TI PSL 2000/3000 Power Supply Module PSL 2000/3000

TI PSL 2000/3000

Power Supply Module PSL 2000/3000

TI PSL 2000/3000

Power Supply Module PSL 2000/3000Technicallnformation1070078066-104 (09.93) GB

Rag. Nr. 16149-03

© 1993

Alle Rechte bei Robert Bosch GmbH,auch für den Fall von Schutzrechtsanmeldungen.

Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

Schutzgebühr 5.- DM

1 Safety instruetions 1

4 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21

3 Power supply modules PSL 3000 13

6

9

6

6

5

23

24

23

18

19

17

16

14

14

14

13

11

10

PSL 200013000Contents

· .

· .

· .

· .

Power supply moduleType PSL 200013000

............................................................................... ' .

Water connection .

Mains connection

Transformer connection .

Technical data of PSL 3200.00 W


Dimensions .


Shared Data .

PSL 3000 types .

Technical Data .

Construction .

Construction .

Dimensions .

Technical Oets of PSL 2100.00 W

Technical Date .

PSL 2000 Types .

5.3

Connection Instructions

5.1

5.2

3.3.2

3.3.4

3.3.3

3.4

3.3.1

3.3

3.2

3.1

2.4

2.1

2.3.4 Technical Data of PSL 2200.00 W

2.3

2.3.2 Technical Osta of PSL 2040.00 L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7

2.3.1 Shared Osta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6


2.3.3

2.2

Please read the safety instructions prior 10 installation and commissioning end confirm by signing!

P.-No. 3404lE

5

i§ BOSCHFlexible Automation

2 PSL 2000 Power supply modules 5



C§ BOSCHRexible Automation

5.4 Connection to tirner Module "X1" Terminal Connector 26

5.4.1

5.4.2

5.4.3

5.5

Connection 10 tirner modules type PSS 2000 .

Connection 10 timer roodules type E...DYD .

Connection 10 tirner modules type PE (ZPS) .

Mains Vottage Selection .

29

30

30

31

6 Maintenance 33

7 Dimensioning Instructions 35

7.1

7.2

Load Diagram .

Power Lass diagram .

35

38

8 Fault messages , 41

8.1

8.2

Temperature monitoring .

Protective circuit against transient overvoltages .

41

41

9 Accessories 43

9.1 Water saving device 43

9.2 Shock·protection covers . 44

11 P.-No.39041E




For further information with respect to the PS 2000 series, the following documentation is available:

1. Brochure PS 2000

2. TechnicallnforrnationPSS w1th PSP 2000

3. TechnlcallnformationPSL 2000l300O

4. Operating and Pro-gramming ManualPSP 2000

5. TechnicallnformatlonRnd OperatingInstructions PSR

6. TechnicallnformatlonPSS 2081 ...8

7. Operating and Pro-gramming ManualPSS 2081 ••.8

P.-No. 39041E

System descriptlon, construction, dimensions, functionand colored illustrations.P.-No.3901

Conslruclion, dimensions, technical deta, installation andconnection.P.-No.3903

Construction, dimensions, installation and connection.P.-No.3904

Handling of programming module and programming theweid data according 10 flew diagram card.P.-No.3902

Application, funetion, operation, and programming of the measuring endclosed-loop control processesP.-No.4028

Construction, dimensions, function, options, installation, and connectionP.-No.3944

Handling and programming of the weid data using thePR 81 hand-held programming unitP.-No.3957

111

~ BOSCHAexible Automation

Power supply moduleType PSL 2000/3000

Safelyinstructions

1. Safety instructionsPlease read this Technical Information betore putling the PSL 200013000Power supply modules inta operation.

Store this Technicallnfonnation in a place 10 which all users have access alany time.

Normal use

This Technical Information contains all information concerning the normal usaof the produets described. The products described seIVe tor precise delayedtiring of half-waves of welding transformers.

The products described ware developed, manufactured, tested and documented in compliance with all applicable safety standards. Under thecondition Ihat the handling inslructions and safety instruetions issued forengineering, installation end normal use are observed, the product will usuallycausa no danger tor personnel or property.

Qualified personnal

This Technicallnforrnation is designed for welding technicians and engineerswith special training. They require specific knowledge on the hardwarecomponents of the PSS... timer, the power suppJy module and the weldingtransformer.

Any interventions in the hardware and software of our products may only bemade by our specialized staft unless otherwise described in the presentdocumentation.

Unqualified interventions in the hardware or software or noncompliance withthe wamings contained in the present documentation or on the product itselfmay result in severe injuries or damages to persons or property.

The term qualified personnel refers to

• engineering person",.1 familiar with the safety standards of the electricaland automation technology.

• operating personr181 who has been instructed for operating installationsin resistance welding technology and who know the contents of the presentdocumentation as far as operation is concemed.

• commissioning personnel entitled to commission, earth and labelelectricaJ circuits and equipmentlsystems in compliance with the standardsof safety technology.

P.-No. 39041E 1

Safetyinstructions


@I BOSCHAexible Automation

Warnings contained inthis Technical Information

The following safety instructions in complianc8 with the CE standardmay generally be given in our Technical Infonnation brochures. theirmeaning ls as folIows:

2

DANGERThis symbol will be used wherever the failure to observe the correspondingsafety measures may rasult in death, severe bodlly injury or considerabledamage to property. These measures include the following:

• Safety disconnection

• Protect against reclosing

• Verify safe isolation from supply

• Earthing and short-circuiting

• Cover or barrier adjacent live parts

WARNINGThis symbol will be used wherever insufficient or lacking compliance with theinstruetions rnay result in personal injury.

ATTENTIONThis symbol will be used wherever insutficient or lacking compliance with theinstructions may result in damage to equipment or flies.

NOTEThis symbol will be used to infarrn the user an special features.

P.-No.3900E

@I BOSCHRexible AlJtomation

Warnings at the timer components


Safelyinslructions

The following wamings and notes may be attached 10 the aetual tirnercomponents which are designed 10 införm the user on certain circumstances.

P. -No. 3904JE

•

Warning of dangerous voltages!

Waming of dangers in oonnection with accumulators!

Components subject 10 electrostatic induction!

Disconnect mains plug before opening!

Pin only designed tor connecting the PE (protective earth) oonductor!

Only tor connecting a shield conduetor!

3

4


i§I BOSCHFlexible Automation

P.-No. 3904/E

@ BoseHAexible Automation


PSL 2000Conslruclion

2 PSL 2000 Power supply modules

2.1 Construction The power supply modules of the PSL 2000 senes contain the power thyristorwhich selVes as an 8.C. power controller and the mains supply for the timerand programming module.

The power supply modules are mounted 10 a metal base frame and can beeither installed directly in welding machines cr switch cabinets, or in separatehousings.

r------------------ Mains connection trom above,

also possible from below

r------------- Plexiglass covering

~==J~====~===~==IT==::~---Mounting angle••••••••••••••••••••••••••••••••••••..........•............... .••••••••••••••••••••••••••• ••••••••............. ,...•......••.....••..•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• ••••••••........................... .••••••••••••••••••••••••••••••••••••.........................................•...•..• .@OLl

riifi~i=~~---Load diagram

Yellow LED tor incoming firingpulses

'------;:=;:=~f_---Mains supply unit for timer

J 0 111 and programming module

o +----+IJltt----,Fuses F1 and F2 foro supply voltages

10-poJe terminal connector "X1"10 timer unit

••••••••••••••••••••••••••••••••••••...............................................................••........................................... ~~~I ~.................................... ,....................................••••••••••••••••••••••••••••••••••••••• ••••••••• •••••• .Covering plate for options::: BOSCH ,Q ::::::

m .::::::::""=ci!!:=.!":":rtf--l~-+----+*"----- Weldirig Iransformer connection:::::::::::::::::::::::::::::::::::: u11Y1:::::::::::::::::::::::::::::::::::: 0

Water supply inletloutlet

Fig.2.1

P.-No. 39041E

PSL 2000

5

PSL 2000Technlcal data

2.2 PSL 2000 Types



Type name Drawing no. Cooling Power Operating[kVA}" voltage

PSL 2040.00 L 211 052186 Air 40 220 V

PSL 2100.00 W 211 052187 Water 100 up 10

PSL 2200.00 W 211052188 Water 200 550 V

PSL 2500.00 W 211 052824 Waler 500

* approximately corresponds 10 the output of the welding transformer typesalSO % duty cycle (ED).

2.3 Technical Osts

2.3.1 Shared Data

Type of construction Thyristor 8.0. power controller as buih-inmodule in open construction(protection standard IP 00).

Connected voltage 22013801415-4401500-550 V, 50160 Hz(Set 10 380 V when delivered, can bechanged over 10 other voltages by cuslorner,section 5.5), admissible voltage variations+15%, -20%

Percentage duty cycle independent from the possible thyristorswitching currents, limited by built-in deexcitation resistorup 10 380 V-I 00% duty cycleup 10 440 V - 75% duty cycleup to 550 V - 500/0 duty cycle(integration time s; 1 minute)

Thyristor off-state 1600 Vvoltage

Supply voltage tor PSS 27 V a.c. (fuse M 1.25 A)timer module 24 V d.c. (fuse M 2.5 A)

Overvohage protection by MOV (metal-oxide varistor)

6 P.-No. 39041E

i§ BOSCHFlexible ALJtomation



2.3.2 Technical Date cf PSL 2040.00 L

Installed load tor welding transformers up to approx. 40 kVA(at 380 V).Max. admissible switching currents depend onduty eyde and weid times (see load diagram)

Cooling

Ambient temperature

Air cooling (self~convection). Hest sink temperature max. 80° C, thermostatically controlled. Load capacity depends on max. heatsink temperature (see diagram Fig. 7.4).

max. 55" C(valid for load diagram; observe installationinstructions)

0I I 11I PSL 2040

)5 ayc.

0

10

25

50 ---100" ,," .\,

'-:

o~ ~:::s55°C

'"'

750

250

500

100

125

,"MS(A

o 2 5 10 20 50 100

ED(%)

Fig.2.2 Load Diag'ram

P. -No. 3904lE 7

PSL 2000Technical data


~ BOSCHFlexible Automation

2.3.3 Technical Data ot PSL 2100.00 W

Installed load

Cooling

Water connection

Ambient temperature

tor welding transformers up 10 approx.100 kVA (at 380 V).Max. admissible switching currents depend onduty cycle and weid limes (see load diagram)

Water coolingMax. water inlet terrperature 40° C,water flew rate ;;:: 4 liters/min.,differential inlet-ouUet ~ 1 bar at 4 liters/min.Cooling thermostatically controlled

Inlet and autletExternal thread G 318", taper steps 10DIN 8542

max. 55° C(valid tor load diagram; observe installationinstructions)

1

PSL 2100

1 cyc.

ih

'"5, C"'-

10 ."-20

3020 ---t--100

(IJOI'l:I

öt:4 Vmin:s:;40°CAAA

1 1 1 11

SOOO

"MS(A)

4000

3000

2000

1000

o 2 5 10 20 so 100

ED (%)

8

Fig.2.3 Load Diagram

P.-No. 39041E

§ BOSCHFlexible Automation



2.3.4 Technlcal Data of PSL 2200.00 W

Installed load

Cooling

Water connection

Ambient temperature

tor welding transformers up 10 approx.200 kVA (at 380 V).Max. admissible switching currents depend onduty cycle and weid limes (see Ioad diagram)

Water coolingMax. water inlet temperature 40° C,water flow rate::?: 4 liters/min.,differential inlet·outlet :s; 1 bar al 4 liters/min.Cooling thermostatically controlled

lnlel and autlet:Extemal thread G 318", taper steps 10DIN 8542

max. 60" C(valid 10r load diagram; observe installationinstructions)

I I 11

PSL 2200

1eyc.

L""3"-5 ::-...10

20--" i'--i'--

30 I"--'50

'00

o o::4I1min:s40"C -A.A.A

I 1111 11

IAMS (A)

12000

11000

10000

9000

8000

7000

6000

5000

4000

3000

2000

1000

o 2 5 10 20 50 100

ED (%)

P.-No.39041E


9

PSL 2000Technlcal dala


@1 BaSCHFlexible Automation


Installed load

Cooling

Water connection

Ambient temperature

tor welding transformers up 10 approx.500 kVA (at 380 V).Max. admissible switching currents depend onduty cycle and weid limes (see Ioad diagram)

Water coolingMax. water inlat temperature 40° C,water flow rate ~ 4 Iiters/min.,differential inlet-outlet :5 1 bar al 4 liters/min.Cooling thermostatically controlled

Inlet and outlat:External thread G 318u

, taper steps 10DIN 8542

max. 60° C(valid for load diagram; observe installationinstruotions)

10


5 10 20 50 100

ED (%)

P.-No.3904/E

Iij) BOSCHRexible Automation


PSL 2000Dimensions

2.4 Dimensions

The dimensions of Ihe PSL 2000 power supply modules onfy differ in theirwidths. All other dimensions are identical.

AB C

III

IIIIIIII

"'I <0I '"0> "'.__.-_.__ .----'-.

0 0> I

'" '" 00 I

I0 I

II

~IIIIII

0 I

7 2....

"' I I=I I

=====-- =0 "' ='" ~ ='" '" =

- =I ===

fl I

Power supply Dimensions Weightmodule type

A B Ckg

PSL 2040.00 L 234 120 57 11.3

PSL 2100.00 W 234 120 57 11.8

PSL 2200.00 W 294 180 57 11.8

PSL 2500.00 W 294 180 57 12.0

Fig. 2.6 Dimensions

P. -No. 39041E 11

12


@> BOSCHFlexible Automation

P.-No.39041E

@ BOSCHFlexible Automation


PSL 3000Conslruclion

3 Power supply modules PSL 3000

3.1 Construction

The power end supply modules of the PSL 3000 series are equipped withthree power thyristors serving as three-phase 8.C. power controllers 10r threewelding transformers connected in series. The integrated adapter module setses a firing (weid) pulse unit, controlling the three thyristor blocks. The powersupply modules also provide power supply for the timer end programmingmodule.

The power supply modules are mounted 10 a metal base frame end can beeither installed directly in welding machines or switch cabinets, or in separatehousings.

Mains connection from above Load diagram

•oo

Mains supply unk tor the timerand programming module

LED disp~ayMounting angle

I~ ~~I!~IIIIIr:mill_~:.llm_..~r~

@o" "

Plexiglass cover

•

Water connection: Welding transformer connection uIv

inleVoutletFuses F1 and F2 forsupply voltages

lO-pole "Xl" terminal connectortor timer unit

Blanking platetor options

Fig.3.1 PSL 3000

P.-No.39041E 13


3.2 PSL 3000 types



Type name Drawing no. Cooling Power OperatingIkVAj" voltage

PSL 3100.00 W 052115 Water 3 x 100 220 V

PSL 3200.00 W 052791 Water 3x200 up 10

PSL 3500.00 W 052792 Water 3 x 500 550 V

* approximately corresponds 10 the power of the welding transformer typesot 50% duty cycle (ED).

3.3 Technical Oata

3.3.1 Shared Data

14

Type of construction

Connected vohage

Percentage duty cycle

Thyristor off·statevohage

Supply vohage for PSStimer module

Overvohage protection

Three-phase thyristor 8.0. power controlleras built-in module in open construetion(protection standard IP 00).

22013801415-4401500-550 V, 50160 Hz(Set to 380 V when defivered, can bechanged over 10 other vottages by customer,section 5.5), admissible voltage variations+15%, -20%

independent from the possible thyristorswitching currents, limited by built-in deexcitation resistorup 10 380 V-I 00% duty cycleup 10 440 V - 75% duty cycleup 10 550 V - 50% duty cycle(integration time S" 1 minute)

1600 V

27 V o,c. (Iuse M 1.25 A)24 V d.c. ~use M 2.5 A)

by MOV (metaI-oxide varistor)

P.-No.3904/E



PSL 3000Construetlon

P.-No. 3904/E

Monitoring

Cooling

Water connection

Ambient temperature

The 3·phase adapter is integrated into thepower supply module, its functions include:

• phase monitoring, clockwise rotating phasesequenceDisplay via green lED "3- 11

• Iogic voltagelphase monitoring +12V,Display via green LED •+12V·

- weid pulses (5 kHz)Display via 3 x yeJlow LED's

- water 00011n9

- max. water inlet temperature 40°C

• water flow rate 2': 8 liters/minute

• differential inlet-outlet :s: 1 bar si 8liters/minute

- cooling monitored by thermostat (bimetallicswitch opens at 56CC, ± SOC)

inlet end outlet: G 318" external threadtaper steps according 10 DIN 8542

max. 60° C(observe installation instructions)

15

PSL 3000Technical dala


§ BOSCHFlexible Automation

3.3.2 Technlcal dala of PSL 3100.00 W

lnstalled load

Electrical connection

Connection 10 timer

tor welding transformers up 10 approx.100 kVA (at 380 V), the max. admissiblesw~ching currents depend on duty cycle andweid limes (see load diagram)

meins connection (Ll/l2IL3) and protectiveearth conductor trom aboveoutgoing transfonner feedar 3 x UV and pro~

lective conductor trom below via threadedI?ins MB

via 10-pole terminal connector (cable 10 x1.5 mm2 up 10 max. 75 m).When operatecl with tirners of the ES1 .. andZPS senes, connectors B 10 10 are not usecl.

5000

IRMS PSL 3100(A)

4000 1 cyc.

5

300010

20

30

20

2000 100

10001--+-++H-++++--+--'

Ö ",6 Vmins40°C f-+t+t-f11--1-----< .A.A..A.

o 2 5 10 20 50 100

ED (%)

16

Fig.3.2 Load diagram

P. -No. 3904/E

@ BOSCHRexible Automation


PSL 3000Conslruetlon

3.3.3 Technlcal dala of PSL 3200.00 W

Installed load

Eleclrical connection

Connection 10 timer

for welding transformers up 10 approx.200 kVA (at 380 V), the max. admissibleswitching currents depend on duty cycle andweid times (see load diagram)

mains connection (Ll/L.2IL3) and protectiveearth conductor trom aboveoutgoing transformer teeder 3 x UV and protective conductor from below via threadedpins M12

via 1o-pole terminal connector (cable 10 x1.5 mni2 up 10 max. 75 m).When operated with tirners of the ES1 .. andZPS series, connectors 8 10 10 are not used.

I 11

PSL 3200

1 cyc.

2"3." '"5 0-10

20

30

50

'00

Q ;;,:8 J/min.::s40°C I-AA.A.

111

IRMS (A)

12000

11000

10000

9000

8000

7000

6000

5000

4000

3000

2000

1000

o 2 5 10 20 50 100

ED (%)

P.-No.39041E

Fig.3.3 Load diagram

17



@ BOSCHFlexible Automabon

3.3.4 Technical data of PSL 3500.00 W

Installed load

Electrical connection

Conneclion 10 timer

for welding transformers up 10 approx.500 kVA (al 380 V), Ihe max. admissibleswitching cUlTents depend on duty cycle andweid limes (see load diagram)

mains connection (Ll/L2IL3) and protectiveearth conduetor from aboveoutgoing transformer feeder 3 x UV and pro·tective conductor tram below via threadedpins M12

via 10-poJe terminal connector (cable 10 x1.5 mm2 up 10 max. 75 m).When operated with tirners of lhe Es1 .. endZPS series, connectors 8 10 10 are not und.

PSL 3500

18

Fig.3.4

IRMS (A)1 cyc.

12000

211000 3

10000 5

9000 10

8000 20

7000 30

600050

5000 100

4000

3000

2000

1000

0 2

Load diagram

5 10 20 50 100

ED (%)

P.-No.3904/E

§i BOSCHAexible Automation

3.4 Dimensions


PSL 3000Dimensions

The dimensions of the PSL 3000 power supp/y modules only differ in theirwidths. All other dimensions are identical.

BA

D

oo

o

o

•

nl nnl nl =

I======

0 ==.. =N

I I=-

I ==

_'-L

2

Fig. 3.5 Dimensions

Power supply Dimensions Weightmodule type

A B C Dkg

PSL 3100.00 W 425 300 -- 57 26.3

PSL 3200.00 W 624 330 180 57 27.5

PSL 3500.00 W 624 330 180 57 27.7

P.-No. 3904/E 19

20

Power supply moduleType PSL 200013000 §i BOSCH

Flexible Automation

P.-No.39041E

@I BOSCHRexible Automation


PSL 200013000Installation Instructions

4 Installation Instructions

PSL 2000 )(PSL 3000 ><

The power supply modules are designed to be installed in switch cabinets ormachine housings.

In any case it must be made sure that the space intended for installation isin accordance with the applicable regulations of the protection standards.

DANGERThe protection standard of PSL 2000/3000 is IP 00. Please note thai "Shockprotection covers" are available as accessories (see chapter 9).

The power supply module is best positioned on a rnounting plate andfastened by means of botts M 6. The corresponding dimensions tor thefastening holes are shown in the "Dimensions" section.

NOTE11 the PSS... timer module is 10 be installed in the direct vicinity of the powersuppty module, then the timer module should be placed on the rlght handside of the power supply module (see Fig. 4.1).

Minimum lree spacefor ventilaUon and I

wiring ~ 100 mm

~CK8

~000

~~)~~

,

,oo

PSL PSS I_._._[_.- t-l-,-

_·_·_·_·_·_·-1-

Fig.4.1 Arrangement on the mounting plate

P.-No.3904/E 21

PSL 200013000Installation instructions


§ BOSeHFlexible Automation

22

In order 10 make sure that the wiring tor connecting the power supply modulecan be easily calTied out, observe the necessary distance between the upperand lowar module edge and the housing wall. We recommend keeping amin.distance of 100 mm each. In the case cf smeller distances, there is dangerof heat accurnulation which may causa failures of the units.

11 air-coolecl power supply modules are used, it must be possible 10 dissipateIhe heat aceumulated through power Joss by means of the sUlToundinghousing.

The power losses 10rdifferent operating conditions are indicated in the powerlass diagram (see Fig. 7.4). The max. airtemperature in the housing must notexceed 55°C. The cooling effect of the surrounding housing must be checked.

ATlENTION11 water-cooled power supply modules are used, it must be made sure that,in the oase 01 leaks in the cooling water system, leaking cooling water oannotdamage other components (if necessary, provide for appropriate protection).

P.-No. 39041E

I§ BOSCHRexible Automation


PSL 200013000ConnectIon instructlons

5 Connection InstructionsDANGER

Read and observe the safety instructions and swltch off power switchbefore connecting 10 malns!

• Working with high voltages may result in death, severe bodily injury orconsiderable damage to property unless the appropriate precautions havebeen taken. Check the -Safe1y instructions· chapter (page 2) tor the 5components of the safety measures !

• Please note the conneclion diagram on the plexiglass cover. Theplexiglass cover should be removed tor making the connection.

5.1 Mains connection

PSL 2000

• Protec1lve earth conductor (PE) can only be connecled tram above

• Mains connection (L11l2) can be made from above or tram below

PSL 3000

• Protective earth conductor (PE) can only be connected trom above

• Mains connection (L1/L2Il3) can only be made from above

~ 000PE Ll L2 L3

o

oo

o

v3 u1

00v1 u2

00v2 u3

0010 timer unit

P.-No. 3904lE

Fig.5.1 Mains connection of PSL 3000

23

PSL 200013000Connection inslructions



5.2 Transformer connection

The pin assignment of the power supply module is shown on the plexiglasscover. Far convenient connection, the plexiglass cover should be removed.

PSL 2000 I><PSL 3000

PSL 2000

Connection is effected by means of cable lugs (not included in the detivery)for threaded bolts:

• Me

• M12

tor PSL 2040.00 UPSL 2100.00 W

tor PSL 2200.00 W/PSL 2500.00 W

Pin assignment for transfonner:

• Transformer Tl: connection to ullvl

PSL 2000PSL 3000 IX

• Protective earth conductor (PE) for transformer connected 10 separateearthing bar inside the switch cabinet.

NOTEMake sure that the threaded joints are properly tightened. 11 necessary, holdonto other side with second wrench.

PSL 3000

Connection is effected by means of cable lugs (not included in the delivery)for threaded bolts:

• Me

• M12

tor PSL 3100.00 W

tor PSL 3200.00 W/PSL 3500.00 W

Pin assignment for transfonners (see Fig. 5.1):

• Transformer Tl:

• Transformer T2:

• Transfonner T3:

connection 10 ullvl

connection to u2lv2

connection to u3lv3

24

• Protective earth conductor (PE) for transformer connected to separateearthing bar inside the switch ca.binet

NOTEMake sure that the threaded joints are properly tightened. If necessary, holdonto other side with second wrench.

P.-No.3904lE

@ BOSCHAexible Automation

5.3 Water connection


PSL 200013000Connection instructlons

PSL2000 )(PSL 3000 ><

Waler connection is floating, it is made al the boUorn siete of the powersupply module:

• water inlet al left-hand side

• water autist al right-hand side

• external thread G 3/8"

• taper steps according 10 DIN 8542

ATTENTIONPrior 10 swilching on the mains voltage, check threadecl joints 10r tightness.Ensure required water flow rate. (See applicable technical data ·eoeling".)

1\-_..,,------,n~~i~miiiiiiHmiiii~miiii::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::

..............................::::::::::m:::::::::::::::::::::::::::m::::::::::::::m..............................::; .mBOSCH 4}I::mm!:::::!mmmm!m................•.••••.•._...

..................................

t

Io

oo

o

nL---J

P.-No. 39041E

Fig.5.2

Water inlet

Water connection

Water outlet

25

PSL 200013000Connection Instructions


§l BOSCHFlexible Automation

5.4 Connection to Timer Module,"X1" Terminal Connector

PSL 2000 .,..PSL 3000

The following BoseH timer modules can be connected 10 the PSL 200013000power supply modules:

• P$S 2000 versions (standard)

• E. ...DyD versions

• PE...(ZPS) versions

• basically all timer types lhat receive their 27 V 8.0. supply trom the powerand supply unit.

The connection between the power supply module and the timer module ismade via terminal conneclor "Xl". The connection cable is not included inthe detivery.

• Connection is effected 1 10 1, i.B. terminal 1 of power supply module 10terminal 1 of timer module.

• The connection must be a 10-pole connection (terminals included indelivery).

The required cross-seclion is:

• uptol0m~1 mm2

• up 10 75 m = 1.5 mm2

The max. clampable wire cross-section is 1.5 rnnr.

NOTEProvide wire ends with end sleeves. Properly tighten the terminals.

0

00

:mim Xl.::::m!!:::::

m~ 0

26

Fig.5.3 "Xl" lenninal connector

P.-No.3904/E

@} BOSCHAexible Automation


PSL 200013000Conneetlon instruclions

The block diagram shown in Fig. 5.4 illustrates the principle 01 the circuft 01the PSL 2000 power supply module.

At;osO-473 :'1 6

I firing. - 5 'i.2!A2 8 ,.....

I - l2IOsO";;;;:- - 1 I 91

Isupply ~Ov- - ___ I

X1 terminal connectorI 220V- ~ mains

380V- 9_ vl11 440V- 5

27'1- 21: soov-I I Rl

(0)3

1_ I I Ll

41- I I ulthermo 5r.. I I

, 61- ~6 , 11~_firing 7._ -7 firing

12f-.ß- ...

-1+24V", ext 81- I I

OVeXl 9_I I 0(0)I

'at ~ 4)._------

P.-No. 3904lE

Fig.5.4 Block diagram cf PSL 2000

27

PSL 200013000Connectlon instructlons


@ BOSCHRexible Automation

The block diagram shown in Fig. 5.5 illustrates the principle of the circuit ofthe PSL 3000 power supply module. The jumper on the firing board must bechanged over, depending on the tirner module connected.

4)--0'"A3----,10SO 233adapter

I

, tr I

'- I

A1röSö267-' 1 "v",,--,-o l1~c=+1~-4:;-1 u1I firing -~ 2 I

4p X1~_ -. I Ir 1# 7 I I

'-H·12V:t:t=j~~~['_-oI

I

I ++- 3""

I ", r R7

~ '4' n~~-~~"'---1 '-'''' 8 V21060269. ~ :~t:ttt~~~-~-1 u2ISUPPIy I 221 .." 9 I

IoV- - I

220V- 2 mains I380V- 3 23_ 1 I

,1 440V- 4 24L 11 I27V-__-"2C soov:ls 15 ~_ ·fLL.IIt::::':'1R;8?=~I~-<: v,e>'--~:'il- _~ 25 _

I- _ 9 thermo 26 - :~~s~~R~~i~ lthermo 51_ V3 3

I "3+,__->;61- ~ 6 + 31 ~ I

firing 7 _ - 7 llnng 30"'- I~-41- ~- r I

+24V=o,1 81- W :~:1tt=;~f'--0OVexl__-,9<,- _ 10 29 _ _ _ _ I

--""Qt__ ,j11 02:~:t 32~_ J R9 V2

t<r1.l'I33\

Xl tenninsl connector

jumper

Fig.5.5 Block diagram 01 PSL 3000

28 P.·No.39041E



PSL 200013000Conneetlon instruetlons

PSL2000PSL3000 IX

With the PSL 3000 power supply module, the jumper on the firing boardshown in Figs. 5.5 end 5.6 must be changed over, depending on the timermodule connected.

• PSS 2000...

• E..DYD, PE... (ZPS)

jumper between x212 and x213

jumper between x2l1 and x2f2

Fig.5.6

0

~I=>0~0

00 ~0",

0 x200 00

Jumper on the firing board

5,4.1 Connectlon to timer modules type PSS 2000

t+24V d#-, (power supp'f9}

IX1 ~inal connector

<!IJ-<!IJ.<!IJ.lIIl~

lIIl~

"",.lIIl~

"",.

""'.""~=

27V~

tefnperalure contsct

•flrlng -

not used

PSS 2000 timer module

I..._...• lIIl'"

pos. 0-7 of moduJe.. l:.J.. löIc:k. depending on.. lIIl'" limer posilion

lIIJ·lIIJ~

• lIIl·- .:J.~~

P.-No. 39041E

Fig.5.7 Pin assignment

29

PSL 200013000Conneetion instruetions



5.4.2 Conneetion 10 Ilmer modules Iype E...DYD

IpSL2000~PSL 3000

IX1 terminal conneclor

~-~N

~N

"'"IIIlN... .:: inotused.0 S

27V "-

lemperature conlacf

•IlrIn!! '

Timer module E.. .DYDI

Round connector X3

.. ~ A

.. <: 0_(_ S.. (_ T• <: u


Terminal conneclcr inpos. Q.7ollTlDliJ"rack. depending onlimer pcsilion

5.4.3 Conneetlon 10 limer modules Iype PE... (ZPS)

Tirner module PE 1681.xx B

Xl 18rmiJI connector r~

- ~-0127V "-(I[] .... e:z00'" @ -12'3c.:J .. temperature oontact .... 12' 4liIl'" -05I::.J '" fl~ 06

::inOfUSed 07

liil 0 S

30


P.-No. 39041E

§i BOSCHFlexible Automation


PSL 200013000Conneetlon instruclions

5.5 Mains Voltage Selection

When delivered, all power supply modules are set tor a connected vottage of380 V. 11 necessary, the customer can set the following voltages:

• 220 V

• 415-440V

• 500-550V

Admissible vortage variations: +15 %, ·20 %.

DANGERMake sure thai the mains voltage is set when the unit is de-energized. Usainsulated lools.

&I Ue I~

I 500-550V

415-440V

Change over the voltage------\\'-._~- 380Vconnections here. 220V

~

Don't forget 10 enter the -------.....:~~~~~I~·~~v~'Lselected voltage here.

Fig. 5.10 Top view 01 power supply module

P.-No. 3904lE 31

32



P. -No. 3904/E

§ BOSCHAexible Automation

6 Maintenance


PSL 200013000Malntenance

The power supply module is maintenance·free. However, a faully connectioncan causa an activation of the protective fuses in the device. If necessary,these can be replaced by the cuslorner himself (see Fig. 6.1 and Fig. 6.2).

Any other defects should be remedied by the manufacturer.

DANGERDisconnect from mains before searching faults in the power supply module.Cautionl High voltage!

F2 Mains fuse link and MOV

•"1--1==f:'#j=+~ monitoring F1, F2, ...:6.3 A; 500 V; SF (super-quiek-soling):(6.3 x 32) mm

o

Fig.6.1 Power supply roodule, firing board

Fuse F1 for 27 V 8.0. mains supply(timer module):

1.25 A; medium slow.-blow; (5 x 20) mm

Fuse F2 for +24 V d.c. supply voltage(timer module):

2.5 A; medium slow-blow; (5 x 20) mm

P.-No.3904/E

Rg.6.2 Power supply module, ~X1" terminal conneetor

33

34


§ BOSeHFle~ible Automation

P.-No. 3904/E



PSL 200013000Dimenslonlng instruetlons

7 Dimensioning Instructions

7.1 Load Diagram

PSL2000PSL 3000

In principle, the load capacity of thyristors is predetennlned by the typeallocation 10 specifiecl max. transformer sizes.

However, the actual load of the thyristor should be checked by the user inaach specific oase.

Fer this purpose, the Ioad diagram, which is available tor aach individualthyristor. is used. This load dIagram indicates the effective currents thethyristor is capable of sw~chingas a function of the weid time and the dutycycle si max. cooling agent temperature (air cr water) and minimal flow ratein the oase of water.

Effective current IRMS A

Weid time t, oyale

Duty cycle ED %

Cooling agent temperature oeCooling water flew rate Vmin

Far determining the percentage duty eyele (ED), the weid time 15 and the weidcycle time Isp must be known.

1--------15-----1

f-----------tsp-----------1

Fig.7.1 Weid time and weid cycle time

The duty cycle (ED) is calculated as folIows:

"100%=50%ED =

tED = -'- .. 100 %

t,p

Example Fig. 7.1: (ts = 2 cyc., tsp = 4 cyc.) results in a duty cycle ED:

2 cyc.

4 cyc.

P.-No.39041E 35

PSL 200013000Dimenslonlng instructions



Example1:

If there are different weId times end cycle times at ane welding station, Ihelongest weid time and Ihe shortest cycle time (if necessary, by adding thelongesl weid time end Ihe shartesl pause time) are 10 be used 10r calculatingthe ED.

After Ihe duty cycle has been calculated, lhe load diagram can be used forchecking Ihe correct dimensioning of lhe thyristors.

Weid data of machine:

• Weid time t..

• Duty cycle ED

• Current

::: 10 cyc.

::: 10 %

= SOCA

The interseclion ED --> JAMS found in lhe diagram tor Ihe PSl 2040 powersupply module (Fig. 7.2) is still belowthe 10-eycJe curvs. This means thai Ihethyristor is correclly dimensionecl.

The dimensioning of other thyristors or power supply modules is verifiedanalogously on Ihe basis of Ihe respective Ioad diagrams.

1250

IRMS

(Al

1000

750

500

250

I PSL 20405~C.

1.....10~

25

50 "-100 r--..

""'-'-" ,"

1 "- .,l'~"

O~ •f---s55°C

---

36

Fig.7.2

o 2

load diagram

5 10 20 50 100

ED(%)

P.-No. 39041E

§I BOSCHAe)(ible Automation

Example 2:


Weid date of machine:

PSL 200013000Dimenslonlng Instruetions

• Weid time ~

• Duty cycle ED

• Current

= 100cyc.

= 10 %

.750 A

The intersection ED ••> IRMS found in the diagram for the PSL 2040 powersupply module {Fig. 7.3} is above the cUlVe tor 100 cycles. This means thatthe thyristor load is tao high.

NOTEWeid limes;:: 100 cycles are 10 be regarded as permanent current thai shouldbe read off al the 100% ED point cf the load diagrarn.

The dimensioning of ether thyristors or power supply modules is verifiedanalogously on the basis of the respective Ioad diagrams.

1250

IAMS

(A)

1000

750

500

250

_;",,1 PSL 2040

10

25

50

----10. 2

® ---- .... I"'.\

"O~ ~:s55°C

"

P. -No. 39041E

Fig.7.3

o 2

Load diagram

5 10 20 50 100

ED(%)

37

PSL 200013000Dimensloning inslruetions

Power suppiy moduleType PSL 200013000


7.2 Power LossDiagram

'lOO%ED150

In the case cf air-eooled power supply unils, Ihe thyristors are cooled by acorresponding heat sink.

During this process, Ihe effectiveness of cooling depends on Ihe temperatureof Ihe ambient air. As an upper temperature limit, an ambient temperature cf550C is assumed in Ihe power loss diagram (as weil as in Ihe load diagram).

Depending on Ihe thyristor load, Ihan a higher heat-sink temperature occurs.By design, Ihe max. heat-sink temperalure is set 10 BOOC end must not beexceeded during operation, since otherwise Ihe monitoring thermostat willswitch off and it will not be possible 10 continue operation until furtherappropriate down-eooling has taken piece.

In order 10 ensure Ihat Ihe max. heat-sink temperature is not reached, thepower lass diagram shown in Rg. 7.4 is used. If the operating vaJues of theduty cycle and the weid current are within the dotted range, a heat~sink

temperature of 80°C will not be exceeded.

.inadmisslble range.5O%ED

2O%ED

100

50

o

Fig.7.4

38

Power loss diagram

4Hea! sink tempo

10%ED =8QQC

al 50°Cambient tempo

P.-No.39041E

§ BOSCHRexible Automation


PSL 200013000Dlmensionlng Inslructions

Example 3:

The following examples sarve 10 illustrate Ihe application of the power lossdiagram.

WeId data of Ihe rnachine:

• Current JRMS

• Duty cycle ED

= 300A

=20%

Example 4:

According 10 Fig. 7.4, Ihe intersection ED -> IRMS is still within the admissiblerange.

Weid data of Ihe machine:

• Gurrent IRMS

• Duty cycle ED

=400A

=20%

P.-No.39041E

According 10 Fig. 7.4, Ihe intersection ED --> IRMS is within Ihe inadmissiblerange, La. Ihe heat-sink temperature is 100 high.

The power loss dIagram can also be used for determining Ihe overall powerlass Pv (W) thai occurs during operation in Ihe power supply unit.

I1 is necessary 10 know Ihe overall power Ioss tor determining Ihe air velumerequired for cooling (cabinetlhousing size) cr for haat exchangers.

Thus, Ihe power lass under Ihe operating conditions as shown in example 3will be approx. 72 W. This power lass must be dissipated by the air cooling.

39

40



P.-No.3904/E

~ BOSCHRexible Automation


PSL 200013000Fault messages

8 Fault messagesExtensive precautions were taken tor protecting the thyristor block. TheseincJude, La., the following:

• temperalure monitoring

• protective circuit against fransient overvoltages

8.1 Temperature monitoring

PSL 2000PSL 3000

Abimetallic switch is Iocated al the thyristor block which transmjts a message10 the BOSCH control valve in the oase of overterJl)erature (O?: 56°C). As aconsequence, the BOSCH firner is inhibited, the ready signal al Ihe tirnergoes off. The taub message ·Power unit temperature fault" will be output.

Fault Cause Elimination

Power unit tempera- not enough cooling check water inlet andlure fault wafer cutlet

thyristor rating 100 calculate duty cyclesmell %, check thyristor

characteristic

8.2 Protective circuit against transient overvoltages

PSL 2000PSL 3000

In order 10 prevent the thyristor from being destroyed by overvoltages, it isprotected byan MOV (metal-oxide varistor). In the ease of overvoltages in themains (e.g. due to spurious peaks or pulses), the MOV aets as a protectivediode, eutting off the peaks.

As a result, one of the fuses on the firing boarc:l connected in series (F1, F2,...), depending on the phase relation, might melt.

Technical data of the fuse links:

• FF 6.3 A; 500V

DANGER

Size: (6.3 x 32) mm.

P.-No.3904/E

Disconnect from mains before replaclng fuses.

Read and observe the safety instructions!

Handling high voltages may involve death, severe bodily injury orconsiderable damage to property unless appropriate safety measuresare taken.

41



§l BOSCHRe~ible Automation

LED display

PSL 2000PSL 3000

In oase ons of the MOV tuses of a 3-phase power supply unit melts, the faultmessage 8t the timer will be ·Power unk temperature fault". The green LED"3- 11 on the firing board g08S off.

The green LED "3 -" g08S off:

• if ans of the 3 phases is missing,

• if the phase sequence (clockwise rotating phase sequence) is nol correct.

LED displays and thair interpretation (see Ag. 8.1):

the phase sequence js correct(clockwise rotating)

the intemal12V d.c. power supply works

phase l1 has been fired

phase L2 has been fired

phase L3 has been fired

42

Fig.8.1 LED display

P.-No.39041E

~ BOSCHAexible Automation

9 Accessories



9.1 Water saving device

PSL 2000 ,"l>('

PSL3OO0

P,-No, 39041E

This is a device thai raduees wafer consumption and prevents condensation.

The cooling wafer supply is controlled by a solenoid valve and a temperaturesensor. The waler saving device opens the cooling wafer inJet when ~35°C

(±3°C) al the thyristor block are reached and closes the cooling water supplywhen the lelll'erature is ~5°C (±4°C).

The usa of the water saving device is advisable only if the welding equipmentduty cycle is ~% ED. BOSeH therefore recommends not 10 exceed thefollowing values if the wafer saving device 1$ used:

• max. 25% ED (duty cycle)

• ~ cycles weid time wilh respect 10 the specified permanent current ofthe thyristor.

NOTEThe wafer saving device is available as arefrafit kit and can be fitted by thecustomer in all power supply unit types PSL 2100 to PSL 2500.

Part number of the water saving device:

• PSZ 2021 Lg.Nr. 063 583

The delivery includes:

• 1 pce. solenoid valve no. 064 810

• 1 pce. therrnostatic switch no. 064 813

• 1 pce. assembly instructions no. 064 814

DANGERDisconnect the unlt from malns and switch off the coollng water circuitprior to the retroflt works.

Rod and obsarve the safety InstrueUons!

• Handling high voltages may invoive dealh, severe bodily injury orconsiderable damage 10 property unless appropriate safetymeasures are taken.

43




9.2 Shock-protection covers

As an accessory, BoseH offers shock-protection kits made cf plexiglass.These kits are designed 10 protect users trom contact with live high-voltageparts of the power supply modules end 10 prevent the ingress of fareignbodies.

NOTEThe protection standard of power supply modules equlpped with shockprotection covers increases 10 IP20.

A shock-protection kit consists of two parts:

• upper shock-protection cover

• lewar shock-proteclion cover

Openings tor the cable connections are provided by means of culouts whichcan be rernoved depending on the cable diameter and cable position.

The screws of the plexiglass front piste are used for fastening the covers 10the power supply modules (see Fig. 9.1 end Fig. 9.2). Detailed mountinginstruetions will be provided together with the shock~pro1ection kits.

Fig.9.1

44

PSL 2000 Shock-protection covers

P.-No.39041E

@l BOSCHAexible Automation



Fig.9.2 PSL 3000 Shock·protection covers

Part numbers of shock-protection kits:

Power supply module Shock~protection Part numbertype cover

PSL 2040.00 L PSB401100 064 088PSL 2100.00 W

PSL 2200.00 W PSB 2001500 064 030PSL 2500.00 W

PSL 3100.00 W PSB 310 063609

PSL 3200.00 W PSB 3201350 063609PSL 3500.00 W

P.-No.3904lE 45

1070 078 065-104 (93.09) Ga TIM'S ATNWS· Pnnlad in Germany

Documents

TI PSL 2000/3000 Power Supply Module PSL 2000/3000