Bosch Rexroth PSI 6500 Series Manual

exroth Indra

ontrol V

P 20

Industrial

Hydraulics

Electric Drives

and Controls

Linear Motion and

Assembly Technologies Pneumatics

Service

Automation

Mobile

Hydraulics

Rexroth PSI 6500.xxx

Master-Slave

1070087059

Edition 02

Te chnical Information

II Electric Drives

and Controls

Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02

Rexroth PSI 6500.xxx

Master-Slave

Technical Information

DOK-PS6000-MasterSlave-FK02-EN-P

The present manual informs about

DFunctionality and

DSpecial features with regard to the electric connection

of the master-slave mode available in the PSI 6500.xxx.

Description Release

Date

Notes

DOK-PS6000-MasterSlave-FK01-EN-P 06.2003

DOK-PS6000-MasterSlave-FK02-EN-P 04.2004

EBosch Rexroth AG, 2003-2004

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).

The data specified above only serve to describe the product. No

statements concerning a certain condition or suitability for a certain

application can be derived from our information. The given

information does not release the user from the obligation of own

judgement and verification. It must be remembered that our products

are subject to a natural process of wear and aging.

Bosch Rexroth AG

Postfach 11 62

D-64701 Erbach

Berliner Straße 25

D-64711 Erbach

Tel.: +49 (0) 60 62/78-0

Fax: +49 (0) 60 62/78-4 28

Abt.: BRC - WS/VTR

Title

Type of Documentation

Document Typecode

Purpose of Documentation

Record of Revisions

Validity

Published by

Electric Drives

and Controls

IIIBosch Rexroth AGPSI 6500.xxx1070087059 / 02

Table of Contents

Page

1 Safety Instructions 1-1. . . . . . . . . . . . . . . . . . . . . . .

1.1 Possible Safety Markings on the Product 1-1. . . . . . . . . . . . . . .

1.2 Safety Instructions in this Manual 1-2. . . . . . . . . . . . . . . . . . . . . .

1.3 Intended Use 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Qualified Personnel 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Installation and Assembly 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Electrical Connection 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7 Operation of the Product 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8 Retrofits and Modifications by the User 1-10. . . . . . . . . . . . . . . . .

1.9 Maintenance, Repair 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.10 Working Safely 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.11 CE mark 1-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Fundamentals on the Master-Slave Mode 2-1. . .

2.1 Function 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 How to Use Current Sensors 2-4. . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Diagnosis 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Electric Connection 3-1. . . . . . . . . . . . . . . . . . . . . .

3.1 Power, Transformer and Temperature Contact 3-1. . . . . . . . . . .

3.2 External Secondary Circuit Current Sensor (X3) 3-2. . . . . . . . .

3.2.1 Reducing the Measurement Signal 3-3. . . . . . . . . . . . . . . . . . .

3.3 Master-Slave Connection (X6, X7) 3-4. . . . . . . . . . . . . . . . . . . . .

4 CE Marking 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A Appendix A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 Abbreviations A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2 Index A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV Electric Drives

and Controls

Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02

Table of Contents

Notes:

Electric Drives

and Controls

1-1Bosch Rexroth AGPSI 6500.xxx1070087059 / 02

Safety Instructions

1 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.

Nevertheless, there is some residual risk!

Therefore, you should read this manual before installing, connecting or

commissioning the products or programming the welding system.

Store this manual in a place to which all users have access at any time!

The content of this manual refers to

Dthe functionality and

Dthe specific electric connection

of a master-slave combination with PSI 6500.xxx.

You need the present manual as a supplement to the basic docu-

mentation of the product, if you intend the master-slave mode in

your application.

LTherefore, please pay attention to the following documentation as well:

DControl and I/O Level, Technical Information

for PSx 6xxx.100, PSx 6xxx.190 or PSx 6xxx.000

Control and I/O Level, Technical Information

DMedium-Frequency Inverter, Technical Information (1070 080 028)

for PSI 6500.xxx

1.1 Possible Safety Markings on the Product

Warning of dangerous electrical voltage!

Lug for connecting PE conductor only!

Function ground, ground with low parasitic voltage

Connection of shield conductor only

1-2 Electric Drives

and Controls

Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02

Safety Instructions

1.2 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.

DANGER

This symbol is used wherever insufficient or lacking compliance with in-

structions 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.

.This symbol is used to draw the user’s attention to special circumstan-

ces.

LThis symbol is used if user activities are required.

Modifications in this manual as compared to a previous edition are mar-

ked by black vertical bars in the margin.

Electric Drives

and Controls

1-3Bosch Rexroth AGPSI 6500.xxx1070087059 / 02

Safety Instructions

1.3 Intended Use

The product described

Dserves in connection with a welding transformer and the appropriate

power supply unit for

- resistance welding of metals

and

Dis suitable for operation in industrial environments in accordance with

the following standards:

- EN 50178

- EN 50081-2

- EN 50082-2

- EN 60204-1

In residential environments, in trade and commerce as well as small

enterprises class A equipment may only be used if it does not inad-

missibly interfere with other equipment.

It is not intended for any other use!

DANGER

Any use other than for the purpose indicated may result in perso-

nal 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!

.For operation in residential environments, in trade and commercial

applications and small enterprises, an individual permit of the na-

tional authority or test institution is required; in Germany, please

contact the Regulierungsbehörde für Telekommunikation und

Post (RegTP) or its local branch offices.

The faultless, safe functioning of the product requires proper transport,

storage, assembly and installation as well as careful operation.

1-4 Electric Drives

and Controls

Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02

Safety Instructions

1.4 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’

Association) and the VDMA (Verband deutscher Maschinen- und Anla-

genbau - German Engineering Federation) in:

Weiterbildung in der Automatisierungstechnik

edited by: ZVEI and VDMA

Maschinenbau Verlag

Postfach 71 08 64

D-60498 Frankfurt.

This manual is designed for technicians and engineers with special wel-

ding training and skills. They must have a sound knowledge of the soft-

ware and hardware components of the weld timer, the power supply

used, and the welding transformer.

Project engineering, programming, start and operation as well as the

modification of program parameters is reserved to properly trained per-

sonnel! This personnel must be able to judge potential hazards arising

from programming, program changes and in general from the mechani-

cal, electrical, or electronic equipment.

Interventions in the hardware and software of our products, unless des-

cribed otherwise in this manual, are reserved to specialized personnel.

Tampering with the hardware or software, ignoring warning signs atta-

ched to the components, or non-compliance with the warning notes gi-

ven in this manual can result in serious bodily injury or property damage.

Only skilled persons as defined in IEV 826-09-01 (modified) who are fa-

miliar with the contents of this manual may install and service the pro-

ducts described.

Such personnel are

Dthose who, being well trained and experienced in their field and fami-

liar with the relevant standards, are able to analyze the work to be car-

ried out and recognize any hazards.

Dthose who have acquired the same amount of expert knowledge

through years of experience that would normally be acquired through

formal technical training.

Electric Drives

and Controls

1-5Bosch Rexroth AGPSI 6500.xxx1070087059 / 02

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

cause serious personal injury!

Therefore, persons with pacemakers must stay clear of resistance

welding systems.

We recommend that warning sings as per DIN 40023 are posted at

every entrance to manufacturing shops housing resistance-wel-

ding equipment.

No entry for persons with cardiac

pacemakers!

Danger!

Please note our comprehensive range of training courses. More infor-

mation is available from our training center (Phone: +49 (6062) 78-258).

1-6 Electric Drives

and Controls

Bosch Rexroth AG PSI 6500.xxx 1070087059 / 02

Safety Instructions

1.5 Installation and Assembly

DANGEROUS ELECTRICAL VOLTAGE

Danger of life during installation work while systems are switched

on!

Make sure that all plant sections undergoing operations during

the installation are de-energized and sufficiently protected

against accidental reclosing!

DANGER

Non-workmanlike installation or mounting may lead to personal

injury or damage to property.

Therefore, it is essential that you take the technical data (environ-

mental conditions) into account for installation or mounting.

Installation or mounting must be carried out by skilled personnel

only.

DANGER

Danger of injury and of damage to property through incorrect in-

stallation!

Devices and, in particular, operating means, must be installed so

as to be properly safeguarded against unintentional operation or

contact.

DANGER

Danger of personal injury and damage to property through inade-

quate fastening!

The place for installing the modules, and their method of faste-

ning, must be suitable for their weight!

DANGER

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.

DANGER

The safety and accident prevention regulations as amended shall

be observed!

Wear a protective helmet, safety shoes and gloves!

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