BOSCH焊接控制器6.03

最新维修二内部题库单选-2023.03.04一、单选题1.FESTO气缸属于双作用气缸, 它是通过（）控制运动速度。

[单选题] *A.节流阀(正确答案)B.换向阀C.减压阀D.以上都不对2.切边机平移气缸采用（）进行换向。

[单选题] *A.双压阀B.两位五通换向阀(正确答案)C.顺序阀D.以上都不对3.切边机平移气缸属于（）气缸。

[单选题] *A.双作用(正确答案)B.单作用C.单双作用D.以上都不对4.切边机气缸用的是（）。

[单选题] *A.相对压力(正确答案)B.绝对压力C.大气压力D.以上都不对5.切边机气缸上的节流阀的作用是（）。

[单选题] *A.调节气缸的运动速度(正确答案)B.调节气缸缓冲力C.增加气缸压力D.以上都不对6.切边机气缸在整套气路系统中属于（）。

[单选题] *A.动力元件B.执行元件(正确答案)C.控制元件D.以上都不对7.切边机气缸采用（）法,使气缸动作灵敏,没爬行现象。

[单选题] *A.排气节流(正确答案)B.进气节流C.两端同时节流D.以上都不对8.在气路系统种，控制切边机的换向阀属于（）。

[单选题] *A.控制元件(正确答案)B.动力元件C.工作介质D.执行元件9.调节切边机气缸运行速度的是（）。

[单选题] *A.节流阀(正确答案)B.减压阀C.溢流阀D.顺序阀10.为了防止切边机气缸的冲击一般在气缸末端装有（）。

[单选题] *A.缓冲装置(正确答案)B.加速装置C.增压装置D.减压装置11.切边机平移气缸使用的是双作用气缸，还有一种单作用气缸，它是依靠（）复位。

[单选题] *A.弹簧(正确答案)B.双止回阀C.调速阀D.增压缸12.滚床行走轮内的轴承一般为（）。

[单选题] *A.角接触球轴承B.深沟球轴承(正确答案)C.推力球轴承13.一般来说，中等中心距的普通V带的张紧程度是以用拇指能按下多少mm为宜（）。

[单选题] *A.5?B.10?C.15?(正确答案)D.2014.互换装配法的实质就是控制零件的（）来保证装配精度。

BOS 6000焊接控制系统速成接线博世力士乐（中国）有限公司注意事项注意：本速成接线仅供参考使用，所有资料和安全注意事项请以英文原版资料为准！！更多内容请参考英文原版资料！！1．电源系统接线原理1．三相电源线和控制器的接线，另外，PE一定要接电源地线,请注意选用高等级的电缆!!! 2．控制器与变压器的接线3．温度传感器的接线原理注意:在初级电源连接中,从控制器到变压器的高压连接电缆一定要使用高等级的绝缘耐磨可拉伸产品,并一定在三芯电缆外层要加耐磨阻燃套管,并且在电器箱设计中要有漏电保护开关和必要的漏电保护装置,请重视安全,否则发生一切问题与博世力士乐无关!!!高压危险,珍惜生命，注意：接地的电阻不得大于4 欧姆电气系统的中线N和保护接地P(E)1. 中线N不可以作为保护接地P(E)使用，同样保护地线P(E)不可以作为中线N使用，二者不得混淆。

特别需要注意的是在三相四线制的主电源输入的形式中，仅仅可以使用保护地线P(E)，而不得使用中线N。

2. 作为保护地线P(E)引入电气系统后，必须作为永久保护接地进入电气系统(电气箱)，必须直接与电气系统(电气箱)中的总接地排连接。

3. 在整个电气控制系统中，保护接地连接必须是独立连接的，不允许任何借用其他安装目的的螺栓作为保护接地连接。

4. 整个电气系统的保护接地必须采用是树叉状连接。

控制系统(PLC，数控系统，控制系统和HMI等)的保护接地线必须大于6平方毫米。

电源模块的保护接地线必须符合按功率规定的要求以及必须大于10平方毫米。

1．三个温度传感器连接时先全部串联后再接到控制器X32．电流传感器请接到控制器X3，注意要使用屏蔽电缆！3．注意：焊接机器次级的负极是与地（MPE）相通的4．以上为PSG3000变压器的接线图,新一代变压器PSG6130的图纸见下页注意：在机器机械设计制造时候要把变压器的负极接地设计，正极要设计为绝缘！！机架的设计要有正负极的区分。

ECU_PIN/ ECU引脚ECU-Pin name/ECU引脚名称Function/功能Remark/说明101 V_V_BAT1 ECU Power from Battery (permanent) #1 ECU电源+ #1（永久）102 G_G_BAT1 Power Ground 1 ECU电源- 1103 V_V_BAT2 ECU Power from Battery (permanent) #2 ECU电源+ #2（永久）104 G_G_BAT2 Power Ground 2 ECU电源- 2105 V_V_BAT3 ECU Power from Battery (permanent) #3 ECU电源+ #3（永久）106 G_G_BAT3 Power Ground 3 ECU电源- 3117 I_S_T15 Ignition Key on (Terminal 15) 点火开关（T15)118 O_T_FAN Fan Control PWM 电磁风扇继电器PWM控制输出 129 I_A_TL Multiple state switch 多态开关130 O_V_FAN FAN supply 风扇输出电压132 O_S_ACRLY A/C Compressor Relay 空调压缩机继电器信号135 B_D_CANL0 CAN 0 Low CAN低端信号O（整车用）138 B_D_CANH1 CAN 1 High CAN高端信号1（诊断用）141 G_R_TL Multiple state switch GND 多态开关地142 O_V_EBRFL Engine Brake flap 排气制动电磁阀供电148 B_D_CANH0 CAN 0 High CAN高端信号O（整车用）149 V_V_5VAPP1 Accelerator pedal position 1 supply voltage 加速踏板位置传感器1电源150 V_V_5VAPP2 Accelerator pedal position 2 supply voltage 加速踏板位置传感器2电源151 B_D_CANL1 CAN 1 Low CAN低端信号1（诊断用）154 O_V_ACRLY Ac Compressor relay 空调压缩机继电器电源157 O_T_EBRFL Engine Brake Flap PWM 排气制动电磁阀PWM输出201 V_V_BAT4 ECU Power from Battery (permanent) #4 ECU电源+ #4（永久）202 G_G_BAT4 Power Ground 4 ECU电源- 4204 O_T_LSH Lambda sensor heating 氧传感器加热信号206 O_V_LSH Lambda sensor heating supply (BAT+) 氧传感器加热电压209 O_F_ENGN Engine Speed output signal 发动机转速信号输出210 I_S_EBR Engine Brake Switch 排气制动开关211 I_A_LSVN Lambda sensor voltage nernst 氧传感器能斯脱电压212 G_R_LSVG Lambda sensor, virtual ground 氧传感器虚拟地216 I_F_VSS Vehicle speed sensor input signal 车速传感器输入信号（霍尔式） 217 O_S_DIA Diagonostic Lamp 诊断灯（闪码）221 G_R_VSS Vehicle Speed Sensor GND 车速传感器地（霍尔式）222 I_S_CONV Clutch Switch 离合器开关223 I_S_DIAREQ Diagonostic Request Switch 诊断请求开关224 I_A_LSCA Lambda sensor current adjust 氧传感器校正电流225 I_A_LSCP Lambda sensor current pump 氧传感器泵电流226 I_S_CRCRES Cruise Control Resume Switch 巡航控制开关（复位）227 I_S_BRKMN Main Brake Switch 主刹车开关228 O_S_OBD Onboard Diagnostics Lamp OBD灯231 O_P_IOS5 Ignition Coil 5 点火线圈5232 O_P_IOS6 Ignition Coil 6 点火线圈6233 I_S_T50 T50 Switch 电控起动机T50开关235 I_S_CRCPOS Cruise Control Positive Switch 巡航控制开关（提升）236 I_S_CRCNEG Cruise Control Negative Switch 巡航控制开关（降低）239 I_S_GNSW Gear Neutral Indicator Switch 变速箱开关240 I_S_BRKRED Redundant Brake Switch 辅刹车开关241 G_R_APP1 Accelerator position 1 Sensor GND 加速踏板位置传感器1地242 G_R_APP2 Accelerator position 2 Sensor GND 加速踏板位置传感器2地243 G_R_DF09 Ground for frequency input 9 ECU虚拟地244 O_P_IOS3 Ignition Coil 3 点火线圈3245 O_P_IOS4 Ignition Coil 4 点火线圈4246 I_S_ACSW AC Switch 空调开关251 O_V_RH29 Switched Battery output ECU输出电压253 I_S_CRCOFF Cruise Control Off Switch 巡航控制开关（关闭）254 I_A_APP1 Acceleratore Pedal,Sensor 1 加速踏板位置传感器1信号255 I_A_APP2 Acceleratore Pedal,Sensor 2 加速踏板位置传感器2信号257 O_P_IOS1 Ignition Coil 1 点火线圈1258 O_P_IOS2 Ignition Coil 2 点火线圈2301 O_V_GPVL GAS Low PRESSURE SHUT OFF VALVE 燃气低压切断阀电源302 O_S_GPVH Gas High Pressure Shut Off valve 燃气高压切断阀开关307 G_R_FSS Fan Speed Sensor GND 风扇速度传感器 地310 I_A_OPS Oil pressure sensor input signal 机油压力传感器信号（压力）311 I_A_TPPOS1 Throttle Position sensor 1 节气门位置传感器1信号312 I_A_IATS T-MAP Sensor (Temperature) 进气压力传感器（温度）信号 313 I_A_BTS Boost Temperature sensor 增压压力传感器（温度）信号 314 I_A_CTS Coolant Temperature Sensor 冷却液温度信号316 G_R_CRS CrankShaft Sensor GND 曲轴传感器 地317 I_F_CAS Segment (camshaft) speed sensor signal 凸轮轴传感器信号318 I_A_BPS Boost Pressure sensor 增压压力传感器（压力）信号 319 G_R_PGAS Gas low pressure Sensor GND 燃气温度压力传感器 地321 G_R_TPPOS Throttle Position Sensor GND 节气门位置传感器 地323 G_R_BPS Boost Pressure Sensor GND 增压压力传感器 地324 O_V_WGV Waste Gate Valve 废气控制阀电源326 O_V_GPVH GAS HIGH PRESSURE SHUT OFF VALVE 燃气高压切断阀电源328 O_V_FAN1 Motor fan relay 1 supply 电磁风扇继电器1电源332 B_D_ISOK K Line Interface K线334 I_A_PHGAS CNG High Pressure Sensor (Tank Pressure) CNG高压传感器信号（气罐） 335 I_A_PGAS Gas Low pressure sensor 燃气压力传感器信号337 I_A_GQSAJ Adjustable Gas Quality Sensor 气敏元件338 I_A_OTS Oil Temperature Sensor 机油压力传感器信号（温度） 340 I_F_CRS Crankshaft speed sensor signal 曲轴传感器信号341 G_R_CAS Camshaft Sensor GND 凸轮轴传感器 地342 I_A_GTS Gas Low Temperature sensor 燃气温度压力传感器信号（温度） 347 O_S_FAN2 Motor fan relay 2 sensor output 风扇继电器2信号输出348 O_S_FAN1 Motor fan relay 1 sensor output 风扇继电器1信号输出349 O_T_TVANEG Throttle Control Output Negative PWM 节气门输出（负PWM)350 O_T_TVAPOS Throttle Control Output Positive PWM 节气门输出（正PWM)353 O_V_OAV Over run Air valve 喘震阀电源354 O_V_FAN2 Motor fan relay 2 supply 风扇继电器2电源355 G_R_CTS Coolant Temperature Sensor GND 冷却水温度传感器 地358 V_V_5VIAPS Intake manifold pressure with temperature 进气压力传感器电源363 G_R_OPS Oil Pressure Sensor GND 机油压力传感器 地368 G_R_IAPS MAP / Air Temperature (from MAP) GND 进气压力传感器 地372 O_S_STRT Starter Relay for Button Start 起动机继电器开关信号374 O_T_WGV Waste Gate Valve PWM 废气控制阀PWM376 O_S_OAV Over Run Air valve 喘震阀开关信号377 O_T_GPVL Gas Low Pressure Shut Off valve 燃气低压切断阀信号379 I_A_IAPS T-MAP Sensor (Pressure) 进气压力传感器（压力）信号 381 V_V_5VPGAS Gas Low pressure/temperature sensor supply voltage燃气温度压力传感器电源382 V_V_5VOPS Oil pressure sensor supply voltage 机油压力传感器电源383 G_R_PHGAS Gas high pressure sensor ground 燃气高压传感器 地（气罐） 384 V_V_5VTPPOS Throttle plate actuator supply voltage 节气门电源386 V_V_5VBPS Boost pressure sensor supply voltage 增压压力传感器电源392 I_A_TPPOS2 Throttle Position sensor 2 节气门位置传感器2信号396 O_V_STRT Starter Relay 起动继电器电源401 O_P_SVH22 Injector 2 "high" Bank 2 喷油器2电容高端2403 O_P_SVH23 Injector 3 "high" Bank 2 喷油器3电容高端2404 O_P_SVH12 Injector 2 "high" Bank 1 喷油器2电容高端1405 O_P_SVH11 Injector 1 "high" Bank 1 喷油器1电容高端1406 O_P_SVL13 Injector 3 "low" Bank 1 喷油器3电容低端1407 O_P_SVL32 Injector 2 "low" Bank 3 喷油器2电容低端3410 O_P_SVH32 Injector 2 "high" Bank 3 喷油器2电容高端3411 O_P_SVH13 Injector 3 "high" Bank 1 喷油器3电容高端1412 O_P_SVL11 Injector 1 "low" Bank 1 喷油器1电容低端1413 O_P_SVL12 Injector 2 "low" Bank 1 喷油器2电容低端1414 O_P_SVL23 Injector 3 "low" Bank 2 喷油器3电容低端2416 O_P_SVL22 Injector 2 "low" Bank 2 喷油器2电容低端2。

五轴智能焊锡机控制系统QZ-SMC1305（手持盒版）V6.6说明书苏州琼宇电子科技有限公司目录1.产品介绍 (2)1.1产品概述 (2)1.2功能简介 (3)1.3功能特性 (3)1.4产品列表 (4)2.接线说明图 (5)2.1 控制系统按线示意图 (5)2.2 安装尺寸.......................................................................................................... .. (6)3.按键说明 (7)3.1手持盒按键图 (7)3.2手持盒按键说明 (8)4.手持盒操作说明 (10)4.1开机画面介绍 (10)4.2主菜单功能介绍 (12)4.3新增功能操作 (16)4.4删除指令操作 (19)4.5复制指令操作 (19)4.6阵列复制操作 (19)4.7偏移操作 (20)4.8批量修改 (20)4.9类型批量修改 (20)4.10插入指令 (21)4.11系统 (21)4.12执行方式操作 (22)4.13复位方式操作 (23)4.14产量设定 (23)4.15默认参数 (24)4.16停机位置 (25)4.17焊接工艺 (25)4.18清洗功能 (25)4.19空移速度 (26)4.20对位操作 (26)4.21MARK点对位操作 (26)5.注意事项 (27)5.1装机事项 (27)5.2常见问题说明与故障排除 (37)1.产品介绍1.1产品概述QZ-SMC1305是由本公司专业数控团队为焊锡机行业量身定做的低成本、高浓缩、高集成度的智能焊锡机控制系统。

完善的焊锡工艺设置，满足不同的加工需求，广泛应用在多轴全自动焬锡机领域。

1.2功能简介1、显示屏采用320*240高分辨率彩屏、全中文操作界面，易学易用。

2、完善的焊锡工艺设置，具有点焊与拖焊等焊接；供锡速度可根据工作速度自动调整。

-SW2-SW3残余漏流电-P1焊钳1极修磨求电请焊钳2极修磨求电请焊钳2极寿命束电结焊钳1极寿命束电结-SWE7没电有电合闭极修磨电0焊钳1 焊钳2位时间复焊钳1 焊钳2位时间复0 1-P6-P2-P4-P5-SW4V24程口编-XS1A 控制器位错误复控制器正常-SL7/PL7修位置维-XS5BHartingEthernetconnector-P31 2 3 4 5 6 7 8 BOS_IND_1 List of material Parts nomenclature A1-X1 von Schutzrechtsanmeldungen. Jede Vefügungsbefugnis, Quantity Designation Type number Manufacturer Part number Materials number a 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Sub-D connector, 9–pole female Metal hood EMI/RFI 9-pole differential current evaluation unit M12-cable 3 pole Load monitoring Housing RAL 7035 HxWxD = 800x600x300 supporting frame Label set Warning sign Screw connection Counternut Screw connection Counternut Screw connection Counternut Screw connection Counternut Screw connection blind plug screw seal plug Relay module Extension spring clamp Miniature plug-in relay 24VDC LED + free-wheeling diode Base for plug-in relay Relay module M12-cable 5 pole Indicator light, yellow Label holder Nameplate Indicator light, yellow Label holder Nameplate Indicator light, yellow Label holder Nameplate Indicator light, yellow Label holder Nameplate Indicator light, yellow Label holder Nameplate Indicator light, green Label holder Nameplate Power circuit breaker Undervoltage release Screw connection point special switch actuator Contact element DE09SSBT 8655.MH0901 RCMA423-D-1KUW/LED A-M12 3x0,34 LOCC-Box-FB 7-6400 KALUGA/MF Gestell/Variab Schildersatz Audi T99 W1R-100 BSK-PA M50x1,5 KMK-PA-METER M50x1,5 BSK-PA M40x1,5 KMK-PA-METER M40x1,5 BSK-PA M16x105 KMK-PA-METERM16x1,5 BSK-PA M12x1,5 KMK-PA-METER M12x1,5 VS M20x1,5 MS M22-B VSK M 40X1.5 EMG 17-REL/KSR- 24/21-21-LC STTB 2,5-PV 55.34.9.024.504099.80.9.024.99 94.84.3 EMG 17-REL/KSR- 24/21-21-LC KUW5-M12 5x0,34 3SB3244-6AA30-0CC0 3SB3925-0AV 3SB1904-2AA 3SB3244-6AA30-0CC0 3SB3925-0AV3SB1904-2AA 3SB3244-6AA30-0CC0 3SB3925-0AV 3SB1904-2AA 3SB3244-6AA30-0CC0 3SB3925-0AV 3SB1904-2AA 3SB3244-6AA30-0CC0 3SB3925-0AV3SB1904-2AA 3SB3244-6AA40-0CC0 3SB3925-0AV 3SB1904-2AA NZMH1-A125 NZM1-XU24DC NZM1-XKS NZM1-XS-U M22-K10 Souriau Souriau Bender LützeLütze Häwa Häwa Rosenbaum Jäger Helu Helu Helu Helu Helu Helu Helu Helu Helu EATON (Moeller Helu Phoenix Phoenix Finder GmbH Finder GmbH Finder GmbH Phoenix Lütze Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens EATON (Moeller EATON (Moeller EATON (Moeller EATON (Moeller EATON (Moeller DE09SSBT 8655.MH0901 RCMA423-D-1 468020.0150 716400 KALUGA/MF Gestell/Variab Schildersatz T99 W1R-100 94816 97822 94815 97821 98018 97817 94814 97816 98130 216388 94775 2940391 3031539 55.34.9.024.5040 99.80.9.024.99 94.84.3 2940391 456802.0150 3SB3244-6AA30-0CC0 3SB3925-0AV 3SB1904-2AA 3SB3244-6AA30-0CC0 3SB3925-0AV 3SB1904-2AA 3SB3244-6AA30-0CC0 3SB3925-0AV 3SB1904-2AA 3SB3244-6AA30-0CC0 3SB3925-0AV3SB1904-2AA 3SB3244-6AA30-0CC0 3SB3925-0AV 3SB1904-2AA 3SB3244-6AA40-0CC0 3SB3925-0AV 3SB1904-2AA 284414 259452 260019 110106 216376R911171279 R911171280 R911171282 R911172056 R911171283 e d R911171331R911171332 R911171334 R911171355 R911171355 c b R911172479 A1-X1 A3 BV1 wie Kopier- und Weitergaberecht, bei uns. Alle Rechte bei Bosch Rexroth AG, auch für den Fall F1 Gehaeuse Gehaeuse Gehaeuse Gehaeuse Gehaeuse Gehaeuse GehaeuseGehaeuse Gehaeuse Gehaeuse Gehaeuse Gehaeuse Gehaeuse Gehaeuse Gehaeuse K1 K2 K2 K2 K2 K3 KYP1 P1 P1 P1 P2 P2 P2 P3 P3 P3 P4 P4 P4 P5 P5 P5 P6 P6 P6 Q0 information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. Q0 Q0 Q0 Q0 This document, as well as the data, specifications and other f Bill of materials WSC60HA-040.21-Basis en 1070091891 Sheet/Bl. 21 Sheets/Bl. 281 2 3 4 5 6 7 8 BOS_IND_1 List of material Parts nomenclature Q0 von Schutzrechtsanmeldungen. Jede Vefügungsbefugnis, Quantity Designation Type number Manufacturer Part number Materials number a 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 3 1 9 2 6 2 2 2 2 1 1 1 1 1 2 1 1 1 1 1 1 Cover Extension axis Circuit-breaker, size S0 Control element, round Switching element Nameplate Label holder Illuminated pushbutton, yellow Label holder Nameplate Complete unit, round Label holder Nameplate Complete unit, round Label holder Nameplate Complete unit, round, knob Label holder Nameplate Control element, round Switching element Label holder Nameplate measuring converter Snap-on mounting Power supply connecting cable End support cover Jumper Jumper Extension spring clamp doublestick terminal doublestick terminal element-series terminal Extension spring clamp End support Universal clamp Plug element with screwed flange, tension spring connection Plug element with threaded flange, tension spring connection Female plug-in connectors Flat gasket Protective cap Hexagon bolt Wall penetration dustcap for wall penetration Wall penetration dustcap for wall penetration Patch cable Pin insert NZM1-XIPK Achse lang 3RV1421-0KA103SB3000-1CA11 3SB3403-0C 3SB1904-2AA 3SB3925-0AV 3SB3247-0AA31-0CCO 3SB3925-0AV 3SB1904-2AA 3SB3208-2DA11-0CC0 3SB3925-0AV 3SB1904-2AA3SB3208-2DA11-0CC0 3SB3925-0AV 3SB1904-2AA 3SB3201-2KA11-0CC03SB3925-0AV 3SB1904-2AA 3SB3000-5AE51 3SB3403-0A 3SB3925-0AV 3SB1904-2AA W35ABP B 98080501 CPSB2-120-24 LiYY CLIPFIX 35 D-STTB 2,5 FBS 2-5 FBS 3-5 STTB 2,5-PV STTB 2,5-PE STTB 2,5 STTB 2,5-2DIO/O-UL/UR-UL STTB 2,5-DIO/O-U E/AL-NS 35 UK35 FKC 2,5/ 4-ST-5,08-RF FKIC 2,5/ 4-ST-5,08-RNDA15SSBT F99-920-702 F1042-2SK F-GSCH1/5-K130 Han® PushPull RJ45 Han® PushPull Han® PushPull RJ45 Han® PushPull PATCHKABEL2GR HAN25D EATON (Moeller GMB Günther Müller Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Siemens Bender Bender Lütze Bender Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Souriau EVG Schuricht Distrelec GmbH FCT Electronic GmbH Harting Harting Harting Harting Reichelt Harting 266744 Achse lang 3RV1421-0KA10 3SB3000-1CA11 3SB3403-0c 3SB1904-2AA 3SB3925-0AV 3SB3247-0AA31-0CCO 3SB3925-0AV 3SB1904-2AA 3SB3208-2DA11-0CC0 3SB3925-0AV 3SB1904-2AA 3SB3208-2DA11-0CC0 3SB3925-0AV 3SB1904-2AA 3SB3201-2KA11-0CC03SB3925-0AV 3SB1904-2AA 3SB3000-5AE51 3SB3403-0A 3SB3925-0AV 3SB1904-2AA B980800051 B 98080501 722983 WX-250 3022218 3030459 3030161 3030174 3031539 3036026 3031270 3031584 3031555 1201662 3008012 1925715 1925883DA15SSBT F99-920-702 126496 F-GSCH1/5-K130 09 35 221 0311 09 35 002 5402 09 35 221 0311 09 35 002 5402 PATCHKABEL2GR 09 21 025 3001 R911172000R911172480 Q0 QT1 S1 wie Kopier- und Weitergaberecht, bei uns. Alle Rechte bei Bosch Rexroth AG, auch für den Fall S1 S1 S1 SL7/-PL7 SL7/-PL7 SL7/-PL7 SW2 SW2 SW2 SW3 SW3 SW3 SW4 SW4 SW4 SWE7 SWE7 SWE7 SWE7 T1 T1 T10 WT1 XL XL XL XL XL XL XL XL XL XL10 XL10 XQ0 XQ0 XS1A XS1A XS1A XS1A XS5A XS5A b R911172016 c R911172478 d e information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. XS5B XS5B XS5B XS6.1 This document, as well as the data, specifications and other f Bill of materials WSC60HA-040.21-Basis en 1070091891 Sheet/Bl. 22 Sheets/Bl. 281 2 3 4 5 6 7 8 BOS_IND_1 List of material Parts nomenclature XS6.1 von Schutzrechtsanmeldungen. Jede Vefügungsbefugnis, Quantity Designation Type number Manufacturer Part number Materials number a 1 1 10 1 1 1 1 10 1 2 1 Add-on enclosurewith folding cover Socket insert Female contacts Coding socket Pin insert Add-on enclosure with folding cover Socket insert Female contacts Sleeve housing Pin contacts Coding pin HAN25D HAN25D BUCHSEN 0,5MM² 09 33 000 9909 HAN25DHAN25D HAN25D BUCHSEN 0,5MM² HAN25D STIFTE 0,5MM² 09 33 000 9908 Harting Harting Harting Harting Harting Harting Harting Harting Harting Harting Harting 09 20 016 0321 09 21 025 3101 09 15 000 6203 09 33 000 9909 09 21 025 3001 09 20 016 0321 09 21 025 3101 09 15 000 6203 19 20 016 1440 09 15 000 6103 09 33 000 9908 R911171301 R911171291 b R911171291 XS6.1 XS6.1 XS6.1 wie Kopier- und Weitergaberecht, bei uns. Alle Rechte bei Bosch Rexroth AG, auch für den Fall XS6.2 XS6.2 XS6.2 XS6.2 XS6.2 XS6.2 XS6.2 c d e information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. This document, as well as the data, specifications and other f Bill of materials WSC60HA-040.21-Basis en 1070091891 Sheet/Bl. 23 Sheets/Bl. 28This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. wie Kopier- und Weitergaberecht, bei uns. von Schutzrechtsanmeldungen. Jede Vefügungsbefugnis, Alle Rechte bei Bosch Rexroth AG, auch für den Fall 1 Structure of hall installation plate 1070091891 Sheet/Bl. Sheets/Bl. 2 3 4 5 6 WSC60HA-040.21-Basis en 28 24 a c d b e f BOS_IND_1 7 8This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. wie Kopier- und Weitergaberecht, bei uns. von Schutzrechtsanmeldungen. Jede Vefügungsbefugnis, Alle Rechte bei Bosch Rexroth AG, auch für den Fall frame G1 G1 1 Optional supporting HA-040.22 1070091892 2 3 X 4 5 1070091891 Sheet/Bl. Sheets/Bl. 6 G1 WSC60HA-040.21-Basis en 28 25 e f X 7 8 BOS_IND_1 a c d bThis document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. wie Kopier- und Weitergaberecht, bei uns. von Schutzrechtsanmeldungen. Jede Vefügungsbefugnis, Alle Rechte bei Bosch Rexroth AG, auch für den Fall 1 supporting frame primed for hanging up flame retracted (standard 2 3 4 5 1070091891 Sheet/Bl. Sheets/Bl. 6 WSC60HA-040.21-Basis en flame retracted (standard top of the cabinet flagband yellow / black bonded both-sided 28 26 a c d b e f primed for hanging up BOS_IND_1 7 81 2 3 4 5 6 7 8 BOS_IND_1 Parts list - hall installation plate Item designation BV1 von Schutzrechtsanmeldungen. Jede Vefügungsbefugnis, page/ path /13.4 /25.1 /25.1/25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1/25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1/25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1/25.1 /25.1 Bosch Rexroth Amount 1 1 1 2 1 2 1 2 1 1 1 2 2 3 6 3 1 2 8 3 1 2 0,4 m 2 2 2 5 2 3 3 1 2 1 1 0,85 m 0,3 m 1 1 1 1 0,25 m 0,4 m 1 1 1 1 1 1 1 1 Designation Flow monitor waterplate Audi X77 Stainless steel tube Stainless steel tube Stainless steel tube Stainless steel tube Water distributor Closing cone Closing cone Label set dirt trap cable clamp cablestar Ermeto pipe clamp mounting rail positiv reducing coupling Ermeto pipe clamp Ermeto pipe clamp Ermeto pipe clamp Pipe protection caps Screw-type covering cap Screw-type covering cap Cable duct Hose nozzle Hose nozzle Screw-in gland Screw-in gland Screw-in gland Screw-in gland Hose nozzle Ball valve Ball valve Sealing head Sealing head Parker plug-in hose Parker plug-in hose Maintenance unit Pressure gauge Pressure gauge Silencer Compressed-air hose Compressed-air hose Elbow coupling Angular plug-in connection Straight cable gland Elbow coupling Straight cable gland Double nipple Reducing nozzle Double nipple Type number 300112C7CH Wasserplatte/X77 JAE-VA-ROHR-370mm beideseitig Aussengewinde 1/2 zoll JAE-VA-ROHR-710mm beideseitig Aussengewinde 1/2 zoll JAE-VA-ROHR-650mm beideseitig Aussengewinde 1/2 zoll JAE-VA-ROHR-730mm beideseitig Aussengewinde 1/2 zollWasserverteiler für HA Audi T99 China STOPFEN 1/2 STOPFEN 3/8 AUDI T99/HIP SF00.1.2.1.0 X6.080.001 X6.081.003 RAP533.7X TMA/TMB1VERZX M6 1"x1/2"V4A VK38MSV VK12MSV RAP321.3X GPN250/15 3/8 Zoll 800M 1/2 Zoll 800M 01341152 39-V-16631 1/2 39-V-16631 3/8 39-D-1402/3 3/8"-1/2" 39-D-1403/3 1/2"-1/2" 39-D-1403/2 3/8"-3/8" 39-D-1403/5 1"-1" 39-V-16631 1" SKG0110130blauSKG0110131rot 36C82-10-6BK 37C82-10-6BK 831-6RED-RL 831-8RED-RL AS2-FRE-G038-GAN-100-PBP-H0-05.00 G1/4 ANZEIGE 0-10 BAR PG1-ROB-G014-SAS-D63-0-10 BAR SI1 G1/4 1820712086 1820712087 G1/2 G12 G1/2 G1/4 QR2-S-RVTG3/8 QR2-S-RPN R3/8a-R1/2a G1/4A-G3/8i G3/8A-G3/8A manufacturer Günther GmbH Jäger Jäger Jäger Jäger Jäger Papp Zerspanungstechnik Jäger Jäger Rosenbaum PKP Prozessmesstechnik Nimak Nimak Kistenpfennig AG Kistenpfennig AG Stapf Kistenpfennig AG Kistenpfennig AG Kistenpfennig AG Pöppelmann PöppelmannPöppelmann Uni-Elektro Reinhold Quiter GmbH Reinhold Quiter GmbH Reinhold Quiter GmbH Reinhold Quiter GmbH Reinhold Quiter GmbH Reinhold Quiter GmbH Reinhold Quiter GmbH PKP Prozessmesstechnik PKP Prozessmesstechnik Parker Parker Parker Parker Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Article number300112C7CH Wasserplatte/X77 JAE-VA-ROHR-370mm JAE-VA-ROHR-710mm JAE-VA-ROHR-650mm JAE-VA-ROHR-730mm Wasserverteiler für HA Audi T99 China STOPFEN 1/2 STOPFEN 3/8 AUDI T99/HIP SF00.1.2.1.0 X6.080.001 X6.081.003 RAP533.7X TMA/TMB1VERZX 328279 VK38MSV VK12MSV RAP321.3XGPN250/15 3/8 Zoll 800M 1/2 Zoll 800M 01341152 39-V-16631 1/2 39-V-16631 3/8 39-D-1402/3 3/8"-1/2" 39-D-1403/3 1/2"-1/2" 39-D-1403/2 3/8"-3/8" 39-D-1403/5 1"-1" 39-V-16631 1" SKG0110130blau SKG0110131rot 36C82-10-6BK 37C82-10-6BK 831-6RED-RL 831-8RED-RL R412006203 R412004417 R412004423 R412004817 1820712086 1820712087 1823391840 1823391944 1823373054 1823391718 1823373051 1823391020 8931843804 1823391019 Materials number R911172481 aHIP HIP HIP wie Kopier- und Weitergaberecht, bei uns. Alle Rechte bei Bosch Rexroth AG, auch für den Fall HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP b c d e information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. HIP HIP HIP HIP This document, as well as the data, specifications and other f Parts list - hall installation plate WSC60HA-040.21-Basis en 1070091891 Sheet/Bl. 27 Sheets/Bl. 281 2 3 4 5 6 7 8 BOS_IND_1 Parts list - hall installation plate Item designation HIP von Schutzrechtsanmeldungen. Jede Vefügungsbefugnis, page/ path /25.1 /25.1 /25.1/25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /25.1 /8.6 Bosch Rexroth Amount 3 1 1 1 1 1 1 1 1 2 1 2 1 Designation Sleeve Elbow coupling Elbow coupling Cross connector Reducing screw fitting Elbow coupling T-connector screw seal plug Elbow coupling Elbow coupling screw seal plug Double nipple Prop. valve Type number FPT-S-RSK-G012 FPT-SRVK-R012 FPT-S-RVT-R038-G038 G3/8 - Kreuzanschluss FPT-S-RDZ-G038-G014 FPT-S-RVT-R014-G014 FPT-S-RTK-G012 FPT-S-RBI-G012 R1/2 FPT-S-RVT-R012-G012 G1/2 FPT-S-RVK-G012 G1/2 G1/4 R1/2a-R1/2a ED05-000-100-010-1M12S manufacturer Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Bosch Rexroth Article number 1823300008 1823391736 1823391729 1823390043 1823391013 1823391728 1823391742 1823462031 1823391730 1823391724 1823462003 1823391029 R414002297 Materials number a HIP_ HIP_ HIP_ wie Kopier- und Weitergaberecht, bei uns. Alle Rechte bei Bosch Rexroth AG, auch für den Fall HIP_ HIP_ HIP_ HIP_ HIP_ HIP_ HIP_ HIP_ KYP1 b c d e information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. This document, as well as the data, specifications and other f Parts list - hall installation plate WSC60HA-040.21-Basis en 1070091891 Sheet/Bl. 28 Sheets/Bl. 28。

PST 6000PST 6000.XXX Thyristor Power Unit with integrated control functionTechnical Information101EditionPST 6000PST 6000.XXX Thyristor Power Unitwith integrated control functionTechnical Information1070 080 058-101 (2001.04) GBReg. no. 16149-03E2000-2001This manual is the exclusive property of Robert Bosch GmbH,also in the case of Intellectual Property Right applications.Without their consent it may not be reproduced or given to third parties.Discretionary charge 10.-1070 080 058-101 (2001.04) GB ContentsPage 1Safety instructions 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Safety instructions and symbols attached to the product 1-1. . . . . . 1.2Safety instructions and symbols used in this manual 1-2. . . . . . . . . 1.3Intended use 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4No admittance for persons fitted with cardiac pacemakers 1-4. . . . 1.5Qualified personnel 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6Installation and assembly 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7Electrical connection 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8Ensuring EMC of the completely assembled system 1-12. . . . . . . . . 1.9Operation of the thyristor power units 1-13. . . . . . . . . . . . . . . . . . . . . . 1.10Retrofits and modifications by the user 1-14. . . . . . . . . . . . . . . . . . . . . 1.11Maintenance, repair 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12Working safely 1-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Setup 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Features 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2Modules and components 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3Function 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4Monitoring 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Notes on Rating 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Commissioning 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Maintenance 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Malfunction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Type overview 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1Features 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8PST 6100.XXX L 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1PST 6100.XXX L overview 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2Explanation of drawings 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3PST 6100.XXX L front panel 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4Technical data, PST 6100.XXX L 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . 8.5Dimensioned drawing, PST 6100.XXX L 8-5. . . . . . . . . . . . . . . . . . . 8.6Electrical connection, PST 6100.XXX L 8-6. . . . . . . . . . . . . . . . . . . . 8.7Load diagram, PST 6100.XXX L 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . 8.8Accessories, PST 6100.XXX L 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.1Dimensioned drawing, accessories kit 8-8. . . . . . . . . . . . . . . . . . . . . 8.9Ordering accessories 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1070 080 058-101 (2001.04) GBPage9PST 6250.XXX L 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1PST 6250.XXX L overview 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2Explanation of drawings 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3PST 6250.XXX L front panel 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4Technical data, PST 6250.XXX L 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . 9.5Dimensioned drawing, PST 6250.XXX L 9-5. . . . . . . . . . . . . . . . . . . 9.6Electrical connection, PST 6250.XXX L 9-6. . . . . . . . . . . . . . . . . . . . 9.7Load diagram, PST 6250.XXX L 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . 9.8Accessories, PST 6250.XXX L 9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.1Dimensioned drawing, accessories kit 9-8. . . . . . . . . . . . . . . . . . . . . 9.9Ordering accessories 9-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10CE declaration of conformity 10-1. . . . . . . . . . . . . . . . . . A Annex A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1Index A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1070 080 058-101 (2001.04) GB1Safety instructionsThe products described were developed, manufactured and tested in com-pliance with the fundamental safety requirements of the EU machine direc-tive. 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 com-missioning the products. Store this manual in a place to which all users have access at any time!This manual describes the:D PST 6000 thyristor power unitsThe functions of the integrated weld timer are described in a separate manual.1.1Safety instructions and symbols attached to the productWarning of dangerous electrical voltage!Lug for connecting PE conductor only!1070 080 058-101 (2001.04) GB1.2Safety instructions and symbols used in this manualDANGEROUS ELECTRICAL VOLTAGE This symbol is used to warn of dangerous electrical voltage. Failure to observe the instructions in this manual in whole or in part may result in per-sonal 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 ..Note: This symbol is used to draw the user’s attention to special cir-cumstances.L This symbol is used if user activities are required.Modifications in this manual as compared to a previous edition are marked by black vertical bars in the margin.1070 080 058-101 (2001.04) GB1.3Intended usePST 6000 thyristor power units are designed for connection of welding trans-formers.These thyristor power units are designed for use in D resistance welding of metals andD are suitable for operation in industrial environments as per DIN EN 50082-2 and 50081-2 on electromagnetic compatibility (EMC).They are not intended for any other use!DANGER Any use other than for the purpose indicated may result in personal 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!.Note: For operation in residential environments, in trade and commer-cial 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, stor-age, erection and installation as well as careful operation.1070 080 058-101 (2001.04) GB1.4No admittance for persons fitted with cardiac pacemakersDANGERWARNING for persons fitted with cardiac pacemakers!T o protect persons fitted with cardiac pacemakers, noĆentry signsshould be posted because pacemaker malfunction (missedpulses,total failure), pacemaker program interference or even programdestruction is to be expected.Note: We recommend that warning sings like the one shown below are posted at every entrance to manufacturing shops housing resistance-welding equipment:No entry for persons with cardiac pacemakers!Danger!DIN 400231070 080 058-101 (2001.04) GB 1.5Qualified personnelThe requirements as to qualified personnel are based on the requirements profiles as defined by the ZVEI (Zentralverband Elektrotechnik und Elek-tronikindustrie - German Electrical and Electronic Manufacturers’ Associ-ation) and the VDMA (Verband deutscher Maschinen- und Anlagenbau -German Engineering Federation) in:Weiterbildung in der Automatisierungstechnik edited by: ZVEI and VDMA Maschinenbau Verlag Postfach 71 08 64D-60498 Frankfurt .This manual is designed for technicians and engineers with special welding training and skills. They must have a sound knowledge of the hardware com-ponents of the weld control system, the PST 6000 thyristor power units and the welding transformers.Interventions in the hardware and software of our products, unless de-scribed otherwise in this manual, are reserved to specialized Bosch person-nel.Tampering with the hardware or software, ignoring warning signs attached to the components, or non-compliance with the warning notes given in this manual can result in serious bodily injury or property damage.Only skilled persons as defined in IEV 826-09-01 who are familiar with the contents of this manual may install and service the products described.Such personnel areD those who, being well trained and experienced in their field and familiar with the relevant standards, are able to analyze the work to be carried out and recognize any hazards.D those who have acquired the same amount of expert knowledge through years of experience that would normally be acquired through formal tech-nical training.DANGER!An exception are persons with cardiac pacemakers! The strong magnetic fields occurring in resistance welding may af-fect 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 ev-ery entrance to manufacturing shops housing resistance-welding equipment.Please note our comprehensive range of training courses. More information is available from our training center (Phone: +49 / 6062 / 78-258).1.6Installation and assemblyDANGERNon-workmanlike installation or mounting may lead to personal in-jury 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 personnelonly.DANGERInsufficient degree of protection may be life-threatening or causedamage to property!The degree of protection of thyristor power units is IP 20. They mustbe installed in switchgear cubicles providing a degree of protectionof no less than IP 54.DANGERDanger of injury and of damage to property through incorrect instal-lation!Devices and, in particular, operating means, must be installed so asto be properly safeguarded against unintentional operation or con-tact.DANGERRisk of injury from sharp-edged sheet metal!Wear protective gloves!DANGERDanger of personal injury and damage to property through inade-quate fastening!The place for installing the thyristor power units, and their methodof fastening, must be suitable for their weight!Injuries and bruises may be caused by lifting weights which are tooheavy or by sharp metal edges!Due to the heavy weight of individual modules several persons arerequired for installation and assembly.Wear safety shoes and safety gloves!DANGEROUS ELECTRICAL VOLTAGEBefore the modules are installed, the respective mounting station must be safely isolated from supply and properly safeguarded to pre-vent unintentional or unauthorized reclosing.CAUTIONShort circuits!When cut-outs are drilled or sawed in switchgear cubicles, metal burr may get into modules already installed there. Or, when cooling water lines are connected, water may leak into the thyristor power units installed.The possibility of short circuits occurring in the process or even the destruction of the devices cannot be entirely ruled out. Therefore, guard any existing modules well before you install a new module! Any and all warranty excluded in case of non-compliance.CAUTIONHeat accumulation!Thyristor power units must be mounted with a minimum clearance of 100 mm on top and at the bottom. Without this minimum clearance, heat may accumulate and cause power unit failure.CAUTIONIn the case of airĆcooled thyristor power units, the temperature inside the housing must stay within the specified range. Thyristor power units must always be operated under forcedĆair cooling conditions. Convection cooling will not be sufficient!CAUTIONLeaks in the cooling water circuit may cause consequential damage! Cooling water leaks may damage adjacent components. Therefore, when mounting water-cooled modules, always ensure that other de-vices in the switchgear cabinet are well protected against leaking cooling water.CAUTIONDamage to property through inappropriate or insufficient cooling of the thyristor power units!Water-cooled thyristor power units may only be operated when the cooling water circuit is active! Condensation on water-carrying com-ponents must be prevented.Damage to property through insufficient water quality in the cooling water circuit!Deposits in the cooling system may reduce the water flow, thus im-pairing the performance of the cooling system with time.Therefore, you should ensure that your cooling water has the follow-ing properties:D pH value:7 to 8.5D Degree of hardness D max:10 German degrees(1 German degree = 1.25 British degrees = 1.05 US degrees =1.8 French degrees)D Chlorides:max. 20 mg/lD Nitrates: max. 10 mg/lD Sulfates:max. 100 mg/lD Insoluble substances:max. 250 mg/lTap water usually meets these requirements. However, an algicide should be added.L Make sure that all contact surfaces are bright, i.e. free of paint, plastic coat-ing or dirt/oxidation.L Mount the device in a vertical position.1.7Electrical connectionDANGEROUS ELECTRICAL VOLTAGEThe mains voltage is associated with many dangers!Possible consequences of improper handling include death or mostsevere injuries (personal injuries) and damage to property. For thisreason, the electrical connection must always be made by an electri-cal expert in compliance with the valid safety regulations, the mainsvoltage and the maximum current consumption of the individualunits of the equipment.The mains voltage must match the nominal voltage given on thenameplate of the product!The equipment must be appropriately fused on the supply side!Prior to connecting a thyristor power unit, the following must bestrictly observed:D Power OFF.D Provide a safeguard to prevent unintentional reclosing.D Verify that the system is safely isolated from supply andde-energized.D Connect to earth and short circuit.D Cover up or safeguard all live parts.DANGEROUS ELECTRICAL VOLTAGEHandling live parts at mains voltage may result in death, severebodily injury or considerable damage to property unless appropriateprecautions are taken.For this reason, the electrical connection must always be made byan electrical expert in compliance with the valid safety regulations,the mains voltage and the maximum current consumption of the indi-vidual units of the equipment.Incorrect mains voltage may render the system dangerous or causeelectrical component failure!Therefore, please ensure the following:D The mains voltage must match the nominal voltage given on thenameplate of the product!D Mains voltage fluctuation or variation from the nominal voltagemust be within the specified tolerance range (see Technical Data).D The equipment must be appropriately fused on the mains side!D Proper and well insulated tools must be used for handling electricconnections!DANGEROUS ELECTRICAL VOLTAGEDanger of life through insufficient protective conductor system!The thyristor power units must be connected to the protective earth-ing (PE) circuit of the system. Please ensure that the cross-sectional area of cables used for protective conductor wiring is sufficiently large. The electrical continuity of the protective earthing circuit must be verified in accordance with EN 60204 Part 1.DANGEROUS ELECTRICAL VOLTAGEThyristor power units may be operated in earth neutral systems only.Protective grounding is the only protective measure permitted as per EN 50 178 (DIN VDE 0160)!DANGEROUS ELECTRICAL VOLTAGEOperation in unbalanced networks (only one network phase grounded) is not permitted..Note: It is recommended that the whole welding system be operated within a separate welding power network.CAUTIONConnecting lines and signal lines must be laid so as to avoid nega-tive effects on the function of the units through capacitive or induc-tive interference!Interference is frequently coupled and de-coupled in long cables.Therefore, thyristor power unit cables and control cables must be routed separately. The influence of interfering cables on cables sus-ceptible to interference can be minimized by keeping the following distances:D> 100 mm if cables are run in parallel for < 10 m,D> 250 mm if cables are run in parallel for > 10 m.The thyristor power unit should be mounted close to the welding systems so as to avoid cable lengths of more than 25 m.CAUTIONConnection cables may come off and apply dangerous voltage to system components!It is crucial that cables are properly fixed.L PE connection: Connect to a central earth point. Make sure that cable cross-sectional areas are sufficiently large!L All conductor cross-sections must be large enough for the loads to be con-nected.L U1 connection:Connect to L1 system phase.L V1 connection: Connect to L2 system phase.L U2 and V2 welding transformer outputs: Connect to welding trans-former.1.8Ensuring EMC of the completely assembled system.Note: The completely assembled system with the welding transformercomplies with prEN 50240, the EMC product standard for resistancewelding systems, and EN 55011 (October 1997), EMC product familystandard class A, group 2, rated current > 100 A.D Only for industrial applications.D Safe clearance from residential areas y 30 m.D Safe clearance to communication systems (wireless, telephone) y 10 m.D Cable length of mains feeder y 10 m.D Interference suppression measures: When switchgear cabinet doors areopen, operation of radio devices or cell phones is permitted only beyonda safe clearance of y 2 m.1.9Operation of the thyristor power unitsDANGERDanger of personal injury and damage to property if devices are op-erated before they have been properly installed!The devices are designed to be installed in housings or switchgearcabinets and must not be operated unless properly installed andswitchgear cabinet doors are closed!DANGERDanger of personal injury and damage to property through missingor false interpretation of fault messages!Therefore, closing of the temperature contact (thermostatic switch,break contact) must inhibit the connected timer!As regards fault analysis, see also the section on ”Malfunction”.DANGERDanger of bruises through electrode movement!All users, line designers, welding machine manufacturers and weld-ing gun producers are obliged to connect the output signal of theBosch weld timer which initiates the electrode movement so that theapplicable safety regulations are complied with.The risk of bruises can be considerably reduced by means of, e.g.,two-handed start, guard rails, light barriers etc.CAUTIONDamage to property through insufficient cooling of the modules!Ensure that the modules are properly cooled during operation. Con-densation on water-carrying components must be prevented. In thecase of air-cooled thyristor power units, the temperature inside themounting station must remain in the specified range. In the case ofwater-cooled thyristor power units, the maximum permitted cooling-water temperature must not be exceeded.CAUTIONDamage to property through excessive welding current!The maximum welding current depends on the thyristor unit and thewelding transformer in use. It must not be exceeded.Therefore, the user must check the load in each case. See also thesection on ”Load diagrams”.Any and all warranty excluded in case of non-compliance.1.10Retrofits and modifications by the userDANGERRetrofits or modifications may have negative effects on the safety ofthe unit!Product modification may cause death, severe or light personalinjury, damage to property or environmental damage.Therefore, please contact us prior to making any modification. Thisis the only way to determine whether modified components aresuitable for use with our products.1.11Maintenance, repairDANGEROUS ELECTRICAL VOLTAGEPrior to any maintenance work - unless described otherwise - thesystem must always be switched off!In the event of necessary measurement or test procedures on the ac-tive system, these have to be performed by skilled electrical person-nel.In any case, suitable insulated tools must be used!DANGERDanger of life through inappropriate EMERGENCY-STOP facilities!EMERGENCY-STOP facilities must be operative in all modes of thesystem. Releasing the EMERGENCY-STOP facility must by no meansresult in an uncontrolled restart of the system! First check the EMER-GENCY-STOP circuit, then switch the unit on!DANGERDanger of explosion of batteries!Do not forcefully open batteries, do not attempt to charge, solder orincinerate the battery.Empty batteries should always be replaced by new ones!The applicable regulations on the disposal of empty batteries or ac-cumulators must be observed.DANGERThe right to perform repair/maintenance work on the components ofthe thyristor power units is reserved to the BOSCH service depart-ment or to repair/maintenance units authorized by BOSCH!CAUTIONOnly use spare parts approved by BOSCH!1070 080 058-101 (2001.04) GB1.12Working safelyDANGERDuring operation of the welding equipment welding splashes are to be expected! They may cause eye injuries or burns.Therefore:D wear protective goggles D wear protective glovesDwear flame-retardant clothesDANGERDanger of injury from sheet metal edges and danger of burns from weld metal!Therefore: - wear protective glovesDANGERIn the environment of resistance welding systems, magnetic field strengths have to be expected which are above the limit values spe-cified in VDE 0848 Part 4. Especially if manual guns are used, the limit values for extremities may be exceeded.In cases of doubt, you should measure the field strength and take additional measures to ensure safety and health at work.CAUTIONThe strong magnetic fields occurring in the resistance welding pro-cess may cause permanent damage to wrist watches, pocket watches, or cards with magnetic stripes (e.g. EC cards).Therefore, you should not carry any such items on you when working in the immediate vicinity of the welding equipment.1070 080 058-101 (2001.04) GB2Setup2.1FeaturesDIntegrated control functionality D Integrated weld timerD Flexible parallel and/or serial I/O interfaces D Fieldbus interfaces for communicationD Integrated control and monitoring functionsD Control functionality separate from monitoring functionality D Air or water cooledD Less cabling required due to system component integration D Functionality designed for welding quality optimization DEasily integrated into a portable welding box system (SCHWEISSKOFFER)D BOS-5000 operator interface provides for easy programming, operation and diagnosticsPST 6000.XXX thyristor power unit1070 080 058-101 (2001.04) GB2.2Modules and componentsThe PST 6000 thyristor power units serve to control the welding trans-formers.Integrated features:D the weld timer (central processing unit, CPU)D one slot for the type-specific I/O interfaceD one slot for the field bus module for programming (optional)D one slot for retrofitting a quality module (optional)Setup for welding1070 080 058-101 (2001.04) GBBlock diagram of a thyristor power unit1070 080 058-101 (2001.04) GB2.3FunctionThe thyristor power unit is designed for alternating current resistance weld-ing. Key components of an AC welding system are the thyristor power unit,the weld timer and the welding transformer.The figure below shows the basic functional design.Basic functional design of the AC welding process2.4MonitoringIn order to ensure high operational reliability, various monitoring functions are incorporated in the PST 6000 thyristor power unit.There is a thermostatic switch to signal any overload on the thyristor power unit to the weld timer.The weld timer will then output a ”Thyristor unit fault” message.When the fault has been cleared, the error message is reset as follows:D with the reset button on the weld timer front panelD by an input signal for acknowledgement (type-specific)D by an input on the BOS-5000 operator interface D by an input on the Bosch operator terminal (BT)1070 080 058-101 (2001.04) GB3Notes on RatingThe load capability of a thyristor power unit is always predefined by the type designation indicating the specific maximum welding transformer rating.CAUTIONOverloading may cause damage to the thyristor power unit!Always check the actual load applied on the thyristor power unit! Any and all warranty excluded in case of damage caused by overload.To check the actual load, use the load diagram. It shows the D output currents (I PRIM in A) relative to D the duty cycle (ED in %) atD maximum ambient temperature (in °C)that can be switched by the PST 6000 thyristor power unit.The weld time t s and the overall weld cycle duration tsp must be known to determine the duty cycle.Weld time and overall weld cycle durationThe duty cycle is computed as follows:ED =t st sp* 100%Example:ED =2 per.4 per.In the graph shown above, the weld time is 2 periodsand the overall weld cycle duration is 4 periods.This results in a duty cycle ED = 50%.• 100% = 50%.Note: If different weld times or overall weld cycle times occur on a machine, the longest weld time and the shortest overall weld cycle time (to be determined, if required, by adding the longest weld time to the shortest cool time) must be used for calculating the duty cycle!When you have calculated the duty cycle, you can use load diagrams to verify the proper selection of the thyristor power unit.。