Rexroth Indra Control VCP 20Rexroth PSI 6xxx.000LT-IB Operator Interface Technical Information 1070087066 Edition 02II Bosch Rexroth AG Electric Drives PSI 6xxx.000 1070087066 / 02and ControlsTitle Rexroth PSI 6xxx.000LT-IB operator interfaceType of Documentation Technical InformationDocument Typecode DOK-PS6000-LT-IB*****-FK02-EN-PPurpose of Documentation The present manual provides information on●Installation and●functionalityof the “LT-IB” operator interface/parameterization software.Record of Revisions Description ReleaseNotesDate−−−−DOK-PS6000-LT-IB*****-FK02-EN-P 03.2005Copyright © Bosch Rexroth AG, 2003−2005Copying this document , giving it to others and the use orcommunication of the contents thereof without expressauthority, are forbidden. Offenders are liable for the paymentof damages. All rights are reserved in the event of the grantof a patent or the registration of a utility model or design (DIN34-1).Validity The data specified above only serve to describe theproduct. No statements concerning a certain condition orsuitability for a certain application can be derived from ourinformation. The given information does not release theuser from the obligation of own judgement and verification. Itmust be remembered that our products are subject to anatural process of wear and aging.Published by Bosch Rexroth AGPostfach 11 62D-64701 ErbachBerliner Strafle 25D-64711 ErbachTel.: +49 (0) 60 62/78-0Fax: +49 (0) 60 62/78-4 28Abt.: BRC − WS/VTRContentsContentsPage3 Operation 3−13.1 Starting / Exiting the software 3−13.2 Setting the basic parameters 3−23.3 Parameterizing the setpoint input 3−93.4 Setting the date/time 3−11 3.5 Displaying the device type and the firmware version 3−113.6 Displaying the error log 3−113.7 Fault reset 3−123.8 Backing-up data 3−123.9 Restoring data backups 3−133.10 Triggering device Reset 3−13 3.11 Loading factory setting of the device 3−14Operation3 Operation3.1 Starting / Exiting the software★Before starting the LT-IB software, you should make sure that the 24 V supply voltage for the digital welding current source has been switchedon.This is indicated by the “LOGIC” LED on the front panel of the interfacemodule:LOGIC LED, green. Is on if 24 V DC (logicsupply voltage) is available.●Start the LT-IB software by double-clicking on the link symbol createdin the course of installation.☞If the program window remains empty after the start, or if it closesagain automatically, the software is not able to detect a digital weldingcurrent source at either of the serial interfaces of the PC. In this case, you should check whether●the connecting cable has been properly wired and plugged in.●the 24 V supply to the digital welding current source has beenswitched on.If a digital welding current source is connected and has beendetected, the main menu of the software will appear as follows:Device type andfirmware version ofthe digital weldingcurrent sourceconnectedMain menuInput prompt3−2 Bosch Rexroth AG Electric Drives PSI 6xxx.000 1070087066 / 02 and ControlsOperationThe cursor is flashing at the input prompt. In this condition, you can activate the functions displayed simply by pressing the corresponding key.For a description of the individual functions ofkey “P”: refer to Sect. 3.2 page 3−2.key “F”: refer to Sect. 3.6 page 3−11.key “K”: refer to Sect. 3.3 page 3−9.key “B”: refer to Sect. 3.8 page 3−12.key “R”: refer to Sect. 3.9 page 3−13.key “Z”: refer to Sect. 3.7 page 3−12.key “D”: refer to Sect. 3.4 page 3−11.key “N”: refer to Sect. 3.5 page 3−11.Keys “E” or “Esc”: exit the software.3.2 Setting the basic parameters------------------------------------------------------------------------------------------------------------------------------------ CAUTIONIncorrect parameter settings may damage the transformers, thewelding system, or produce incorrect welds. Therefore, you should notchange any parameters unless you are totally sure about theconsequences of such a change.In cases of doubt, please ask your supervisor!------------------------------------------------------------------------------------------------------------------------------------ Here, you can set the basic parameters of the digital welding currentsource. The display/query of some parameters depends on thecurrent firmware version and the parameter settings made for the unit:●Configuration (only if master/slave operationis supported by the inverter)●Regulation mode●Current measurement●Toroid sensitivity● Measuring range (with secondary currentmeasurement only)●Transformer type●Number of transformers●Type of transformer connection●Transformer ratio (for third-party transformers only)●Transformer secondary current (for third-party transformers only)● Diode type (for third-party transformers only)●Number of parallel diodes (for third-party transformers only)●Diode monitoring (on/off)1070087066 / 02 PSI 6xxx.000 Electric Drives Bosch Rexroth AG 3−3 and ControlsOperation★Press key “P” in the main menu while the cursor is at the input prompt.All necessary parameters are displayed one by one by the system,queried, a nd immediately transmitted to the unit after acknowledgment by the “Enter” or “Esc” key.☞If you do not want to change a parameter, press the “Enter” or “Esc” keywithout entering a value.When all parameters have been displayed/queried, the main menu is built up again.Example:Resulting query sequence with the following parameter input:●Configuration as master with 1 slave●KSR mode (current regulation)●Primary current measurement●Toroid sensitivity = 150●Connection of 1 x transformer PSG 3100.00●Diode monitoring is active●Normal controller dynamics3−4 Bosch Rexroth AG I Electric Drives PSI 6xxx.000 1070087066 / 02 and ControlsOperationRegulation modePossible settings:●0 : Pulse width mode (PHA mode)The welding heat within the welding circuit is influenced by changing thepulse width. The pulse width only depends on the command value present in this case.● 2 : Current regulation (KSR mode)The programmed current (in kA) is determined by the command value signal supplied (0 to 10 V DC). There is closed-loop control of the actual current in the secondary circuit. The welding heat within the welding circuit is influenced by the controller which changes the pulse width as needed.★Make sure that the setting matches the type of command value input by the external weld timer!☞For more information on the regulation modes, refer to the manual “Controland I/O level, Technical Information (1070 087 065)”, keyword “Regulationmodes”.Current measurementPossible settings:●0 : Primary current measurementAn sensor integrated in the primary circuit inside the device is used as current sensor. The device converts the measured value into the correspondingsecondary current based on the transformer parameter settings.● 1 : Secondary current measurementAn external current sensor linked to X3 is used in the secondary circuit.☞The following applies for secondary current measurement: max. weld time< 1s!1070087066 / 02 PSI 6xxx.000 Electric Drives Bosch Rexroth AG 3−5and ControlsOperationToroid sensitivityInternal evaluation factor for the measured current.This function may be used to adjust the device to an external currentmeasuring unit (reference ammeter) (calibration).Measuring range☞ The parameter is only offered if secondary current measurement is active.Possible settings:●11 : 0.5 to 5 kA●12 : 1 to 10 kA●13 : 2 to 20 kA●14 : 4 to 40 kA●15 : 8 to 80 kA●16 : 16 to 160 kADefines the current range covered by the currents to be measured.★Please make sure that the measuring range set for the currents to bemeasured is not too small. The measured currents should be in the upperthird of a measuring range.Transformer typePossible settings:●0 : PSG 3050.00● 1 : PSG 3050.10● 2 : PSG 3075.10● 3 : PSG 3100.00● 4 : PSG 3200.00● 5 : no PSG transformer (third-party transformer)From this setting, the unit derives certain PSG transformer parameters fordiode monitoring and conversion from primary into secondary current values.★After having changed this parameter, you should perform a device reset(refer to Sect. 3.10 page 3−13) as soon as the main menu was built up again!3−6 Bosch Rexroth AG Electric Drives PSI 6xxx.000 1070087066 / 02 and ControlsOperationNumber of transformersPossible settings:● 1 to 8Number of welding transformers connected to the unit.★After having changed this parameter, you should perform a device reset(refer to Sect. 3.10 page 3−13) as soon as the main menu was built up again!Type of transformer connectionPossible settings:●0 : serial● 1 : parallelYou specify whether the welding transformers on the secondary side areconnected in parallel or in series.★After having changed this parameter, you should perform a device reset(refer to Sect. 3.10 page 3−13) as soon as the main menu was built up again! Transformation ratio☞The parameter is only offered for third-party transformers(trans former type = 5).It specifies the transformation ratio (primary/secondary side) of the welding transformers used.Maximum transformer secondary current☞The parameter is only offered for third-party transformers(trans former type = 5).Specifies the maximum permitted secondary current of the transformer(in kA).1070087066 / 02 PSI 6xxx.000 Electric Drives Bosch Rexroth AG 3−7and ControlsOperationType of diode☞ The parameter is only offered for third-party transformers(trans former type = 5).Possible settings:●0 : SKN 4000● 1 : SKN 6000● 2 : SDD71B0200● 3 : D 4457 NSpecifies the diode types the transformers in use are equipped with.★After having changed this parameter, you should perform a device reset(refer to Sect. 3.10 page 3−13) as soon as the main menu was built up again! Number of parallel diodes☞ The parameter is only offered for third-party transformers(transformer type = 5).Possible settings:● 1 to 4Specifies the number of diodes connected in parallel in the transformer per branch.Diode monitoring active------------------------------------------------------------------------------------------------------------------------------------ CAUTIONPossibility of destroying the power unit or the welding transformer!If diode monitoring is not active, the diodes of the welding transformer are no longer monitored by the PSI. In the event of excessive load, this may result in considerable damage to the welding equipment.Therefore, diode monitoring should always be switched on.------------------------------------------------------------------------------------------------------------------------------------ Possible settings:●0 : Monitoring deactivated● 1 : Monitoring activated★After having changed this parameter, you should perform a device reset(refer to Sect. 3.10 page 3−13) as soon as the main menu was built up3−8 Bosch Rexroth AG Electric Drives PSI 6xxx.000 1070087066 / 02 and ControlsOperationController adjustmentPossible settings:●−10 to 10, step size 1. Default setting: 0.Influences the dynamics of the constant-current regulator.Negative values mean a potentially slower current rise, positive values afaster current rise.------------------------------------------------------------------------------------------------------------------------------------ CAUTIONOscillation of current control is possible!Changing this parameter to inappropriate values may cause the control tooscillate and lead to improper welds!After having changed this parameter, please check whether the resultingcurrent characteristic during the weld is correct.------------------------------------------------------------------------------------------------------------------------------------1070087066 / 02 PSI 6xxx.000 Electric Drives Bosch Rexroth AG 3−9 and ControlsOperation3.3 Parameterizing the setpoint input☞The parameter settings for the command value input are not active unless KSR regulation mode has been selected.In order to optimally adjust the setpoint signal input of the digital weldingcurrent source (at X2, input voltage range: 0 to 10 V DC) to the setpoint signal of an external controller, two pairs of values can be parameterized (voltage inmV, resulting welding current in kA) to specify a linear characteristic.The digital welding current source will then use this characteristic to convert any active voltage to the corresponding command current.★Proceed as follows to set the parameters for these two pairs of values:1. Press key “K” in the main menu while the cursor is at the input prompt.The system then waits for input of the first voltage value.☞If you do not want to change the currently active characteristic, press the“Enter” or “Esc” key without entering a value in subsequent steps 2, 3, 4 or 5.After having queried all values, the system will report “Function aborted –please repeat” in this case without changing the existing characteristic.2. Enter the first voltage value in mV.The lower one of the two voltages must be input at this point. In theexample below, this would be 2000.Acknowledge the value input with the “Enter” key.The system then waits for input of the first current value.3. Enter the first current value in kA.The lower one of the two current values must be input at this point. In theexample below, this would be 60.Acknowledge the value input with the “Enter” key.The system then waits for input of the second voltage value.4. Enter the second voltage value in mV.The higher one of the two voltages must be input at this point. In theexample below, this would be 10000.Acknowledge the value input with the “Enter” key.The system then waits for input of the second current value.5. Enter the second current value in kA.The higher one of the two current values must be input at this point. In the example below, this would be 120.Acknowledge the value input with the “Enter” key.The system calculates the characteristics from the data input and showsthe resulting currents for the input voltages of 0 V and 5 V as controloutput.The main menu is built up again afterwards.3−10 Bosch Rexroth AG Electric Drives PSI 6xxx.000 1070087066 / 02 and ControlsOperationExample for Type PSI 6500.000:Desired adjustment toexternal controller:Parameter input procesdurecorresponding to step 2. to 5.(see above):1st pair of values2nd pair of valuesControl displayParameter input for the setpoint signal input☞ Please note that voltage values below 1 V are basically interpreted as 0 V, therefore, no activity is initiated.1070087066 / 02 PSI 6xxx.000 Electric Drives Bosch Rexroth AG 3−11 and ControlsOperation3.4 Setting the date/timeThis function will copy the current date and the current time of the PC to the digital welding current source.☞ Errors cannot be logged properly unless these values have been setcorrectly!★Proceed as follows:1. Check whether the date and time settings of the PC are correct.Otherwise, set the proper date and time at the PC.2. Press key “D” in the main menu while the cursor is at the input prompt.The time settings of the PC and the digital welding current source havebeen synchronized.The main menu is built up again.3.5 Displaying the device type and the firmware versionDisplays the device type and the firmware version.★Press key “N” in the main menu while the cursor is at the input prompt.The information is displayed, and the main menu is built up again afterwards.3.6 Displaying the error logDisplays the internal error log − starting with the error that occurredlast − page by page on the screen.★Press key “F” in the main menu while the cursor is at the input prompt.●Enter key:scrolling by pages through the error log●“Esc” key:cancels the error log display.When the last page of the error log has been displayed or if the display has been canceled, the main menu is built up again.3−12 Bosch Rexroth AG Electric Drives PSI 6xxx.000 1070087066 / 02 and ControlsOperation3.7 Fault resetWhile the digital welding current source automatically resets“selfacknowledging errors” as soon as the corresponding error condition no longer exists, “non-self-acknowledging errors “ must be reset manually using “Fault reset”.Whether or not an error is currently pending is indicated on the front panel of the interface module.☞For more details concerning possible errors, please refer to the“Display error log” function (refer to Sect. 3.6).★First, the cause of the error should be corrected.★Press key “Z” in the main menu while the cursor is at the input prompt.The main menu is built up again.If the error condition is no longer present, the “READY” LED on the frontpanel of the interface module will be lit again.3.8 Backing-up dataFor backup purposes or for series commissioning of a plant, the currentparameter settings of the digital welding current source can be saved on the PC:“Data backup” can be performed at any time, even during a weldingschedule.★Press key “B” in the main menu while the cursor is at the input prompt.The complete parameter settings are saved to the “BACKUP.SST” file in thecurrent working directory.When the process is finished, main menu is built up again.☞ To restore the data: refer to section 3.9.1070087066 / 02 PSI 6xxx.000 Electric Drives Bosch Rexroth AG 3−13 and ControlsOperation3.9 Restoring data backupsWhen the parameters of the digital welding current source have alreadybeen backed up (refer to “Backing-up data”, Section 3.8), the backup datacan be restored when necessary.☞ Backup data can be restored to a device of the same type only!------------------------------------------------------------------------------------------------------------------------------------ CAUTION“Restore” will interrupt the currently active welding process!This will result in an incorrect weld. Therefore, you should only use thisfunction if●the unit is not involved in a production process.------------------------------------------------------------------------------------------------------------------------------------ ★Proceed as follows:1. Make sure that the “BACKUP.SST” file containing the appropriateparameters exists in the current working directory.2. Press key “R” in the main menu while the cursor is at the input prompt.3. Then confirm the query “Are you sure” by hitting “Y”.Any other key will abort the function.The Ready status of the unit is deactivated while data is being restored.During this time span, welding is not possible.If there is no error, the unit will automatically restore the Ready condition when the data restoring process has been completed.The main menu is built up again.3.10 Triggering device ResetUse this function to reboot the digital welding current source.This process is equivalent to reinitialization of the device and may benecessary after certain parameter changes (e.g. in the area of diodemonitoring) in order to ensure proper functioning.Where this is the case, you will be informed accordingly.------------------------------------------------------------------------------------------------------------------------------------ CAUTIONDevice Reset will interrupt the currently active welding process! This willresult in an incorrect weld. Therefore, you should only use this function if●the unit is not involved in a production process.------------------------------------------------------------------------------------------------------------------------------------------------3−14 Bosch Rexroth AG Electric Drives PSI 6xxx.000 1070087066 / 02 and ControlsOperation★Press key “*” in the main menu while the cursor is at the input prompt.The device is rebooted without any further safety query.The main menu is built up again.3.11 Loading factory setting of the deviceThis option should be used in order to●reset all parameters of the digital welding current source to their defaultvalues, and●delete the contents of all process log memories.------------------------------------------------------------------------------------------------------------------------------------ CAUTIONLoading the factory settings of the device will delete the current parameter settings!The default value settings (e.g. transformer values, characteristic forconverting the setpoint signal into a current setpoint) may not be suitable for your specific application. Therefore, you should only use this function if●you are fully aware of its consequences●the unit is not involved in a production process.------------------------------------------------------------------------------------------------------------------------------------ ☞Deleting the process log memory contents of units that are involved in theproduction process is not permitted by quality assur a nce in many cases.If you are not sure whether or not the process log memory contents of thedevice may be deleted, please contact your supervisor.★Proceed as follows:1. Press key “L” in the main menu while the cursor is at the input prompt.2. Then confirm the query “Are you sure” by hitting “Y”.Any other key will abort the function.The main menu is built up again.BOSCH psi6500.000現有參數設定值:Regulation mode :( 0: Pulse width mode (PHA mode), 2: Current regulation (KSR mode)) Possible settings: 2Current measurement (0:Primary 1: Secondary)Possible settings: 1Sensor responsiveness :Possible settings: 150Measuring range : ( 11:5kA ;12:10kA;13:20kA; 14:40kA; 15:80kA; 16:160kA)Possible settings: 15Transformer type: (0: PSG 3050.00, 1: PSG 3050.10. 2: PSG 3075.10, 3: PSG 3100.00, 4: PSG 3200.00, 5:OEM)Possible settings: 5Number of transformers :Possible settings: 4Type of transformer connection :( 0: serial, 1: parallel)Possible settings: 1Transformation ratioPossible settings: 55Maximum transformer secondary currentPossible settings: 0Type of diode:( 0: SKN 4000, 1: SKN 6000, 2: SDD71B0200, 3: D 4457 N)Possible settings: 0Number of parallel diodes : (1-4)Possible settings: 2Diode monitoring active : ( 0:off, 1: on)Possible settings: 1BOSCH psi6500.000 KSR現有設定值3.3 Parameterizing the setpoint inputThe parameter settings for the command value input are not active unless KSR regulation mode has been selected.aborted −please repeat. in this case without changing the existing characteristic.2. Enter the first voltage value in mV. 10003. Enter the first current value in kA. 104. Enter the second voltage value in mV.100005. Enter the second current value in kA. 483-2 Bosch Rexroth AG | Electric Drives PSG 6xxx. | 1070087063 / 03 andControlsTransformer selection3.2 Technical dataNameTypes PSG ...3075.10 xx 6130.00 xxNominal power SN 80 kVA (at 20% duty cycle) 130 kVA (at 20% duty cycle) maximum primary continuous current I1P76 A 118 APrimary voltage U1N 500 Vmaximum DC current Idmax refer to load diagrams in the sections that deal with thetransformersContinuous DC current Id (100% duty cycle) 4.2 kA 6.5 kA No-load DC voltage UdiO 8.4 V 9 V Frequency f (primary circuit) 1000 HzSensitivity Ratio 55 : 1min. conductor area (primary circuit) 16 mm2 35 mm2 min. cooling water quantity 6 l/min 8 l/min max. cooling water temperature 30° Cmax. cooling water pressure drop refer to differential pressure diagrams in the sections that dealwith the transformersmax. operating temp. (primary winding) 150° Cmax. operating temperature (diodes) 80° CDegree of protection of transformer block IP65Degree of protection(connection zone on primary side)1)Degree of protection(connection zone on secondary side)IP00Insulation class of welding transformers FWeight 14.5 kg 16 kg Dimensions and locations of connections refer to dimensioned drawingsColor RAL 7005; grey RAL 1004; yellow 1) With terminal box: IP55; without terminal box: IP009-40 Bosch Rexroth AG | Electric Drives PSI 6xxx. | 1070080059 / 02 andControlsPSI 6500.xxx W19.6.2 Technical dataType 3-phase rack-mounted mid-frequency converterWeld timer integratedI/O interface Slot for parallel, serial or fieldbus interfaceQuality module Slot provided for later additionDegree of protection IP 20; designed for installation in housing or switch cabinet with IP 54 Storage temperature range −25° C to +70° COperating temperature range (in installation space) +10° C to +45° C; in the case of a thermal capacity that is greater than half of the nominal capcity, a cabinet cooler that regulates the cabinet temperature to 35 degrees Celsius is used.Cooling using water; 10 l/min; supply flow max. 30° C Temperature monitoring integratedCorrosion The ambient air must be free of high concentrations of acids, brines, corrosives, salt and metallic vapors.Humidity 3K3 according to EN 60721−3−3 Condensation on the mid-frequency converter is not permitted.Air pressure 0 to 2000 m above sea level.Main supply voltage connection to grounded TN or TT network. 400 V −20% to 480 V +10%; 50/60 Hz Nominal main supply voltage(maximum thermal continuouscurrent)660 A (with cabinet cooler) 330 A (without cabinet cooler)Max. output current(primary current)2400 AMax. secondary current(transformer−dependent)120 kA (with PSG 3100)Logic main supply(e.g. for weld timer CPU, I/O interfaces, etc.) 24 V=, min: 19 V=; max: 30 V=, acc. to EN 61131-2. Supply possibilities: using external power pack; using separate supply with the integrated power pack (from the welding main supply).1070080059 / 02 | PSI 6xxx Electric Drives | Bosch Rexroth GmbH 9-41and ControlsPSI 6500.xxx W1Over voltage protection MOV (metal oxide varistor)Electrical connection main supply andusing terminal ends; M10 screws per connectiontransformerWire range 2−4 cables per 120 mm2Basic switchgear cabinet losses 100 Wmax. cooling losses 4400 WSwitchgear cabinet losses at max. power 850 WWeight approx. 70 kg; mechanically divisibleMounting position vertical or lying on rearProduct informationPerformance chartSecondary current ranges of PSI 6xxxs from thermal current up to peak current with 9VTransformers3* PSI 6500 2* PSI 6500PSI 6500PSI 6400PSI 6200PSI 6300PSI 6100PSI 60256V transformerThe master/slave conceptThe PSI 6500 inverter can be operated in a master/slave configuration to increase its power. In this mode, up to 3 units can be connected in parallel. Each inverter is connected to one or several identical transformers in this case.The transformers can then be connected in parallel on the secondary side in a simple symmetrical configuration in order to achieve three times the power of one individual unit. The hardware of the units is identical. The slave or master function is selected by suitable parameter settings.Technical dataBosch Rexroth AG“The Drive & Control Company”Vertriebskoordination WiderstandsschweißenPostfach 1162D-64701 Erbach/OdenwaldTel: +49 (0)60 62-78-231Fax: +49 (0)60 62-78-728。
