Table of Contents
Related Manuals for Bosch Rexroth PSI 6500 Series
Summary of Contents for Bosch Rexroth PSI 6500 Series
- Page 1 Industrial Electric Drives Linear Motion and Service Mobile Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics Rexroth IndraControl VCP 20 Rexroth PSI 6500.xxx 1070087059 Edition 02 Master-Slave Technical Information...
- Page 2 DOK-PS6000-MasterSlave-FK01-EN-P 06.2003 DOK-PS6000-MasterSlave-FK02-EN-P 04.2004 E Bosch Rexroth AG, 2003-2004 Copyright Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1).
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Page 3: Table Of Contents
1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Table of Contents Table of Contents Page Safety Instructions ..... . . - Page 4 Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Table of Contents Notes:...
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Page 5: Safety Instructions
1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Safety Instructions Safety Instructions The products described were developed, manufactured and tested in compliance with the fundamental safety requirements of the EU machi- nery directive. 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. -
Page 6: Safety Instructions In This Manual
Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Safety Instructions Safety Instructions in this Manual DANGEROUS ELECTRICAL VOLTAGE This symbol is used to warn of dangerous electrical voltage. The fail- ure to observe the instructions in this manual in whole or in part may re- sult in personal injury. -
Page 7: Intended Use
1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Safety Instructions Intended Use The product described D serves in connection with a welding transformer and the appropriate power supply unit for - resistance welding of metals D is suitable for operation in industrial environments in accordance with... -
Page 8: Qualified Personnel
Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Safety Instructions Qualified Personnel The requirements as to qualified personnel are based on the require- ment profiles defined by the ZVEI (Zentralverband Elektrotechnik und Elektronikindustrie - German Electrical and Electronic Manufacturers’... - Page 9 1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Safety Instructions DANGER! An exception are persons with cardiac pacemakers! The strong magnetic fields occurring in resistance welding may affect the proper functioning of pacemakers. This may be fatal or...
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Page 10: Installation And Assembly
Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Safety Instructions Installation and Assembly DANGEROUS ELECTRICAL VOLTAGE Danger of life during installation work while systems are switched Make sure that all plant sections undergoing operations during the installation are de-energized and sufficiently protected... - Page 11 1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Safety Instructions CAUTION Short circuits! When cut-outs are drilled or sawed in switchgear cubicles, metal burr may get into modules already installed there. Or, when cooling water lines are connected, water may leak into the modules installed.
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Page 12: Electrical Connection
Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Safety Instructions Electrical Connection DANGEROUS ELECTRICAL VOLTAGE The line voltage causes considerable risks! Improper handling may result in death, personal injury or material damage. For that reason, the electric connection may only be established by an electrician. -
Page 13: Operation Of The Product
1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Safety Instructions Operation of the Product DANGER In the environment of resistance welding systems, magnetic field strengths have to be expected which are above the limit values specified in VDE 0848 Part 4. -
Page 14: Retrofits And Modifications By The User
1-10 Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Safety Instructions DANGER Danger of bruises through electrode movement! All users, line designers, welding machine manufacturers and welding gun producers are obliged to connect output signals which initiate the electrode movement so that the applicable sa- fety regulations are complied with. -
Page 15: Maintenance, Repair
1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG 1-11 and Controls Safety Instructions Maintenance, Repair DANGEROUS ELECTRICAL VOLTAGE Prior to any maintenance work - unless described otherwise - the system must always be switched off and sufficiently secured! -
Page 16: Working Safely
1-12 Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Safety Instructions 1.10 Working Safely DANGER If the start signal is present in the event of an error reset (acknowl- edgement), the control immediately starts the program run! Haz-... -
Page 17: Ce Mark
1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG 1-13 and Controls Safety Instructions 1.11 CE mark CAUTION The CE mark for thyristor unit - welding transformer combinations (see section 4) refers to industrial applications. For other combinations/applications, the certificate must be deri- ved from the above, or a new certificate must be issued, if neces- sary, by the line designer / user. - Page 18 1-14 Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Safety Instructions Notes:...
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Page 19: Fundamentals On The Master-Slave Mode
1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Fundamentals on the Master-Slave Mode Fundamentals on the Master-Slave Mode The types PSI 6500.xxx of the PS 6000 series are provided with the “ma- ster-slave mode” functionality. Features of the master-slave mode: D Synchronization of up to 3 PSI 6500.xxx of the same type, for increa-... -
Page 20: Function
Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Fundamentals on the Master-Slave Mode CAUTION There may be malfunctions and damage! Improper installation, incorrect connection or maloperation may cause unexpected or wrong unit reactions and may, thus, result in hazardous situations at the welding system. - Page 21 1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Fundamentals on the Master-Slave Mode No more than 3 units (of the same type) Master Slave 1 Slave 2 (with I/O and programming (without I/O and (without I/O and...
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Page 22: How To Use Current Sensors
Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Fundamentals on the Master-Slave Mode How to Use Current Sensors Some special items must be observed in the master-slave mode when actual currents are measured. 1. Actual currents may only and exclusively be controlled or moni-... - Page 23 1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Fundamentals on the Master-Slave Mode Master Control Power module section Toroid input Secondary current sensor Slave Con- Power nection section logic Electrodes Secondary All PSGs are current Slave...
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Page 24: Diagnosis
Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Fundamentals on the Master-Slave Mode For fundamental explanations on the PHA and CCR regulation mo- des, please refer to the “Control and I/O Level, Technical Informa- tion” documentation of the particular unit types (PSx 6xxx.100, PSx 6xxx.190 and PSx 6xxx.000). -
Page 25: Electric Connection
1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Electric Connection Electric Connection For detailed information on the electric connection of a single unit, please refer to the D “Control and I/O Level, Technical Information” documentation of the particular unit types (PSx 6xxx.100, PSx 6xxx.190 and PSx 6xxx.000) and... -
Page 26: External Secondary Circuit Current Sensor (X3)
Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Electric Connection External Secondary Circuit Current Sensor (X3) Connection: Master-side to X3. Female connector, 3.5 mm grid, 8 poles, max. 1.5 mm The mating male connector is included in the scope of delivery. -
Page 27: Reducing The Measurement Signal
1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Electric Connection Toroid input Toroid input Shield Shield connection to X3 terminal 3 only! Connection of several seondary-side current sensors If secondary-side welding currents are >120 kA, adjustment mea- sures must be taken when connecting the sensors! Observe the instructions in Chapter 3.2.1. -
Page 28: Master-Slave Connection (X6, X7)
Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Electric Connection If you use the adjustment circuit, you must D deactivate the “measuring circuit test” function (the external resi- stance in the measuring circuit is considerably increased if the adjust-... -
Page 29: Ce Marking
1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls CE Marking CE Marking... - Page 30 Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls CE Marking Notes:...
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Page 31: A Appendix
1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Appendix Appendix Abbreviations Alternate current. Hold-open time. Time between two spots, in which the solenoid valve is not activated. Direct current. Only relevant in the serial-spot mode. Assemblies under electrostatic risk. -
Page 32: Index
Bosch Rexroth AG Electric Drives PSI 6500.xxx 1070087059 / 02 and Controls Appendix Index Symbols Modules sensitive to electrostatic discharge. See “Master-slave mode” principle, 2-3 ESD-sensitive components AER, A-1 PE, A-1 Assembly, 1-6 Primary circuit, 3-2 Cables, 1-8 Qualified personnel, 1-4... - Page 33 1070087059 / 02 PSI 6500.xxx Electric Drives Bosch Rexroth AG and Controls Appendix Notes:...
- Page 34 Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Phone +49 (0)93 52-40-50 60 +49 (0)93 52-40-49 41 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany 1070087059 DOK-PS6000-MASTERSLAVE-FK02-EN-P...