Bosch 6000 Technical Information Page 1

PSI 6000 Medium-Frequency Inverterswith integrated control functionTechnical InformationPSI 6000101Edition

Safety instructions1-31070 080 059-101 (2001.04) GB1.3 Intended usePSI 6000 MF inverters are designed for connection of PSG 3000 weldingtransformers.T

PSI 6500.XXX W112-31070 080 059-101 (2001.04) GB[1] M6 mounting optionsD rear panel[2] mains supply connection with shrouding cover[3] MF inverter sym

PSI 6500.XXX W112-41070 080 059-101 (2001.04) GB12.3 Technical data, PSI 6500.XXX W1Type 3-phase MF inverter, module designed forrecessed mountingWeld

PSI 6500.XXX W112-51070 080 059-101 (2001.04) GB12.4 Dimensioned drawing, PSI 6500.XXX W13830.75Side view, left(as seen from the front)Rear view396356

PSI 6500.XXX W112-61070 080 059-101 (2001.04) GB12.5 Electrical connection, PSI 6500.XXX W1electrical connections:2 to 4 cables, max. 120 mm2, ea.,wit

PSI 6500.XXX W112-71070 080 059-101 (2001.04) GB12.6 Cooling water connection, PSI 6500.XXX W1U1 V1 W1U2V23/PE~+−2/~2/PE~D - 64711 Erbach 107 Made in

PSI 6500.XXX W112-81070 080 059-101 (2001.04) GBThe heat sink of the water-cooled MF inverter is connected internally to theprotective earth conductor

PSI 6500.XXX W112-91070 080 059-101 (2001.04) GB12.7 Load diagram, PSI 6500.XXX W1. Note: For a general description of load diagrams, see Section 3.11

PSI 6500.XXX W112-101070 080 059-101 (2001.04) GB12.8 Accessories, PSI 6500.XXX W1D For PSG 3000 welding transformers, see Technical Information, PSG3

PSI 6500.XXX W112-111070 080 059-101 (2001.04) GB12.9 Ordering, PSI 6500.XXX W1Designation Part no.PSI 6500.XXX W1 medium-frequency inverter 1070 079

PSI 6500.XXX W112-121070 080 059-101 (2001.04) GBNotes:

Safety instructions1-41070 080 059-101 (2001.04) GB1.4 No admittance for persons fitted with cardiac pacemakersDANGERWARNING for persons fitted wi

CE declaration of conformity13-11070 080 059-101 (2001.04) GB13 CE declaration of conformity

CE declaration of conformity13-21070 080 059-101 (2001.04) GBNotes:

AnnexA-11070 080 059-101 (2001.04) GBA AnnexA.1 IndexAAccessories kit, 8-10, 9-15, 11-15Accessories PSI 6025.XXX L1, 8-8Accessories PSI 6100.XXX L1/L2

AnnexA-21070 080 059-101 (2001.04) GBElectrical connection PSI 6100.XXX L1/L2/W1/W2,9-8Electrical connection PSI 6200.XXX W1/W2, 10-6Electrical connec

AnnexA-31070 080 059-101 (2001.04) GBPSI 6025.XXX L1, 8-1PSI 6025.XXX L1 front panel, 8-2PSI 6100.XXX L1/L2/W1/W2, 9-1PSI 6100.XXX L1/L2/W1/W2 front p

AnnexA-41070 080 059-101 (2001.04) GBNotes:

A-11070 080 059-101 (2001.04) GB1070 080 059-101 (2001.04) GB · TI WS· AT/VWS · Printed in Germany

Safety instructions1-51070 080 059-101 (2001.04) GB1.5 Qualified personnelThe requirements as to qualified personnel are based on the requirementsprof

Safety instructions1-61070 080 059-101 (2001.04) GB1.6 Installation and assemblyDANGERNon-workmanlike installation or mounting may lead to personal in

Safety instructions1-71070 080 059-101 (2001.04) GBDANGEROUS ELECTRICAL VOLTAGEBefore the modules are installed, the respective mounting stationmust b

Safety instructions1-81070 080 059-101 (2001.04) GBCAUTIONDamage to property through inappropriate or insufficient cooling ofthe medium-frequency inve

Safety instructions1-91070 080 059-101 (2001.04) GB1.7 Electrical connectionDANGEROUS ELECTRICAL VOLTAGEThe mains voltage is associated with many dang

Safety instructions1-101070 080 059-101 (2001.04) GBDANGEROUS ELECTRICAL VOLTAGEDanger of life through insufficient protective conductor system!The me

Safety instructions1-111070 080 059-101 (2001.04) GBCAUTIONConnecting lines and signal lines must be laid so as to avoid nega-tive effects on the func

Safety instructions1-121070 080 059-101 (2001.04) GB1.8 System perturbationWhen operating a medium-frequency inverter a harmonic load must be ac-count

PSI 6000PSI 6000 Medium-Frequency Inverterswith integrated control functionTechnical Information1070 080 059-101 (2001.04) GBReg. no. 16149-03E 2000,

Safety instructions1-131070 080 059-101 (2001.04) GB1.9 Ensuring EMC of the completely assembled system. Note: The completely assembled system with th

Safety instructions1-141070 080 059-101 (2001.04) GB1.10 Operation of the medium-frequency invertersDANGERDanger of personal injury and damage to prop

Safety instructions1-151070 080 059-101 (2001.04) GB1.11 Retrofits and modifications by the userDANGERRetrofits or modifications may have negative eff

Safety instructions1-161070 080 059-101 (2001.04) GB1.12 Maintenance, repairDANGEROUS ELECTRICAL VOLTAGEPrior to any maintenance work - unless describ

Safety instructions1-171070 080 059-101 (2001.04) GB1.13 Working safelyDANGERDuring operation of the welding equipment welding splashes are tobe expec

Safety instructions1-181070 080 059-101 (2001.04) GB1.14 CE conformityCAUTIONThe CE mark is valid for the medium-frequency inverter only with re-spect

Setup2-11070 080 059-101 (2001.04) GB2 Setup2.1 FeaturesD Integrated control functionality for medium frequency weldingD Integrated welding controlD F

Setup2-21070 080 059-101 (2001.04) GB2.2 Modules and componentsThe PSI 6000 medium-frequency inverters serve to control the PSG 3000welding transforme

Setup2-31070 080 059-101 (2001.04) GBU1V1V2Mediumfrequency inverterU2Welding transformerStop circuit24VDC supplyexternaldeviceShunt tripPressuretyp

Setup2-41070 080 059-101 (2001.04) GB2.3 FunctionThe medium-frequency welding system (MF welding system) is designed fordirect current resistance weld

Setup2-51070 080 059-101 (2001.04) GB2.4 MonitoringIn order to ensure high operational reliability, various monitoring functionsare incorporated in th

Setup2-61070 080 059-101 (2001.04) GB2.5 Advantages and benefits of medium-frequency weldingThe PSI 6000 medium-frequency inverters supply an MF outpu

Setup2-71070 080 059-101 (2001.04) GBkAmssplash limitbonding limitgalvanized sheetbare sheetWelding of different sheet types, conventional 50/60 Hz we

Setup2-81070 080 059-101 (2001.04) GBNotes:

Notes on Rating3-11070 080 059-101 (2001.04) GB3 Notes on RatingThe load capability of an MF inverter is always predefined by the type desig-nation in

Notes on Rating3-21070 080 059-101 (2001.04) GB3.1 Load diagramsVarious types of semiconductors are used as power breakers in the weldingsystems. Gene

Commissioning4-11070 080 059-101 (2001.04) GB4 CommissioningDANGEROUS ELECTRICAL VOLTAGEDanger of life in case of contact with live parts!Upon commiss

Commissioning4-21070 080 059-101 (2001.04) GBNotes:

Maintenance5-11070 080 059-101 (2001.04) GB5 MaintenanceDANGEROUS ELECTRICAL VOLTAGEAll maintenance work must be carried out by skilled electricians i

Maintenance5-21070 080 059-101 (2001.04) GBDANGEROUS ELECTRICAL VOLTAGEThe right to perform repair/maintenance work on the timer compo-nents is reserv

ContentsV1070 080 059-101 (2001.04) GBContentsPage1 Safety instructions 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Safety instruct

Malfunction6-11070 080 059-101 (2001.04) GB6 MalfunctionAlthough the design of the MF inverters is quite rugged, malfunctions mayoccur in a few except

Malfunction6-21070 080 059-101 (2001.04) GBNotes:

Type overview7-11070 080 059-101 (2001.04) GB7 Type overview7.1 FeaturesPSI 6025.XXX L1D Medium-frequency inverter 0.5 to 7 kAD Air coolingD Integrate

Type overview7-21070 080 059-101 (2001.04) GBPSI 6200.XXX W1D Medium-frequency inverter 9 to 54 kAD Water coolingD Integrated control functionD Rated

PSI 6025.XXX L18-11070 080 059-101 (2001.04) GB8 PSI 6025.XXX L18.1 Explanation of drawingsThe following drawings show theD front plate with modules o

PSI 6025.XXX L18-21070 080 059-101 (2001.04) GB8.2 PSI 6025.XXX L1 front panelU1V1W1D - 64711 Erbach 107 Made in GermanyU1 V1 W1U2V23/PE~+−2/~2/PE~ADR

PSI 6025.XXX L18-31070 080 059-101 (2001.04) GB[7] slot for retrofitting a quality module[8] slot for fieldbus interface for programming[9] battery co

PSI 6025.XXX L18-41070 080 059-101 (2001.04) GB8.3 Technical data, PSI 6025.XXX L1Type 3-phase MF inverter, module designed forrecessed mountingWeld t

PSI 6025.XXX L18-51070 080 059-101 (2001.04) GB8.4 Dimensioned drawing, PSI 6025.XXX L1100 mm min. installation clear-ance at top and bottom of MFinve

PSI 6025.XXX L18-61070 080 059-101 (2001.04) GB8.5 Electrical connection, PSI 6025.XXX L1Side view, right(as seen from the front)V2U2V1all terminalsma

ContentsVI1070 080 059-101 (2001.04) GBPage8 PSI 6025.XXX L1 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Explanation of drawing

PSI 6025.XXX L18-71070 080 059-101 (2001.04) GB8.6 Load diagram, PSI 6025.XXX L1. Note: For a general description of load diagrams, see Section 3.1140

PSI 6025.XXX L18-81070 080 059-101 (2001.04) GB8.7 Accessories, PSI 6025.XXX L18.7.1 Dimensioned drawing, accessories kitAn accessories kit is availab

PSI 6025.XXX L18-91070 080 059-101 (2001.04) GBD For PSG 3000 welding transformers, see Technical Information, PSG3000 MF Welding Transformers, part n

PSI 6025.XXX L18-101070 080 059-101 (2001.04) GB8.8 Ordering, PSI 6025.XXX L1Designation Part no.PSI 6025.100 L1 medium-frequency inverter 1070 080 99

PSI 6100.XXX L1/L2/W1/W29-11070 080 059-101 (2001.04) GB9 PSI 6100.XXX L1/L2/W1/W29.1 PSI 6100.XXX L1/L2/W1/W2 overviewD PSI 6100.XXX L1 :D air-cooled

PSI 6100.XXX L1/L2/W1/W29-21070 080 059-101 (2001.04) GB9.3 PSI 6100.XXX L1/L2/W1/W2 front panelU1V1W1D - 64711 Erbach 107 Made in GermanyU1 V1 W1U2V2

PSI 6100.XXX L1/L2/W1/W29-31070 080 059-101 (2001.04) GB[7] slot for retrofitting a quality module[8] slot for fieldbus interface for programming[9] b

PSI 6100.XXX L1/L2/W1/W29-41070 080 059-101 (2001.04) GB9.4 Technical data, PSI 6100.XXX L1/L2/W1/W2Type 3-phase MF inverter, module designedfor reces

PSI 6100.XXX L1/L2/W1/W29-51070 080 059-101 (2001.04) GBMax. cooling losses L1/L2: 360 WW1: 420 WW2: 500 WSwitchgear cabinet loss at max. power L1: 17

PSI 6100.XXX L1/L2/W1/W29-61070 080 059-101 (2001.04) GB9.5 Dimensioned drawing, PSI 6100.XXX L1/L2100 mm min. installation clear-ance at top and bott

ContentsVII1070 080 059-101 (2001.04) GBPage12 PSI 6500.XXX W1 12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 Explanation of drawi

PSI 6100.XXX L1/L2/W1/W29-71070 080 059-101 (2001.04) GB9.6 Dimensioned drawing, PSI 6100.XXX W1/W2nipple (brass) with standard taperbore IAWDIN EN 56

PSI 6100.XXX L1/L2/W1/W29-81070 080 059-101 (2001.04) GB9.7 Electrical connection, PSI 6100.XXX L1/L2/W1/W2V2U2V1W1U1PESide view, right(as seen from t

PSI 6100.XXX L1/L2/W1/W29-91070 080 059-101 (2001.04) GB9.8 Cooling water connection, PSI 6100.XXX W1/W2cooling water inletcooling watercooling wa

PSI 6100.XXX L1/L2/W1/W29-101070 080 059-101 (2001.04) GBThe heat sink of the water-cooled MF inverter is connected internally to theprotective earth

PSI 6100.XXX L1/L2/W1/W29-111070 080 059-101 (2001.04) GB9.9 Load diagram, PSI 6100.XXX L1/W1. Note: For a general description of load diagrams, see S

PSI 6100.XXX L1/L2/W1/W29-121070 080 059-101 (2001.04) GB9.10 Load diagram, PSI 6100.XXX L2/W2. Note: For a general description of load diagrams, see

PSI 6100.XXX L1/L2/W1/W29-131070 080 059-101 (2001.04) GB9.11 Accessories, PSI 6100.XXX L1/L2/W1/W29.11.1 Dimensioned drawing, accessories kitAn acces

PSI 6100.XXX L1/L2/W1/W29-141070 080 059-101 (2001.04) GBD For PSG 3000 welding transformers, see Technical Information, PSG3000 MF Welding Transforme

PSI 6100.XXX L1/L2/W1/W29-151070 080 059-101 (2001.04) GB9.12 Ordering, PSI 6100.XXX L1/L2/W1/W2Designation Part no.PSI 6100.100 L1 medium-frequency i

PSI 6100.XXX L1/L2/W1/W29-161070 080 059-101 (2001.04) GBNotes:

ContentsVIII1070 080 059-101 (2001.04) GBNotes:

PSI 6200.XXX W1/W210-11070 080 059-101 (2001.04) GB10 PSI 6200.XXX W1/W210.1 PSI 6200.XXX W1/W2 overviewD PSI 6200.XXX W1:D water-cooledD 400 V -20% t

PSI 6200.XXX W1/W210-21070 080 059-101 (2001.04) GB10.3 PSI 6200.XXX W1/W2 front panelU1 V1 W1U2V23/PE~+−2/~2/PE~D - 64711 Erbach 107 Made in GermanyU

PSI 6200.XXX W1/W210-31070 080 059-101 (2001.04) GB[5] Cooling water connectionnipple (brass) with standard taper bore IAW DIN EN 560, external thread

PSI 6200.XXX W1/W210-41070 080 059-101 (2001.04) GB10.4 Technical data, PSI 6200.XXX W1/W2Type 3-phase MF inverter, module designed forrecessed mounti

PSI 6200.XXX W1/W210-51070 080 059-101 (2001.04) GB10.5 Dimensioned drawing, PSI 6200.XXX W1/W2Front viewSide view, right(as seen from the front)100 m

PSI 6200.XXX W1/W210-61070 080 059-101 (2001.04) GB10.6 Electrical connection, PSI 6200.XXX W1/W2V2U2all terminalsmax. 95 mm2U1 V1 W1U2V23/PE~+−2/~2/P

PSI 6200.XXX W1/W210-71070 080 059-101 (2001.04) GB10.7 Cooling water connection, PSI 6200.XXX W1/W2Front viewU1 V1 W1U2V23/PE~+−2/~2/PE~D - 64711 Erb

PSI 6200.XXX W1/W210-81070 080 059-101 (2001.04) GBThe heat sink of the water-cooled MF inverter is connected internally to theprotective earth conduc

PSI 6200.XXX W1/W210-91070 080 059-101 (2001.04) GB10.8 Load diagram, PSI 6200.XXX W1. Note: For a general description of load diagrams, see Section 3

PSI 6200.XXX W1/W210-101070 080 059-101 (2001.04) GB10.9 Load diagram, PSI 6200.XXX W2. Note: For a general description of load diagrams, see Section

Safety instructions1-11070 080 059-101 (2001.04) GB1 Safety instructionsThe products described were developed, manufactured and tested in com-pliance

PSI 6200.XXX W1/W210-111070 080 059-101 (2001.04) GB10.10 Accessories, PSI 6200.XXX W1/W2D For PSG 3000 welding transformers, see Technical Informatio

PSI 6200.XXX W1/W210-121070 080 059-101 (2001.04) GB10.11 Ordering, PSI 6200.XXX W1/W2Designation Part no.PSI 6200.100 W1 medium-frequency inverter 10

PSI 6300.XXX L1/L2/W1/W211-11070 080 059-101 (2001.04) GB11 PSI 6300.XXX L1/L2/W1/W211.1 PSI 6300.XXX L1/L2/W1/W2 overviewD PSI 6300.XXX L1:D air-cool

PSI 6300.XXX L1/L2/W1/W211-21070 080 059-101 (2001.04) GB11.3 PSI 6300.XXX L1/L2/W1/W2 front panelU1V1W1D - 64711 Erbach 107 Made in GermanyU1 V1 W1U2

PSI 6300.XXX L1/L2/W1/W211-31070 080 059-101 (2001.04) GB[7] slot for retrofitting a quality module[8] slot for fieldbus interface for programming[9]

PSI 6300.XXX L1/L2/W1/W211-41070 080 059-101 (2001.04) GB11.4 Technical data, PSI 6300.XXX L1/L2/W1/W2Type 3-phase MF inverter, module designedfor rec

PSI 6300.XXX L1/L2/W1/W211-51070 080 059-101 (2001.04) GBMax. ventilating and cooling lossdissipated via external air-coolerL1/L2: 360 WW1: 420 WW2: 5

PSI 6300.XXX L1/L2/W1/W211-61070 080 059-101 (2001.04) GB11.5 Dimensioned drawing, PSI 6300.XXX L1/L2100 mm min. installation clear-ance at top and bo

PSI 6300.XXX L1/L2/W1/W211-71070 080 059-101 (2001.04) GB11.6 Dimensioned drawing, PSI 6300.XXX W1/W2nipple (brass) with standard taperbore IAWDIN EN

PSI 6300.XXX L1/L2/W1/W211-81070 080 059-101 (2001.04) GB11.7 Electrical connection, PSI 6300.XXX L1/L2/W1/W2V2U2V1W1U1PESide view, right(as seen from

Safety instructions1-21070 080 059-101 (2001.04) GB1.2 Safety instructions and symbols used in this manualDANGEROUS ELECTRICAL VOLTAGEThis symbol is u

PSI 6300.XXX L1/L2/W1/W211-91070 080 059-101 (2001.04) GB11.8 Cooling water connection, PSI 6300.XXX W1/W2cooling water inletcooling watercooling

PSI 6300.XXX L1/L2/W1/W211-101070 080 059-101 (2001.04) GBThe heat sink of the water-cooled MF inverter is connected internally to theprotective earth

PSI 6300.XXX L1/L2/W1/W211-111070 080 059-101 (2001.04) GB11.9 Load diagram, PSI 6300.XXX L1/W1. Note: For a general description of load diagrams, see

PSI 6300.XXX L1/L2/W1/W211-121070 080 059-101 (2001.04) GB11.10 Load diagram, PSI 6300.XXX L2/W2. Note: For a general description of load diagrams, se

PSI 6300.XXX L1/L2/W1/W211-131070 080 059-101 (2001.04) GB11.11 Accessories, PSI 6300.XXX L1/L2/W1/W211.11.1 Dimensioned drawing, accessories kitAn ac

PSI 6300.XXX L1/L2/W1/W211-141070 080 059-101 (2001.04) GBD For PSG 3000 welding transformers, see Technical Information, PSG3000 MF Welding Transform

PSI 6300.XXX L1/L2/W1/W211-151070 080 059-101 (2001.04) GB11.12 Ordering, PSI 6300.XXX L1/L2/W1/W2Designation Part no.PSI 6300.100 L1 medium-frequency

PSI 6300.XXX L1/L2/W1/W211-161070 080 059-101 (2001.04) GBNotes:

PSI 6500.XXX W112-11070 080 059-101 (2001.04) GB12 PSI 6500.XXX W112.1 Explanation of drawingsThe following drawings show theD front plate with module

PSI 6500.XXX W112-21070 080 059-101 (2001.04) GB12.2 PSI 6500.XXX W1 front panelU1 V1 W1U2V23/PE~+−2/~2/PE~[1]D - 64711 Erbach 107 Made in GermanyADR[