cycles 1 sequence 1 over all weld cycle 3s 150 0 02s 18t sequence 2 x 15 weld time periods subsequent sequences 15 weld time periods each bh ts 15 x 0 02s 0 3s 15 cycles each lsec Ep LE 3 see 60 sec Sample data 1070 080 087 101 2001 04 GB BOSCH 1070 080 087 101 2001 04 GB Load diagrams 7 3 e 3 Calculate the duty cycle ED 2s of the diodes on the basis of the se quence with the highest number of weld time periods number of weld time periods 30 periods x 0 02 Yo ED 28 2 seconds ARE 2 seconds x 100 30 e 4 Use the load diagram to determine the maximum welding current per mitted for the diodes First draw a vertical line through the duty cycle value of the diodes which you have just calculated ED 30 Next take the characteristic of the diodes with the next higher number of weld time periods than the required one with 30 weld time periods given in the example this would be the 4 characteristic and mark its intersec tion with the vertical line you have drawn Now you can find the max welding current i permitted for the diodes at
55. nformity 14 1 Hersteller Erklarung EXPERT MASCHINENBAU GMBH D 64653 Lorsch Seehofstra e 56 58 Stromquelle f r die Widerstandsschwei technik und Proze technik Beschreibung Transformator Transformator Gleichrichter Einheit Zubeh r Produktbezeichnung Die bezeichneten Produkte sind ausschlie lich zum Einbau in andere Maschinen bestimmt Die Inbe triebnahme ist solange untersagt bis die Konformit t des Endproduktes mit der EG Maschinen richtlinie 897397 EWG Anhang lB 91 EWG 93 44 EWG festgestellt ist Hiermit best tigen wir die Konformit t der oben aufgef hrten Produkte mit den nachfolgenden Richt linien Normen Richtlinien FHAVEWGS Normen EN 60204 Teil 1 EN 50063 Niederspannungs Richtlinie Elektrische Ausr stung von Maschinen Sicherheilsanforderungen f r den Bau und die Errichtung von Einrichlungen zum Widerstandsschwei en und f r verwandie Verfahren Weitere technische Normen wurden ber cksichtigt ISO 7284 150 5826 150 10656 ISO DIS 1266 150 669 DIN 44766 Teil 1 2 3 NFA 82 040 ff Resistance welding equipment Particular specifications applicable to trans formers with two separate secondary windings for multi spot weiding as used in the automobile industry Transformatoren f r Widerstandsschwei maschinen Electric resistance welding Integrated transformers for welding guns Resistance welding equipment Particular specifications applica
56. number of spot welds per minute number of weld time periods number of overall weld cycles are used to determine e 1 the maximum admissible welding current depending on the diode load and e 2 the maximum admissible welding current depending on the transfor mer load To ensure proper execution of weld schedules the lowermost of these two values must not be exceeded 7 2 Load diagrams BOSCH 7 1 Rating example e 1 Look for the related load diagram of the PSG 3000 you want to use Example OT E ON E a 600 00 25 00 500 00 Hipo 22 2 He paaa bng 4 21 2 E Se O pr er u R AS A NG 400 00 20 00 Ni P2 l N iz 17 1 SS a diode integration time 2 s z a i io El i 1 o kr _ 15002 a Do x P ee A ee ee wu Stic t ER 300 00 E a Ng 5 8 2 o oa E 10 00 he 200 00 1 PAG il 5 00 i ld a aa 7 100 00 Ka mag o Al i A 10 5 i 0 00 i lug ed pes _ Hal BIG 10 10 0 20 0 30 0 100 0 A Transformer and inverter related limitation ED duty cycle The load curves represent absolute limit va A Diode related limitation at 50 weld time periods lues To ensure the reliability in continuous Diode related limitation at 20 weld time periods operation we recommend that no more than XxX Diode related limitation at 10 weld time periods 80 of tak max load capacity be utilized O Diode related li
57. o EN 50063 must be installed In this case the ground connection between the transformer neutral and the earthing bolt must be crossed out in an indelible manner 1070 080 087 101 2001 04 GB 3 Primary winding and rectifier block temperature monitoring T1 T2 Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY e 711 thermal release rectifier block 80 C e T2 thermal release welding transformer primary side 150 C 4 Connection M current transformer secondary side Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY e white brown e measuring voltage Um 150 mV kA 2 5 at ohmic resistance of 1kQ 5 Connection S connection of secondary voltage monitoring 6 Secondary side connection of electrodes 12 12 PSG 3100 00 X BOSCH 12 12 Load diagram 1 x PSG 3100 00 X 40 CN a u kI r 800 35 m i EOS 700 F 30 AH E 600 1 NG TI 25 L en NI E 500 T A h Ni Wg Ds t lt g 20 SE 40 Jn 5 ft 300 15 PSG integration time 60s t F le 10 Baba HHH 200 NAN 5 th nk 100 i 1 0 10 100 0 duty cycle ED A Transformer related limitation The load curves represent absolute limit A Diode related limitation at 50 weld time periods values To ensure the reliability in contin Diode related limitation at 20 weld time periods uous operation we recommend that no X Diode related limita
58. omponents installed after the current transformer Indirect contact with live parts will re lease the line switch However please read the manufacturer s specifications carefully and check whether the current operated e l c b system to be used for are suitable for MF system operation with a DC link circuit and at a frequency of 1000 Hz cf EN 50178 EN 60947 2 etc The applicable standards are to be ob served 1070 080 087 101 2001 04 GB 3 8 Protective conductor connection BOSCH 3 2 1 Installation of a residual current protective resistor remove MPE jumper fixing parts of eae eee bolt M6x10 jump aag spring lock washer 06 plain washer 06 protective resistor connection MPE connection Diagram shows protective resistor with long connecting leads Installation of a residual current protective resistor with long connecting leads 1070 080 087 101 2001 04 GB BOSCH Protective conductor connection 3 9 remove MPE jumper fixing parts of MPE jumper bolt M6x10 ES spring lock washer 6 plain washer 06 protective resistor connection MPE connection Diagram shows protective resistor with short connecting leads Installation of a residual current protective resistor with short connecting leads 1070 080 087 101 2001 04 GB 3 10 Protective conductor connection BOSCH 3 3 Ordering protective resistors Designation Part No
59. onditions into account for installation or mounting Installation or mounting must be carried out by skilled personnel only CAUTION Leaks in the cooling water circuit may cause consequential damage Cooling water leaks may damage adjacent components Therefore when mounting water cooled modules always ensure that other de vices in the switchgear cabinet are well protected against leaking cooling water 1070 080 087 101 2001 04 GB BOSCH Safety instructions 1 7 CAUTION Damage to property through inappropriate or insufficient cooling of the welding transformers Water cooled welding transformers may only be operated when the cooling water circuit is active Condensation on water carrying com ponents 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 Therefore you should ensure that your cooling water has the follow ing properties e pH value 7to8 5 e Degree of hardness Dmax 10 German degrees 1 German degree 1 25 British degrees 1 05 US degrees 1 8 French degrees e Chlorides max 20 mg l e Nitrates max 10 mg l e Sulfates max 100 mg l e Insoluble substances max 250 mg l Tap water usually meets these requirements However an algicide should be added 1070 080 087 101 2001 04 GB Make sure that
60. onitoring max 150 C Rectifier block monitoring max 80 C 12 4 PSG 3100 00 X BOSCH 12 4 Technical data PSG 3100 00 C e with current transformer in secondary circuit e designed for MC 135 plug Medium frequency transformer rectifier unit Sy 100 kVA at X 50 Primary voltage Un 500 V Max primary continuous current I4p 116A Secondary current range lon 3 to 36 kA Continuous direct current ly 5 8 kA 100 duty cycle ED Cable cross section U2 V2 gt U V 35mm Frequency f 1000 Hz Transformer ratio U 50 1 No load direct voltage Ugio 9 3V Continuous d c forward current rating Pgio 53 9 kW 100 duty cycle ED Max rated surge forward current lrsiy 120 kA 10 ms Tyj max 180 C Max direct current ly max cf load diagram Transformer degree of protection IP65 Primary connection zone degree of protection IP00 Welding transformer insulation class F Weight 24 4 kg Color RAL 1004 yellow Cooling water volume min 101 min Cooling water temperature max 30 C Cooling water pressure drop max 2 5 bar Primary circuit monitoring max 150 C Rectifier block monitoring max 80 C 1070 080 087 101 2001 04 GB BOSCH PSG 3100 00X 12 5 12 5 Dimensioned drawing PSG 3100 00 A PSG 3100 00 S ouch guard required for primary connection For connection cover type and order data cf attached she
61. onnected in parallel 12 13 Load diagram PSG 3025 00 A 9 2 9 4 Load diagram PSG 3050 00 A 10 4 10 9 Load diagram PSG 3050 10 A 10 10 Load diagram PSG 3050 10 S 10 10 Load diagram PSG 3075 10 A 11 8 Load diagram PSG 3075 10 P 11 8 Load diagram PSG 3200 00 A 13 5 Load diagrams 7 1 Maintenance 1 15 5 1 Maximum welding current 1 13 7 1 MC 180 multi contact connection 6 4 BOSCH MC multi contact connection 6 3 Modifications 1 2 Modifications by the user 1 14 Mounting 1 6 MPE protective conductor jumper 3 1 N Negative pole 3 2 O Operation of the welding transformers Safety in structions 1 13 Ordering PSG 3025 00 A 9 5 Ordering PSG accessories 6 5 Ordering PSG 3050 00 A 10 12 Ordering PSG 3050 10 A 10 12 Ordering PSG 3050 10 S 10 12 Ordering PSG 3075 10 A 11 10 Ordering PSG 3075 10 P 11 10 Ordering PSG 3100 00 A 12 15 Ordering PSG 3100 00 C 12 15 Ordering PSG 3100 00 P 12 15 Ordering PSG 3100 00 S 12 15 Ordering PSG 3200 00 A 13 7 P Pacemaker 1 4 Parallel connection four PSG 3100 XX X connected to PSI 6500 XXX 4 2 two PSG 3100 XX X connected to PSI 6200 XXX 4 2 two PSG 3200 XX X connected to PSI 6500 XXX 4 2 PE connection 1 10 PE terminal 3 2 Positive pole 3 3 Primary connection 6 2 Primary voltage 2 4 Protection class 1 3 1 Protective conductor connection checking 3 2 Protective conductor jumper 3 1 Protective conductor ter
62. or test institution is required in Germany please contact the Regulierungsbeh rde fur Telekommunikation und Post RegTP or its local branch offices The faultless safe functioning of the product requires proper transport stor age erection and installation as well as careful operation BOSCH 1 4 Safety instructions No admittance for persons fitted with cardiac pacemakers 1 3 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 welding equipment No entry for persons with cardiac pacemakers Danger DIN 40023 1070 080 087 101 2001 04 GB BOSCH 1 4 Qualified personnel Safety instructions 1 5 The requirements as to qualified personnel are based on the requirements profiles as defined by the ZVEI Zentralverband Elektrotechnik und Elek tronikindustrie German Electrical and Electronic Manufacturers Associ ation and the VDMA Verband deutscher Maschinen und Anlagebau German Engineering Federation in Weiterbildung in der Automatisierungstechnik edited by ZVEI and VDMA Maschinenbau Verlag Postfach 71 08 64 D 60498 F
63. r T1 M external 3 4 Block diagram PSG 3200 00 A 1 Primary side e U welding transformer gt U2 medium frequency inverter e V welding transformer gt V2 medium frequency inverter 2 MPE neutral earth conductor A DANGEROUS ELECTRICAL VOLTAGE If the MPE protective conductor jumper is to be removed another protective measure to EN 50063 must be installed In this case the ground connection between the transformer neutral and the earthing bolt must be crossed out in an indelible manner 3 Primary winding and rectifier block temperature monitoring T1 T2 Connecting cable 2 x 2 x 0 75 mm screened LiYCY e 711 thermal release rectifier block 80 C e T2 thermal release welding transformer primary side 150 C 4 Connection M current transformer secondary side Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY e white brown e measuring voltage Um 150 mV kA 2 5 at ohmic resistance of 1kQ 5 Secondary side connection of electrodes 1070 080 087 101 2001 04 GB BOSCH PSG 3200 00 A 13 5 13 5 Load diagram PSG 3200 00 A 40 00 diode int tion time 2 1000 00 35 00 0 30 00 _ 800 00 25 00 600 00 z gt 20 00 E u 1 2 2 15 00 o i ee tuo a 400 00 10 00 200 00 5 00 0 00 __ 0 00 1 0 10 0 100 0 duty cycle ED Transformer related limitation The load curves represent absolute limit A Diode
64. ram PSG 3025 00 A 1 Primary side e U welding transformer gt U2 medium frequency inverter e V welding transformer gt V2 medium frequency inverter 2 Jumpers on primary side e Optional connection jumper 1 Primary winding connected in parallel 2 8 V no load output voltage e Optional connection jumper 2 Primary winding connected in series 6 2 V no load output voltage 3 Primary winding and rectifier block temperature monitoring T Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY 4 MPE neutral earth conductor DANGEROUS ELECTRICAL VOLTAGE If the MPE protective conductor jumper is to be removed another protective measure to EN 50063 must be installed In this case the ground connection between the transformer neutral and the earthing bolt must be crossed out in an indelible manner 5 Secondary side connection of electrodes 1070 080 087 101 2001 04 GB 9 4 PSG 3025 00 A 9 5 Load diagram PSG 3025 00 A BOSCH 6000 5000 ts 200ms 4000 3000 Isec KA diode integration time T 2 s 2000 1000 M2 rectifier circuit 2x1 diode 80 K temperature gradient 10 duty cycle ED 4 Limitation by transformer transformer inte gration time T 60 s 100 Load diagram PSG 3025 00 A 1070 080 087 101 2001 04 GB BOSCH 9 6 Ordering PSG 3025 00 A 1070 080 087 101 2001 04 GB PSG 3025 00 A 9 5 De
65. rankfurt This manual is designed for technicians and engineers with special welding training and skills They must have a sound knowledge of the hardware com ponents of the weld timer the medium frequency inverters 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 Only skilled persons as defined in IEV 826 09 01 who are familiar with the contents of this manual may install and service the products described Such personnel are e those who being well trained and experienced in their field and familiar with the relevant standards are able to analyze the work to be carried out and recognize any hazards e those who have acquired the same amount of expert knowledge through years of experience that would normally be acquired through formal tech nical training DANGER An exception are persons with cardiac pacemakers The strong magnetic fields occurring in resistance welding may af fect the proper functioning of pacemakers This may be fatal or cause serious personal injury Therefore persons with pacemakers must stay clear of resistance welding systems We recommend that warning sings
66. related limitation at 50 weld time periods values To ensure the reliability in contin Diode related limitation at 20 weld time periods uous operation we recommend that no X Diode related limitation at 10 weld time periods more than 8096 of the max load capacity O Diode related limitation at 5 weld time periods be utilized Load diagram PSG 3200 00 A 1070 080 087 101 2001 04 GB 13 6 PSG 3200 00 A BOSCH 13 6 Current resistance characteristic PSG 3200 00 A R over Isec at 150 A h v R uQ 700 300 200 10071 11 0 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 Isec in KA Current resistance characteristic PSG 3200 00 A 1070 080 087 101 2001 04 GB BOSCH 13 7 Ordering PSG 3200 00 A 1070 080 087 101 2001 04 GB PSG 3200 00 A 13 7 Designation PSG 3200 00 A welding transformer with current sensor in secondary circuit Part no 1070 070 123 13 8 PSG 3200 00 A BOSCH Notes 1070 080 087 101 2001 04 GB BOSCH Declaration of Conformity 14 Declaration of Co
67. rimary current regulation without current sensor PSG 3100 00 S e Medium frequency welding transformer 100 kVA Welding current range 3 to 36 kA Integrated temperature monitoring Integrated current sensor and temperature monitoring Connection for secondary voltage monitoring PSG 3100 00 C e Medium frequency welding transformer 100 kVA e Welding current range 3 to 36 kA e Integrated current sensor and temperature monitoring e For multi contact connector MC 135 PSG 3200 00 A e Medium frequency welding transformer 200 kVA e Welding current range 6 to 40 kA e Integrated current sensor and temperature monitoring BOSCH 1070 080 087 101 2001 04 GB BOSCH 9 PSG 3025 00 A 9 1 Technical data PSG 3025 00 A 1070 080 087 101 2001 04 GB PSG 3025 00 A 9 1 Medium frequency transformer rectifier unit Sy 12 kVA at X 50 Primary voltage Un 500 V Max primary continuous current I4p 14A Secondary current range lon 0 25 to 6 kA Rated direct current ly 1 4 kA 50 duty cycle ED level 1 Continuous direct current ly 1 0 kA 100 duty cycle ED level 1 Cable cross section U2 V2 gt U V 4mm Frequency f 1000 Hz Transformer ratio U 144 1 level 1 72 1 level 2 No load direct voltage Ugio 2 8 V level 1 6 2 V level 2 Continuous d c forward current rating Paio 6 2 kW 10096 duty cycle ED level 1 Max direct current ly max cf load dia
68. rimary voltage U n 500 V Max primary continuous current I4p 60A Secondary current range lon 3 0 to 20 kA Continuous direct current ly 4 2 kA 10096 duty cycle ED Cable cross section U2 V2 gt UN 216mm Frequency f 1000 Hz Transformer ratio U 70 1 No load direct voltage Ugio 6 3V Continuous d c forward current rating Pgio 26 2 kW 100 duty cycle ED Max rated surge forward current IEsm 50 kA 10 ms Ty max 180 C Max direct current ly max cf load diagram Transformer degree of protection IP65 Primary connection zone degree of protection 1P54 Secondary connection zone degree of protection IPOO Welding transformer insulation class F Weight 14 5 kg Color RAL 5015 blue Cooling water volume min 61 min Cooling water temperature max 30 C Cooling water pressure drop max 0 6 bar Primary circuit monitoring max 150 C Rectifier block monitoring max 80 C 1070 080 087 101 2001 04 GB 10 4 PSG 3050 00 A PSG 3050 10 A PSG 3050 10 S BOSCH 10 4 Dimensioned drawing PSG 3050 00 A and PSG 3050 10 A i i ion Cooling water Cooling water Touch guard required for primary connection E G 1 4 outlet G 1 4 o sii aid pa ego jm 12 5 a Nameplate u rectifier pa mj ca pa ti si wo gad aa WA in a ER d M8 6x tb be 12 deep Aj hs an Taal
69. rt G 3 8 DIN EN 560 G 3 8 Cooling water connection PSG 3100 00 X 1070 080 087 101 2001 04 GB BOSCH PSG 3100 00 X 12 9 12 9 Block diagram PSG 3100 00 A PSG 3100 00 C T2 3 Terminating connector external T1 M 3 4 Block diagram PSG 3100 00 A PSG 3100 00 C 1 Primary side e U welding transformer gt U2 medium frequency inverter e V welding transformer gt V2 medium frequency inverter 2 MPE neutral earth conductor A DANGEROUS ELECTRICAL VOLTAGE If the MPE protective conductor jumper is to be removed another protective measure to EN 50063 must be installed In this case the ground connection between the transformer neutral and the earthing bolt must be crossed out in an indelible manner 1070 080 087 101 2001 04 GB 3 Primary winding and rectifier block temperature monitoring T1 T2 Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY e 711 thermal release rectifier block 80 C e T2 thermal release welding transformer primary side 150 C 4 Connection M current transformer secondary side Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY e white brown e measuring voltage Um 150 mV kA 2 5 at ohmic resistance of 1kQ 5 Secondary side connection of electrodes 12 10 PSG 3100 00 X BOSCH 12 10 Block diagram PSG 3100 00 P
70. signation PSG 3025 00 A welding transformer Part no 1070 079 345 9 6 PSG 3025 00A BOSCH Notes 1070 080 087 101 2001 04 GB PSG 3050 00 A PSG 3050 10 A PSG 3050 10S 10 1 10 PSG 3050 00 A PSG 3050 10 A PSG 3050 10 S 10 1 Technical data PSG 3050 00 A e with current transformer in secondary circuit Medium frequency transformer rectifier unit Sn 56 kVA at X 50 Primary voltage Un 500 V Max primary continuous current Ip 60A Secondary current range lon 3 0 to 20 kA Continuous direct current ly 4 2 kA 100 duty cycle ED Cable cross section U2 V2 gt U V gt 16mm Frequency f 1000 Hz Transformer ratio U 70 1 No load direct voltage Ugio 6 3 V Continuous d c forward current rating Pgio 26 2 kW 100 duty cycle ED Max rated surge forward current Irsy 50 kA 10 ms Ty max 180 C Max direct current ly max cf load diagram Transformer degree of protection IP65 Primary connection zone degree of protection IPOO Welding transformer insulation class F Weight 14 5 kg Color RAL 5015 blue Cooling water volume min 6 I min Cooling water temperature max 30 C Cooling water pressure drop max 0 6 bar Primary circuit monitoring max 150 C Rectifier block monitoring max 80 C 1070 080 087 101 2001 04 GB 10 2 PSG 3050 00 A PSG 3050 10 A PSG 3050 10 S BOSCH 10 2 Technical data PSG 3050 10 A e with
71. t current ly max cf load diagram Transformer degree of protection IP65 Primary connection zone degree of protection 1P54 Welding transformer insulation class F Weight 14 5 kg Color RAL 7005 grey Cooling water volume min 61 min Cooling water temperature max 30 C Cooling water pressure drop max 0 6 bar Primary circuit monitoring max 150 C Rectifier block monitoring max 80 C 1070 080 087 101 2001 04 GB PSG 3075 10 A PSG 3075 10 P 11 2 11 2 Technical data PSG 3075 10 P e without current transformer in secondary circuit e with higher diode rating e with MC 135 plug receptacle Medium frequency transformer rectifier unit Sy 75 kVA at X 50 Primary voltage U n 500 V Max primary continuous current l p 76A Secondary current range lon 3 0 to 20 kA Continuous direct current ly 4 2 kA 10096 duty cycle ED Cable cross section U2 V2 gt UN 216mm Frequency f 1000 Hz Transformer ratio U 55 1 No load direct voltage Ugio 8 4V Continuous d c forward current rating Pgio 35 0 kW 100 duty cycle ED Max rated surge forward current lesm 50 kA 10 ms Tyj max 180 C Max direct current lg max cf load diagram Transformer degree of protection IP65 Primary connection zone degree of protection IP54 Secondary connection zone degree of protection IPOO Welding transformer insulation class F Weight 14 5 kg
72. the level of intersection P1 on the left axis approx 21 kA in this example Optionally you can determine the point of intersection by interpolation between two characteristics taking the actual number of weld time pe riods as a basis of calculation characteristics a and O in this example see intersection P1 po This way you can determine the max welding current in our example more precisely at approx 22 2 KA iy po e 5 Calculate the duty cycle ED 60s of the PSG 3000 ts x number of spots per min 1 x 100 0 3s x 21 x 100 10 5 60s 60s Note For the calculation of ts see step 2 above ED 60s e 6 Use the load diagram to determine the max welding current permitted for the PSG 3000 transformer First draw a vertical line through the duty cycle value of the PSG transfor mer which you have calculated previously ED 10 5 Next mark the intersection of the A characteristic with the vertical line Now you can find the max welding current io permitted for the PSG 3000 transformer at the level of intersection P2 on the left axis approx 17 kA in this example 7 The maximum welding current for any welding operation should al ways be defined by the lower of the two welding currents i and io thus determined 17 kA in this example 7 4 Load diagrams BOSCH Notes 1070 080 087 101 2001 04 GB BOSCH Type overview 8 Type overview 1070 080 087 101 2001 04 GB PSG 3025 00 A
73. tion at 10 weld time periods more than 8096 of the max load capacity O Diode related limitation at 5 weld time periods be utilized Load diagram 1 x PSG 3100 00 X 1070 080 087 101 2001 04 GB BOSCH PSG 3100 00 X 12 13 12 13 Load diagram 2 x PSG 3100 00 X connected in parallel 1600 00 1400 00 1200 00 800 00 Isec kA Iprim A 10 00 0 00 1 0 00 10 10 0 100 0 duty cycle ED A Transformer related limitation The load curves represent absolute limit A Diode related limitation at 50 weld time periods values To ensure the reliability in contin LI Diode related limitation at 20 weld time periods uous operation we recommend that no X Diode related limitation at 10 weld time periods more than 8096 of the max load capacity O Diode related limitation at 5 weld time periods be utilized Load diagram 2 x PSG 3100 00 X connected in parallel 1070 080 087 101 2001 04 GB 12 14 PSG 3100 00 X BOSCH 12 14 Current resistance characteristic 1 x PSG 3100 00 X R 10 900 800 700 600 500 400 300 200 100 50 2 4 6 8 1012 1416 18 20 22 24 26 28 30 32 34
74. tive conductor connection 3 1 welding transformer rectifier electrode gun U open O be test point test point approx 10A AC Checking the protective conductor connection 1 Inspect the protective conductor jumper MPE for damage 2 Perform the following measurement with the protective conductor jumper MPE installed e Supply an AC current of approx 10 A between the PE terminal of the transformer and the negative pole of the rectifier electrode gun e The voltage measured between the PE terminal and the test point nega tive pole must not exceed 1 V cf EN 60204 Section 20 2 and Table 7 DANGEROUS ELECTRICAL VOLTAGE DANGER OF LIFE If a voltage gt 1 Vis measured the jumper MPE between the protec tive conductor and the negative pole of the rectifier is defective inef fective This defect may have been caused by circulating currents Note The measurement described above may be performed analogously to check the protective conductor connection to the transformer housing 1070 080 087 101 2001 04 GB BOSCH Protective conductor connection 3 3 3 1 1 What are circulating currents Circulating currents are defined as currents which do not flow as desired from the positive pole of the welding equipment through the workpiece and to the negative pole of the welding equipment during the welding process but rather through the workpiece and
75. to EN 50063 must be installed In this case the ground connection between the transformer neutral and the earthing bolt must be crossed out in an indelible manner 3 4 5 6 Primary winding and rectifier block temperature monitoring T1 T2 Connecting cable 2 x 2 x 0 75 mm screened LiYCY e 71 thermal release rectifier block 80 C e T2 thermal release welding transformer primary side 150 C Connection M current transformer secondary side Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY e white brown e measuring voltage Um 150 mV kA 2 5 at ohmic resistance of 1kQ Connection S connection of secondary voltage monitoring Secondary side connection of electrodes 1070 080 087 101 2001 04 GB PSG 3050 00 A PSG 3050 10 A PSG 3050 10S 10 9 10 9 Load diagram PSG 3050 00 A 250 00 200 00 150 00 o y E 100 00 6 001 5 l a 4 00 hu i WET 50 00 2 00 ende i an i a L 0 00 la ES GE H 000 1 0 10 0 100 0 duty cycle ED A Transformer related limitation The load curves represent absolute limit A Diode related limitation at 50 weld time periods values To ensure the reliability in contin LI Diode related limitation at 20 weld time periods uous operation we recommend that no X Diode related limitation at 10 weld time periods more than 80 of the max load capacity
76. umption of the individual units of the equipment Incorrect mains voltage may render the system dangerous or cause electrical component failure Therefore please ensure the following e The mains voltage must match the nominal voltage given on the nameplate of the product e Mains voltage fluctuation or variation from the nominal voltage must be within the specified tolerance range see Technical Data e The equipment must be appropriately fused on the mains side e The welding transformers must be connected to the protective earthing PE circuit of the system Please ensure that the cross sectional area of cables used for protective conductor wiring is sufficiently large The electrical continuity of the protective earthing circuit must be verified in accordance with EN 60204 Part 1 e Before carrying out any work on the mains system or welding system connections it must be ensured that the MF inverter has been safely isolated from the supply for at least 5 minutes capaci tor discharge time e Proper and well insulated tools must be used for handling electric connections 1070 080 087 101 2001 04 GB BOSCH Safety instructions 1 9 DANGEROUS ELECTRICAL VOLTAGE Danger of life through insufficient protective conductor system The welding transformers must be connected to the protective earthing PE circuit of the system Please ensure that the cross sectional area of cables used for protective conductor wirin
77. ween the transformer neutral and the earthing bolt must be crossed out in an indelible manner 1070 080 087 101 2001 04 GB 3 Primary winding and rectifier block temperature monitoring T1 T4 Turck FSD 4 4 0 5 Connecting cable 2 x 2 x 0 75 mm2 screened LiYCY e 711 thermal release rectifier block 80 C e 74 thermal release welding transformer primary side 150 C 4 Secondary side connection of electrodes PSG 3075 10 A PSG 3075 10 P 11 8 Load diagram PSG 3075 10 A PSG 3075 10 P 18 09 16 00 14 00 12 00 10 00 4 8 00 Isec kA 6 00 4 00 2 00 0 00 10 diode integration time 2 s 10 0 duty cycle ED OxoDb gt Transformer related limitation Diode related limitation at 50 weld time periods Diode related limitation at 20 weld time periods Diode related limitation at 10 weld time periods Diode related limitation at 5 weld time periods Iprim A The load curves represent absolute limit values To ensure the reliability in contin uous operation we recommend that no more than 80 of the max load capacity be utilized Load diagram PSG 3075 10 A PSG 3075 10 P 1070 080 087 101 2001 04 GB BOSCH PSG 3075 10 A PSG 3075 10P 11 9 11 9 Current resistance characteristic PSG 3075 10 X R UQ 900 800 700 600 500

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