Rexroth PS 6000 The integrated system for the highest quality in resistance welding Safe, flexible and economical
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Rexroth PS 6000 powerful in medium frequency and AC applications Used in countless applications, welding systems made by the European market leader Rexroth are the first choice of satisfied car manufacturers, tier one suppliers, and welding equipment manufacturers worldwide. Our new PS 6000 system for applications up to 360 kA is the sequel to this success story. The benefits for you: increased process reliability, reduced rework costs and consistent weld spot quality even with the most challenging material combinations.
The modular concept behind the
PS 6000 integrates fully compatible and coordinated components in one particularly cost-effective system: intelligent inverter highly dynamic electric servo cylinder precise pneumatic servo cylinder powerful medium frequency transformers The flexible control system, adaptive control modes and high-dynamic servo drives allow you to break into new innovative applications. Standard functions, such as constantcurrent regulation, pressure regulation, electrode management and tip dressing, ensure the weld quality lives up to your demands.
Benefits
high reliability achieved through
the use of tried and tested technology maximum flexibility in the I/O and network area thanks to plugin cards such as PROFIBUS, PROFINET IO, DeviceNet, INTERBUS and Ethernet TCP/IP 100% quality control and documentation of spot welds derived from the latest ultrasonic technology expulsion reduction achieved by adaptive control of the welding process electric or pneumatic servo gun drives integrated into the compact weld control Windows-based user interface for all process functions with SQL database innovative functions for process monitoring and component protection flexibility for retrofitting function and process modules
Rexroth PS 6000 the powerful system
solution for the automotive industry and for suppliers and manufacturers of welding systems
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Intelligent inverter
Modular medium frequency resistance welding control system with integrated servo gun control (servo electric or servo pneumatic) and PSQ 6000 process module. Upgrades are possible with plug-in I/O modules for all commonly-used networks.
Highly dynamic electric servo cylinder
Our innovative drive with an integrated force sensor allows for opening and closing the welding guns with position and force accurately with user definable settings. The regulated and safe operation ensures the best process quality.
Precise pneumatic servo cylinder
The optimum combination of intelligent electronics, along with the power and low price of pneumatics. The control ensures high speed with soft touch positioning, freely programmable position control and maximum repeatability and follow-up accuracy of the electrode force.
Powerful medium frequency transformers
Medium frequency transformers combining high power density with compact
dimensions and low weight. Included features: temperature monitoring, secondary current sensor and voltage tap.
System components
Development/Engineering
System solution
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Rexroth PSI 6000 the right inverter
any time for any application The intelligent PSI 6000 inverters have been specifically designed for spot, projection and resistance seam welding. The extensive control functions guarantee high process reliability. The PSI 6000 family offers a variety of additional functions for welding highstrength metals, aluminium and three sheet stackups.
The 1 000 Hz medium frequency/ DC
technology has proven its economic efficiency in many applications compared to other processes: Weld quality improved by more dynamic current control than can be achieved with mains frequency Weld-ability of many materials increased by more powerful energy supply expulsion reduced by decreased welding current and/or current time electrode life lengthened thanks to lower thermal and mechanical load on the electrode caps smaller and lighter transformers for integration into the weld gun
PSI 6100/6300 inverter
The international benchmark for
robotic applications up to 36 kA air-cooled/water-cooled PSQ 6000 quality control board (optional) connection to PSG 6130 MF transformer
PSI 6100 L1/L21)
PSI 6100 W11)
PSI 6200 W11)
PSI 6300 L1/L21)
PSI 6300 W11)
PSI 6500 W11)
110
110
220
110
110
660
400
400
1200
800
800
2400
Typical available output
kA
20
20
54
36
36
120
Recommended operating current range
kA
3 - 20
3 - 20
9 - 54
6 - 36
6 - 36
9 - 120
Conductor cross-section
mm2
35
35
95
35
35
2 to 4 cables, each 120 mm2
kg
21
25
56
21
25
70 mech. separable
Mains rated current
(max. continuous thermal current)
Max. output current
(peak output current)
Weight
1)
Mains voltage
L1/W1: 400 V to 480 V, 50/60 Hz
L2: 480 V to 690 V, 50/60 Hz
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PSI 63 S inverter
PSI 6200 inverter
PSI 6500 inverter
Inverter up to 36 kA with integrated
servo gun control air-cooled PSQ 6000 quality control board (optional) connection to PSG 6130 MF transformer UL-certified
Inverter for steel and aluminium
applications and resistance seam welding up to 54 kA water-cooled PSQ 6000 quality control board (optional) connection to PSG 6130 MF transformer
Inverter for resistance seam and
projection welding applications up to 120 kA water-cooled master-slave functions parallel connection of max. 3 inverters for currents of up to 360 kA
PSI 6000 series flexible in terms of plug-in I/O cards, field buses and function and process modules
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Rexroth PSQ 6000
for supreme quality in spot welding The PSQ 6000 control board with the unique quality monitoring system will ensure maximum process reliability on your production line using intelligent current/ voltage or ultrasonic pulse monitoring and control. The innovative technology also includes in-process monitoring of the weld. This process is supported by documentation, logging and statistical process control via the BOS 6000 user interface.
For process assurance Rexroth offers
the option of retrofitting the PSQ 6000 control board which can be used for current/voltage and ultrasonic control. It is part of the PSQ 6000 quality assurance system which controls, monitors and logs the welding process.
Adaptive current/voltage control
Integrated ultrasonic control and
testing
This allows accurate inspection of
the molten state of the spot welds and includes online display of the ultrasonic transmission variations concurrent with current, voltage and resistance characteristics in one diagram.
Integrated in the process, the ultrasonic measuring system monitors
the quality of the spot welds during the actual welding process. Ultrasonic pulses are used to control the size of the molten weld nugget, and to calculate and display the spot diameter.
BOS 6000 the combined user
interface for weld control and quality monitoring
PSQ 6000 control board for the ultimate
quality control in spot welding
For demanding material and metal
combinations Rexroth offers adaptive current/voltage control with monitoring functions for pass/fail assessments. Combined current/voltage control and ultrasonic testing
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Adaptive current/voltage control for
the highest spot weld quality
The adaptive current/voltage control
mode gives you added flexibility for future requirements in the welding process. By measuring current and voltage, the course of resistance and energy can also be recorded, controlled and accurately evaluated during welding. The adaptive control algorithm ensures constant weld quality and reduced expulsion. Expensive rework is no longer required.
U t
Adaptive current/voltage control consistent weld quality and reduced expulsion
Ultrasonic control for constant
weld spot diameter
The ultrasonic monitoring and
regulation system ensures the quality of the spot welds during the actual welding process. Being based on an independent measurement, the advantage of the ultrasonic transmission curve is its reliability in displaying and documenting the weld spot diameter. The destructive testing of spot welds with hammer and chisel can be eliminated. The ultrasonic system comprises the XQR control board, UDM signal processor and ultrasonic sensors.
Sendeimpuls
Empfangssignal
Ultrasonic control quality assured during the actual welding process
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Rexroth PSG 6000 compact medium
frequency transformer series The certified PSG 6000 transformers are an additional asset to our successful PSI 6000 inverter system. Precisely coordinated and perfectly compatible, these system components facilitate optimum power transfer and additional monitoring functions between the inverter and transformer, resulting in greater profitability and enhanced precision in welding.
The new medium-frequency transformers in the PSG 6000 series are
optimized for greater power and operating efficiency in resistance welding. They are characterized by a particularly compact design and low weight.
Component protection by integrated temperature monitoring of the winding package and the rectifier unit programmable monitoring limit values Advantages
Features of the PSG 6000 series
of transformers
Process monitoring by integrated current measuring coil secondary voltage pick-off for insulation monitoring
Rexroth as system supplier for
the control system the power circuit the medium-frequency transformer Project-related modifications such as integration of the MPE protective resistor are possible
lsec [kA] 50 Transformer load curve
45
20 ms 40 ms 60 ms 100 ms 200 ms 400 ms 1.000 ms 2.000 ms Transf.
40 35 30 25 20 15 10 Diode load curves
5 0 1
10 Duty cycle PSG 6130 [%]
100
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PSI 6000 and PSG 6000 the coordinated power pack
Combination Inverter
Transformer
Nominal DC voltage Usec (V)
Secondary current Iconst. (kA)
PSG 6130
PSG 6170
P (kVA at 20 % duty cycle)
130
170
Nominal DC voltage
Usec (V)
Continuous on-state current
Isec (kA)
6,5
8,5
Cooling water flow
m (l/min)
PSG 6000 transformer series
Imax (kA) Ouput
PSI 6100
PSI 6300
PSI 6200
PSG 3075
8,4
4,2
18
PSG 6130
9,0
6,5
20
2 x PSG 3075
8,4
6,5
36
PSG 6130
9,0
6,5
36
2 x PSG 6130
9,0
13,0
66
PSG 3200
13,0
6,5
40 Dimensions
PSI 6500
6 x PSG 6130
9,0
36,5
132
3 x PSG 3200
13,0
19,5
91
Mass
W x H x D (mm)
m (kg)
160 x 127 x 262 160 x 127 x 297
16
19
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Transformer engineering program
for optimized welding power Every medium-frequency transformer is exposed to a thermal load during welding. This load acts on the rectifiers (diodes) as well as on the iron/copper parts of the mediumfrequency transformer. The TTP transformer engineering program provides assistance with sizing the transformer. And it also points to existing performance reserves.
Given the different heat capacities
for the rectifier and the iron/copper parts it is necessary to calculate two duty cycles when sizing the transformer. The TTP transformer engineering program from Rexroth assists you with the sizing of medium-frequency transformers and inverters for your welding tasks. With the help of the duty cycle values and the welding current calculated by TPP, the load diagram is automatically checked to see whether the selected medium-frequency transformer is adequate for the welding job in question.
Also calculated is the thermal load on
the inverter. The inverter has to supply the required welding current for a certain duty cycle. This is verified by TPP and any performance reserves are indicated. Furthermore, the values calculated by TPP can be used for configuring the secondary section (e.g. connection cables).
Calculation of the connection cables (lamellar strips)
Transformer engineering program
Indication of performance reserves
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11
Transformer types from the 3000 series
Version with PSG
With secondary With pick-off
voltage pick-off for secondary for control circuit monitoring
Secondary Multi-contact Multi-contact Internal current Built-in/cast-in Output voltage, PG connection voltage for connection connection measuring MPE resistor secondary (mains/DC link) control looped MC 135 MC 150 coil and through (mains/DC link) (mains/DC link) temperature monitoring
3075.10 PZ 3075.10 PSV
3075.11 PSV 3075.10 AZ
Temperature monitoring
400 V/500 V
400 V/500 V
400 V/500 V
8,4 V
8,4 V
(without PG) 400 V/500 V
8,4 V
(without PG) 400 V/500 V
3075.10 AZS
3100.00 PSV
3100.01 PSV
8,4 V X
400 V/500 V
400 V/500 V
8,4 V
8,4 V
3200.00 A
8,4 V
8,4 V
(without PG) 400 V/500
Transformer types from the 6000 series
Version with PSG
With secondary With pick-off
voltage pick-off for secondary for control circuit monitoring
Secondary Multi-contact Multi-contact Internal current Built-in/cast-in Output voltage, PG connection voltage for connection connection measuring MPE resistor secondary (mains/DC link) control looped MC 135 MC 150 coil and through (mains/DC link) (mains/DC link) temperature monitoring
6130.00 AS
9V
(without PG) 400 V/500 V
6160.00 AS
11 V
(without PG) 400 V/500 V
6130.00 PS
9V
9V 9V
400 V/500 V
6130.00 PSC
400 V/500 V
6130.00 PSK
400 V/500 V
6130.00 PSV
400 V/500 V
9V
6160.00 PSV
400 V/500 V
11 V
6130.00 PSM
400 V/500 V
9V
6130.00 PSD
400 V/500 V
9V
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Rexroth PST 6000 cost-effective AC series
for standard applications Ideal for standard applications the PST 6000 AC series developed by Rexroth. With the same mechanical footprint as the PSI 6300/6100 series inverters, you have the option of upgrading your AC system to medium frequency with minimal cost. Naturally these control systems offer you the same flexibility in the I/O area and all the control functions of the entire PS 6000 system.
Air-cooled version ideal for spotwelding applications
Water-cooled version the solution of
choice for continuous operation on projection welding and seam welding jobs
The AC control systems are designed
for applications up to 250 kVA air-cooled/water-cooled optimum weld result by means of
primary or secondary current control
competitive solution for standard applications
Characteristic
PST 6100L
Line connection grounded TN or TT system
PST 6100W
PST 6250L
PST 6250W
400 V 20 % to 600 V +10 %, 50/60 Hz
Rated transformer output 20 % duty cycle, at 400 V~ and 80 % transformer
load up to 20 % system utilization
kVA
77/145*
167
224
257
Rated transformer output 50 % duty cycle, at 400 V~ and 80 % transformer
load up to 50 % system utilization
kVA
16/62,5*
106
65/141*
162
69/130*
150
200
230
mm2
50
50
95
95
kg
12,5
21
13
21,5
Rated line current; max. continous thermal current
Connection cross-section
Weight
* without/with fan hood
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Rexroth PST 600E compact power packs
for stationary machines and manual welding units For stationary welding machines and manual welding workstations the PST 600E AC controllers from Rexroth have a compact, slim design which makes them up to 60 % smaller and lighter. Nevertheless the PST 600E has the same extensive functions and the same user-friendly operation and programming as the PST 6000 modular controller.
Air-cooled version ideal for
manual welding gun applications and simple projection welding tasks
Water-cooled version ideal for manual
welding gun and projection welding applications requiring more power
The AC control systems are designed
no more cables and connectors for applications up to 95 or 155 kVA. optional slot for fieldbus module air cooling/water cooling (Ethernet) parallel input/output box with coor- ideal, attractively priced solution for dinated scope of functions use on older welding systems high-precision primary current control without external current sensor
Characteristic Khlung
PST 610EL
PST 610EW
PST 625EL
PST 625EW
PST 650EW
Air
Water
Air
Water
Water
Line connection grounded TN or TT system
400 V 20 % to 600 V +10 %, 50/60 Hz
Maximum output current for duty cycle
A%
300/300* 10/20*
300 20
389/365* 15/30*
400 30
2 400 10
Rated transformer output 50 % duty cycle, at 400 V~ and
80 % transformer load up to 50 % system utilization
kVA
68/95*
95
106/141*
155
500
95/130*
130
200
230
800
mm2
50
50
95
95
240
kg
8,6
7,9
13
9,1
11,2
Rated line current; max. continous thermal current
Connection cross-section Weight
* without/with fan hood
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Rexroth BOS 6000
operation and observation to perfection The BOS 6000 user interface is a user-friendly, future-proof system for monitoring and operation; it is Windows-based with integrated SQL database functionality. BOS 6000 allows joint operation of the weld control system, process module and servo gun control in one standard interface.
BT 6 the compact operator terminal
IndraControl VPP 40 the robust industrial PC
Given its dimensions, the spacesaving BT 6 control and diagnostic
unit is ideal for installation in control cabinet doors or operator consoles. For flexible use on site we can also supply this terminal as a handheld programming unit.
The VPP 40 industrial PC is the
complete solution for control, operation and visualisation. It is specifically designed for use as a Stand-alone or networked PC and can be integrated inexpensively in control cabinets. Depending on the operating requirements this PC can be supplied with a touch screen or keyboard.
BOS 6000 the integrated user interface
for weld control, process module and servo control
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PS 6000 supreme power housed in compact design PSI 6100/6300 and PST 6000 (air-cooled) 75
239
Top view
280 50
300
463
233
81.5
Front view
PSI 6200 Front view
Top view
288
653
280
250
PSI 6500 396
Top view
860
653
278
Front view
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Bosch Rexroth AG Electric Drives and Controls P.O. Box 11 62 64701 Erbach/Odw., Germany Berliner Strae 25 64711 Erbach/Odw., Germany Phone +49 6062 78-233 Fax +49 6062 78-728 www.boschrexroth.com
Presented by:
The data specified above only serve to describe the product.
As our products are constantly being further developed, no statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.
72 901 AE/2008-09A5HW R911312988 Bosch Rexroth AG 2008 Subject to revisions! Printed in Germany
