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Rexroth PSG 6130.xx RSTK R911172815/03.

2014

Mittelfrequenz-Schweißtransformator Medium- Edition 03


DE/EN
Frequency Welding Transformer

Typspezifische Anleitung | Type-Specific Instructions

DEUTSCH
ENGLISH
S
H
IL
G
EN
Die angegebenen Daten dienen der
Produktbeschreibung. Sollten auch Angaben zur
Verwendung gemacht werden, stellen diese nur
Anwendungsbeispiele und Vorschläge dar.
Katalogangaben sind keine zugesicherten
Eigenschaften. Die Angaben entbinden den
Verwender nicht von eigenen Beurteilungen und
Prüfungen. Unsere Produkte unterliegen einem
natürlichen Verschleiß- und Alterungsprozess.

 Alle Rechte bei Bosch Rexroth AG, auch


für den Fall von Schutzrechtsanmeldungen.
Jede Verfügungsbefugnis, wie Kopier- und
Weitergaberecht, bei uns.

Auf der Titelseite ist eine Beispielkonfiguration


abgebildet. Das ausgelieferte Produkt kann daher
von der Abbildung abweichen.

Der deutsche Teil der Typspezifischen Anleitung


beginnt auf Seite 5, der englische Teil beginnt auf
Seite 25.

Sprachversion des Dokumentes DE und EN

Originalsprache des Dokumentes: DE

These Type-Specific Instructions of the Rexroth


Medium-Frequency Inverter contains the
descriptions in both German and English. The
German part of the Type-Specific Instructions starts
at page 5, the English part starts at page 25.
R911172815 | PSG 6130.xx RSTK Bosch Rexroth AG

Contents

Contents

1 To this Documentation ............................................................................. 25


1.1 Validity of the documentation ............................................................ 25
1.2 Required and supplementary documentation .................................... 25
1.3 Display of information ....................................................................... 26
1.3.1 Safety instructions ............................................................ 26
1.3.2 Symbols ............................................................................ 26
1.3.3 Designations ..................................................................... 26
1.3.4 Abbrevations ..................................................................... 26
2 Safety instructions ................................................................................... 27
2.1 Protective conductor connection ....................................................... 27
3 General information on damage to property and products ........................... 28
4 Scope of delivery ..................................................................................... 28
5 Dimensions and locations ......................................................................... 29
6 Circuit diagram ........................................................................................ 32
7 Load diagram .......................................................................................... 35
8 Technical data ......................................................................................... 37
9 Current / resistance characteristic ............................................................. 39
10 Part numbers and accessories.................................................................. 40

ENGLISH
11 Terminal box............................................................................................ 41
12 Transformer selection with BOS................................................................ 41
Bosch Rexroth AG R911172815 | PSG 6130.xx RSTK

Contents

Notes:
R911172815 | PSG 6130.xx RSTK Bosch Rexroth AG To this

Documentation

1 To this Documentation

1.1 Validity of the documentation


This documentation applies to Rexroth Medium-Frequency Welding Transformer
PSG 6xxx.
The content belong to
• Dimensions and locations
• Circuit diagram
• Load diagrams
• Technical data
• Current / resistance characteristic
• Part numbers and accessories
• Terminal Box
• Transformer selection with BOS
of the Rexroth Medium-Frequency Welding Transformer.

This documentation is designed for technicians and engineers with special


welding training and skills. They must have knowledge of the software and
hardware components of the weld timer, the power supply used, and the welding
transformer.

This documentation and the Instruction Manual contain important information on

ENGLISH
the safe and appropriate assembly, transportation, commissioning, maintenance
and simple trouble shooting of Rexroth Medium-Frequency Welding Transformer.
 Read this documentation completely and particular the chapter "Safety
instructions" Rexroth PSG xxxx Medium Frequency Welding Transformer and
Safety and user information, before working with the product.

1.2 Required and supplementary documentation


 Only commission the product if the documentation marked with the book
symbol is available to you and you have understood and observed it.

Tab. 1: Required and supplementary documentation


Title Document number Type of
document
Rexroth PSG xxxx 1070 087062 Instructions
Medium-Frequency Welding
Transformer

Rexroth PSG xxxx R911340198 Safety and user


MF welding transformators information

Rexroth PSI6xxx 1070 080028 Instructions


Medium-Frequency Inverter

User Software BOS6000 Help 1070 086446 Reference


Bosch Rexroth AG To R911172815 | PSG 6130.xx RSTK

this Documentation

1.3 Display of information


In order to enable you to work with your product in a fast and safe way, uniform
Safety instructions, symbols, terms and abbreviations are used. For a better
understanding they are explained in the following sections.

1.3.1 Safety instructions


The safety instructions please look in Tab. 1: Required and supplementary
documentation Rexroth PSG xxxx Medium-Frequency Welding Transformer and
Safety and user information.

1.3.2 Symbols
The following symbols mark notes that are not safety-relevant but increase the
understanding of the documentation.

Tab. 2: Meaning of the Symbols


Symbol Meaning

If this information is disregarded, the product cannot be


used and or operated to the optimum extent.

 Single, independent step


1. Numbered step:
2. The numbers specify that the Steps are completed one
3. after the other.

1.3.3 Designations
This documentation uses the following designations:

Tab. 3: Designations
Designation Meaning

BOS 6000 Weld Control Programming Software

PSG xxxx Medium-Frequency Welding Transformer 1000 Hz

RSTK Sensor connector (primary connector type RobiFix), temperature


switch, front–side secondary termination

1.3.4 Abbrevations

For the abbreviations used in this documentation please look in Tab. 1: Required and
supplementary documentation Rexroth PSG xxx Medium-Frequency Welding Transformer.
R911172815 | PSG 6130.xx RSTK Bosch Rexroth AG

Safety instructions

2 Safety instructions

This section includes important information on the safe handling of the product
described.

Please look up the safety instructions under Tab. 1: Required and supplementary
documentation Rexroth PSG xxxx Medium-Frequency Welding Transformer and Safety and
user information.

2.1 Protective conductor connection

The Rexroth PSG series medium-frequency transformers correspond to degree of


protection 1 according to EN 61558-1.
For degree of protection 1, additional protective measures as stipulated in
EN 62135-1 must be applied as protection against inadmissibly high contact
voltages in case of an insulation failure between primary and secondary circuit.
The plant supplier/operator is responsible for providing such protection.

ENGLISH
WARNING
Dangerous electrical voltage in case of contact with the secondary
connections, the welding gun or the workpiece.
If these protective measures are not applied or are ineffective, there may be
danger of life!

 For degree of protection 1, additional protective measures as stipulated in


EN 62135-1 must be applied as protection against inadmissibly high
contact voltages in case of an insulation failure between primary and
secondary circuit.
 When delivered, the secondary circuit (negative pole) of the medium-
frequency transformers is connected with the protective conductor
connection by a removable protective conductor jumper (MPE). This
corresponds to the protective measure "direct protective conductor
connection" according to EN 62135-1.
If with the MPE conductor jumper the resistance Rf is selected, then has
to be proved with measurung negative pole against housing, the
resistance value of 1 KOhm +- 20%. The removal of the protective
conductor jumper (MPE) must be permanently (in an indelible manner)
indicated on the plate provided on the transformer.
 As a further measure for degree of protection 1, the housing of the
medium-frequency transformers must be connected firmly with the
protective conductor connection of the transformer. This connection
cannot be removed.
Bosch Rexroth AG R911172815 | PSG 6130.xx RSTK

General information on damage to property and products

Dangerous electrical voltage


WARNING
Under certain circumstances, compensation currents ("crossover currents"
according to EN 62135-1) may flow through the MPE protective conductor
connections. This means that human lives may be in danger in the event of an
insulation failure!
 The compensation currents must generally be avoided because they may
interrupt the protective conductor connection through the protective
conductor jumper (MPE).
 An interruption of the protective conductor connection will render the "direct
protective conductor connection" protective measure inoperative.
 In the transformer’s state upon delivery, the “direct protective conductor
connection” protective measure is installed. If the Rf resitance is selected
through the MPE conductor jumper, the resistance value of 1KOhm+-20%
has to be checked by measurement negative pole - enclosure.

3 General information on damage to property


and products
Please look up the general information on damage to property and products under Tab.
1: Required and supplementary documentation Rexroth PSG xxxx Medium-Frequency
Welding Transformer and Safety and user information.

NOTICE
The rectifier must not be used as load-bearing part.
The secondary connections are only included for the electrical contact.
Applications have to be realized, that no forces working on the connections.
The transformer housing must not be used as load-bearing construction element
of the welding gun.

4 Scope of delivery
Transformer with 4 pieces dowel pins
Typspecific instructions and Safety and user information
Notice:
Terminal plugs are not included in scope of delivery.
R911172815 | PSG 6130.xx RSTK Bosch Rexroth AG

Dimensions and locations

5 Dimensions and locations

ENGLISH

Fig. 1: Dimensions and locations PSG 6130.00 RSTK, PSG 6130.01 RSTK,
PSG 6130.02 RSTK
Bosch Rexroth AG R911172815 | PSG 6130.xx RSTK

Dimensions and locations

Fig. 2: Dimensions and locations PSG 6130.10 RSTK


R911172815 | PSG 6130.xx RSTK Bosch Rexroth AG

Dimensions and locations

ENGLISH

Fig. 3: Dimensions and locations PSG6130.20 RSTK, PSG6130.22 RSTK


Bosch Rexroth AG R911172815 | PSG 6130.xx RSTK

Circuit diagram

6 Circuit diagram

Fig. 4: Circuit diagram PSG 6130.00 RSTK, 6130.01 RSTK, 6130.02 RSTK

Name in circuit diagram Meaning

U, V Primary connection to PSI

PE Conductor connection

+, - Secondary connection to electordes

MPE Protective conductor jumper

F in Force signal from gun

U in Voltage input for electrode

M /U out Measuring coil and voltage output

T/ F out Temperature and force output for control

Tab. 4: Circuit diagram names PSG 6130.00 RSTK,


PSG 6130.01 RSTK, PSG 6130.02 RSTK
R911172815 | PSG 6130.xx RSTK Bosch Rexroth AG

Circuit diagram

ENGLISH
Fig. 5: Circuit diagram PSG 6130.10 RSTK

Name in circuit diagram Meaning

U, V Primary connection to PSI

PE Conductor connection

+, - Sekondary connection to electrodes

MPE Protective conductor jumper

F in Force signal from gun

U in Voltage input for electrode

M /U out Measuring coil and voltage output

T/ F out Temperature and force output for control

Tab. 5: Circuit diagram names PSG6130.10RSTK


Bosch Rexroth AG R911172815 | PSG 6130.xx RSTK

Fig. 6: Circuit diagram PSG 6130.20 RSTK, PSG 6130.22 RSTK

Name in circuit diagram Meaning

U, V Primary connection to PSI

PE Conductor connection

+, - Secondary connection to electrodes

MPE Protective conductor jumper

T Temperature output for control

U in Voltage input for electrode

M /U out Measuring coil and voltage output

Tab. 6: Circuit diagram names PSG6130.20 RSTK, PSG6130.22 RSTK


R911172815 | PSG 6130.xx RSTK Bosch Rexroth AG

Load diagram

7 Load diagram
Notice: The calculation of the duty cycle (ED) is in the operation manual Rexroth
PSG 6xxx Medium-Frequency Welding Transformer, please refer to
Tab. 1: Required and supplementary documentation.

ENGLISH
Fig. 7: PSG 6130.xx RSTK – Load diagram with 6 l/min, Isecondary (A), duty factor (%)
Bosch Rexroth AG R911172815 | PSG 6130.xx RSTK

Load diagram

Fig. 8: PSG 6130.xx RSTK – Load diagram with 4 l/min, Isecondary (A), duty factor (%)

Fig. 9: PSG 6130.xx RSTK – Load diagram with 2,5 l/min, Isecondary (A), duty factor (%)
R911172815 | PSG 6130.xx RSTK Bosch Rexroth AG

Technical data

8 Technical data

Tab. 7: PSG 6130.xx RSTK – Technical data

Name PSG 6130.00 RSTK PSG 6130.01 RSTK PSG 6130.02 RSTK
(R911172751) (R911172767) (R911172768)

Primary voltage U1N 530 V 645 V 926 V


(with 400 V mains (with 480 V mains (with 690 V mains
voltage) voltage) voltage)

Frequency 1000 Hz 1000 Hz 1000 Hz

No-load DC voltage U2d 8,9 V 8,9 V 8,9 V

Continuous DC current I2P 6,5 kA with 100% ED 6,5 kA with 100% ED 6,5 kA with 100% ED

Continuous apparent power S1P 62,5 kVA with 100% ED 62,5 kVA with 100% ED 62,5 kVA with 100% ED

Apparent power S1P 139,8 kVA with 20% ED 139,8 kVA with 20% ED 139,8 kVA with 20% ED

Insulation class of welding F F F


transformers

Turns ratio 55:1 66:1 95:1

Weight 16,2 kg 16,2 kg 16,2 kg

Color RAL 1004 yellow RAL 1004 yellow RAL 1004 yellow

Cooling water quantity 6 l/min 6 l/min 6 l/min

ENGLISH
Differential pressure 0.6 bar with 6 l/min 0.6 bar with 6 l/min 0.6 bar with 6 l/min
nominal flow nominal flow nominal flow

Max. Temperature Transformer 70 °C, EN62135-1 70 °C, EN62135-1 70 °C, EN62135-1


housing

Supply side base plate Without color designation RAL5009 azure blue RAL3003 ruby red

Torque secondary connection 20 Nm 20 Nm 20 Nm

Max. permissible torque 60 Nm refer to 1) 60 Nm refer to 1) 60 Nm refer to 1)


secondary connection

Permissible statically bending force Max. 800 N refer to 2) Max. 800 N refer to 2) Max. 800 N refer to 2)
secondary connection

Signal connector (look circuit Weidmüller Weidmüller Weidmüller


diagram) IE-BSS_V14M-HYB-10P- IE-BSS_V14M-HYB-10P- IE-BSS_V14M-HYB-10P-
FJ FJ FJ

Coded pin positive pole equipped equipped equipped

1) If the connection to the welding circuit is made through a central screw, it has to
be ensured by the proper order of assembly that this torque is not exceeded.
2) The permitted mass has to be calculated for the dynamic load; e.g. at 5 g
acceleration: F = m x a → m = F / a → m = 800 / ~50 = 16 ( kg m/s²) / m/s² the
permitted mass is 16 kg.
Bosch Rexroth AG R911172815 | PSG 6130.xx RSTK

Technical data

Tab. 8: PSG 6130.xx RSTK – Technical data

Name PSG 6130.10 RSTK PSG 6130.20 RSTK PSG 6130.22 RSTK
(R911173181) (R911173295) (R911173296)

Primary voltage U1N 530 V 530 V 926 V


(with 400 V mains (with 400 V mains (with 690 V mains
voltage) voltage) voltage)

Frequency 1000 Hz 1000 Hz 1000 Hz

No-load DC voltage U2d 8,9 V 8,9 V 8,9 V

Continuous DC current I2P 6,5 kA with 100% ED 6,5 kA with 100% ED 6,5 kA with 100% ED

Continuous apparent power S1P 62,5 kVA with 100% ED 62,5 kVA with 100% ED 62,5 kVA with 100% ED

Apparent power S1P 139,8 kVA with 20% ED 139,8 kVA with 20% ED 139,8 kVA with 20% ED

Insulation class of welding F F F


transformers

Turns ratio 55:1 55:1 95:1

Weight 16,2 kg 16,2 kg 16,2 kg

Color RAL 1004 yellow RAL 1004 yellow RAL 1004 yellow

Cooling water quantity 6 l/min 6 l/min 6 l/min

Differential pressure 0.6 bar with 6 l/min 0.6 bar with 6 l/min 0.6 bar with 6 l/min
nominal flow nominal flow nominal flow

Max. Temperature Transformer 70 °C nach EN62135-1 70 °C nach EN62135-1 70 °C nach EN62135-1


housing

Supply side base plate Without color designation Without color designation RAL3003 ruby red

Torque secondary connection 20 Nm 20 Nm 20 Nm

Max. permissible torque 60 Nm refer to 1) 60 Nm refer to 1) 60 Nm refer to 1)


secondary connection

Permissible statically bending force Max. 800 N refer to 2) Max. 800 N refer to 2) Max. 800 N refer to 2)
secondary connection

Signal connector (look circuit Weidmüller Souriau Trim Trio Souriau Trim Trio
diagram) IE-BSS_V14M-HYB-10P- UT00128PT UT00128PT
FJ , shield connected Allocation as Allocation as
24V supply for force PSG3100.03 PSV PSG3100.03 PSV
sensor

Coded pin positive pole Not equipped equipped equipped

3) If the connection to the welding circuit is made through a central screw, it has to
be ensured by the proper order of assembly that this torque is not exceeded.
4) The permitted mass has to be calculated for the dynamic load; e.g. at 5 g
acceleration: F = m x a → m = F / a → m = 800 / ~50 = 16 ( kg m/s²) / m/s² the
permitted mass is 16 kg.
R911172815 | PSG 6130.xx RSTK Bosch Rexroth AG

Current / resistance characteristic

9 Current / resistance characteristic

Widerstandskennlinie PSG 6130

700

600

500
Rsek (µOhm)

400

300

200

ENGLISH
100

0
5 10 15 20 25 30 35
Isek (KA)

Fig. 10: Current/ resistance characteristic PSG 6130.xx RSTK, Rsek(µOhm), Isek (kA)
Bosch Rexroth AG Part R911172815 | PSG 6130.xx RSTK

numbers and accessories

10 Part numbers and accessories

Tab. 9: Part numbers


Name Part number

PSG 6130.00 RSTK R911172751

PSG 6130.01 RSTK R911172767

PSG 6130.02 RSTK R911172768

PSG 6130.10 RSTK R911173181

PSG 6130.20 RSTK R911173295

PSG 6130.22 RSTK R911173296


R911172815 | PSG 6130.xx RSTK Bosch Rexroth AG

Terminal box

11 Terminal box

The PSG 6130.xx RSTK welding transformer needs no terminal box.

12 Transformer selection with BOS

1. Select the timer for which the transformer ist o be defined.


2. Open the window, containing the parameters for transformer selection:
BOS6000:
Programming  Electrode
3. Select the appropriate transformer in field Type:
for example PSG 6130.01 RSTK

ENGLISH
Bosch Rexroth AG
Electric Drives and Controls
Postfach 1357
97803 Lohr, Deutschland
Bgm.-Dr.-Nebl-Str.2
Tel. +049 9352 40-0
Fax +049 9352 40-4885
www.boschrexroth.com/electrics