01 - 1 Headline - 36 pt/14.4 MM Second Line PS 6000 The Integrated System For Perfect Resistance Welding

PS 6000
01_1 st Headline_36 pt/14.4 mm
second
The integrated
line system for
perfect resistance welding
LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

2
PS 6000 – powerful in medium

frequency and AC applications
Used in countless applications, welding systems made by the European market leader
Bosch Rexroth are the first choice of satisfied car manufacturers, tier one suppliers and
welding equipment manufacturers worldwide.
PS 6000 for applications up to 360 kA increases process reliability, reduces rework
costs and provides consistent weld spot quality – even with the most complex material
combinations.
The modular concept behind the PS 6000 integrates fully The flexible control system, adaptive control modes and
compatible and coordinated components in one particularly highly-dynamic servo drives allow you to break into new
cost-effective system: innovative applications. Standard functions such as con-
stant-current regulation, pressure regulation, electrode
▶▶ Intelligent inverters management concepts and tip dressing, ensure that weld
▶▶ Powerful medium frequency transformers quality lives up to your demands.
Benefits
▶▶ High reliability achieved through the use of well tried
and tested technology
▶▶ Maximum flexibility in the I/O and network area thanks
to plug-in modules such as PROFIBUS, PROFINET IO,
DeviceNet and EtherNet/IP
▶▶ 100 % quality control and documentation of spot welds
▶▶ Innovative functions for process monitoring
▶▶ Expulsion reduction achieved by adaptive control of the
welding process
▶▶ Servo gun control system
▶▶ Windows-based user interface for all process functions
with SQL database
▶▶ Extensive monitoring functions for maximum system
protection
▶▶ Flexibility for retrofitting function and modules
PS 6000 – the powerful system solution for the automotive

industry, suppliers and welding equipment manufacturers.

3
System components Development/engineering

Intelligent inverters
Modular medium frequency resistance welding con-
trol system with optional servo gun control and PSQ
6000 process module for adaptive control and quality
monitoring. Upgrades are possible with plug-in I/O
modules for all commonly used networks.
System solution
Powerful medium frequency transformers
Medium frequency transformers combining resistance
welding with high power density compact dimensions
and low weight. Included features: temperature moni-
toring, current sensor and safety resistor.
Adaptive current/voltage control

Welding controller for enhanced process stability
and assured spot weld quality. Extensive monitoring
functions verify welding system functionality. Unique
Q-Stop logic optimizes system productivity.


4
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 high-strength metals, aluminium and three
sheet stackups.
The 1,000 Hz medium frequency/DC technology has proven ▶▶ Expulsion reduced by decreased welding current and/or
its economic efficiency in many applications compared to current time
other processes: ▶▶ Electrode life lengthened thanks to lower thermal and
mechanical load on the electrode tips
▶▶ Higher weld quality by more dynamic current control ▶▶ Smaller and lighter transformers for integration into the
than can be achieved with AC technology weld gun
▶▶ Weld-ability of many materials increased by more power-
ful energy insertion
Property PSI 6200/w1 PSI 6300/a1 PSI 6300/a2 PSI 6300/w1 PSI 6300/w2 PSI 6400/w1 PSI 6500/w1
Weight approx. 56 kg approx. 20 kg approx. 21kg approx. 25 kg approx. 25 kg approx. 56 kg approx. 70 kg
Supply voltage range 400…480 V 400…480 V 500…690 V 400…480 V 500…690 V 400…480 V 400…480 V
Rated mains current 220 A 110 A 110 A 110 A 110 A 220 A 330 A
(max. thermal
continuous current)
Max. primary current 1,200 A 800 A 800 A 800 A 800 A 1,600 A 2,400 A
Max. secondary current* 54 kA 36 kA 36 kA 36 kA 36 kA 60 kA 120 kA
Required connection 95 mm2 35 mm2 35 mm2 35 mm2 35 mm2 95 mm2 2 – 4 cables; per
cross-section cable 120 mm2
Mains voltage a1/w1: air-cooled, water-cooled 400 V to 480 V, 50/60 Hz

a2/w2: air-cooled, water-cooled 500 V to 690 V, 50/60 Hz
* Specific to the welding transformer used.

5
PSI 62C0 inverter

Inverter for steel, aluminum and seam welding applications up to 54 kA
▶▶ Water-cooled
▶▶ PSQ 6000 quality system (optional)
▶▶ Connection to MF transformer of the PSG 6000 series
PSI 63C0 inverter

Inverter up to 36 kA for steel applications
▶▶ Air-cooled/water-cooled
▶▶ Connection to MF transformer of the PSG 6000 series
PSI 64C0 inverter

Inverter for aluminum applications up to 60 kA
▶▶ Water-cooled
▶▶ PSQ 6000 quality control system (optional)
▶▶ Connection to MF transformer of PSG 6000 series
PSI 65C0 inverter

Inverter for resistance seam and projection welding applications up to 120 kA
▶▶ Water-cooled
▶▶ Parallel connection of max. 3 inverters for currents up to 360 kA
Interfaces for the PSI 6000 series

Flexible due to pluggable I/O cards and field bus
connections.

6
PST 6000 – cost-effective AC series

for standard application
The PST 6000 AC controllers are mechanically identical to the PSI 6300
inverter series. This provides a low-cost migration path to middle-frequency
AC at a later time. Naturally these control systems offer you the same flexi-
bility in the I/O area and all the control functions of the entire PS 6000
system.
The AC controllers PST 6000 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
◀◀ Left: Air-cooled version

for spot-welding applica-
tions
Right: Water-cooled
version for projection
welding and seam weld-
ing applications with
increased duty cycle
Characteristic PST 6100L PST 6100W PST 6250L PST 6250W
Power supply connection grounded TN or TT system 400 V (-20 %) to 600 V (+10 %), 50/60 Hz
Rated transformer output 20 % duty cycle, at 400 V~ and 80 % transformer kVA 77/145* 167 224 257
load up to 20 % system utilization
Rated transformer output 50 % duty cycle, at 400 V~ and 80 % transformer kVA 16/62.5* 106 65/141* 162
load up to 50 % system utilization
Rated line current; max. continous thermal current A 69/130* 150 200 230
Connection cross-section mm2 50 50 95 95
Weight kg 12.5 21 13 21.5
* without/with fan hood

7
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.
The AC controllers PST 600E are designed for applications

up to 500 kVA
▶▶ Air cooling/water cooling
▶▶ Parallel input/output box with coordinated scope of
functions
▶▶ High-precision primary current control without external
current sensor – no more cables and connectors
▶▶ Optional slot for fieldbus module (Ethernet)
▶▶ Attractively priced alternative for use on older welding
systems
◀◀ Left: Air-cooled version for manual welding gun applications

and simple projection welding tasks
Middle: Water-cooled version for manual welding gun and

projection welding applications requiring more power
Right: Water-cooled version for welding systems with high

performance requirements up to 500 kVA
Characteristic PST 610EL PST 610EW PST 625EL PST 625EW PST 650EW
Cooling Air Water Air Water Water
Power supply 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~ kVA 68/95* 95 106/141* 155 500
and 80 % transformer load up to 50 % system utilization
Rated line current; max. continous thermal current A 95/130* 130 200 230 800
Connection cross-section mm2 50 50 95 95 240
Weight kg 8.6 7.9 13 9.1 11.2
* without/with fan hood

8
PSQ 6000 – for supreme quality

in spot welding
The PSQ 6000 control system is designed to monitor quality performance in

high-volume production operations. Intelligent current/voltage control max-
imizes process reliability and provides online verification of spot weld quality.
The BOS 6000 operating interface includes logging and documentation
features.
The PSQ 6000 has built-in control and monitoring function- Q-Stop logic
ality. The XQR control card is available as an upgrade for PSI Patented Q-Stop logic is a very useful extension of moni-
6000 series systems. toring functionality. It enables users to analyze and opti-
mize system productivity by defining how the system reacts
Adaptive current/voltage control for the highest spot to repetitive faults in a program or on a particular part.
weld quality
The adaptive process control mode gives you added flexi- Process overview
bility for future requirements in the welding process. By To provide the big picture, the status of all attached weld-
measuring current and voltage, the resistance and energy ing controllers is displayed on a bar graph.
can also be recorded, controlled and accurately evaluated
during welding. The adaptive control algorithm ensures
consistent quality and reduces spatter in demanding weld-
ing applications. Expensive rework can be reduced.
Process monitoring
Tolerance limits can be set and monitored for a number of
basic process parameters: current, phase angle, electrode
voltage, resistance, current time, power and energy. Two
consolidated variables, which summarize the basic variables,
are provided to simplify system handling:
▶▶ PSF – the process stability factor indicates the stability

of the welding process
▶▶ UIP – the quality factor provides an indication of actual
spot quality

9

▲▲ Adaptive current/voltage
control – consistent weld
quality and reduced
expulsion
◀◀ BOS 6000 – the com-

bined user interface for
weld control and quality
monitoring
◀◀ Q-Stop logic and the

process overview give
you the tools you need
to analyze and optimize
system productivity

10
PSQ 6000 – for supreme quality

in spot welding
Commissioning strategy
When you are working in the main operating modes
(robotic spot welding and manual spot welding), we
provide you with highly efficient tools and strategies to
speed up and simplify the welding system commissioning
process. This approach has a proven track record in many
automotive projects.
Process analysis
Process analysis/PSQ Analysis provides vital information
during commissioning and ongoing production. You use it
during the commissioning phase to determine the monitor-
ing limits which you then load into the controller. You can
easily determine which systems have reached an acceptable
spatter level. During ongoing production, you can reliably
assess the stability of each system right down to the indi-
vidual spot weld.
Services
On request, we will be right at your side to help you install
and set up your welding systems. We can provide assist-
ance in every phase of your project from parameterization
right through to final optimization. Rexroth has experience
in working with production line builders and end users.
▲▲ Our user interfaces and

tools provide the sup-
port you need during
commissioning and
ongoing production

11
Integrated servo gun controller for

maximum flexibility
The new welding control cabinet from Bosch Rexroth combines a welding
and servo gun controller in a compact cabinet concept. This series, which
features an integrated gun controller and the compact GDM (gun data
module) for saving welding gun data, enables maximum integration and
flexibility.
Compact welding case series with Features

▶▶ Control cabinet variants for application as a suspended
integrated servo gun controller
system, floor standing cabinet, or robot cabinet
▶▶ Comprehensive programming via BOS 6000
The high-performance PSI 63C0 welding controller for steel
applications and the integrated servo gun controller with
Benefits
the compact IndraDrive Cs drive system are combined into
▶▶ Installation surface maximized as a result of small foot-
a compact control cabinet concept.
print
▶▶ Greater flexibility via standardized interfaces
▶▶ Reduced training outlay thanks to proven programming
environment
Gun data module GDM
The compact GDM records and saves welding gun data and
can make it available via the Ethernet-based interface for
production and maintenance purposes.
Benefits
▶▶ Compact construction that requires minimal installation
space
▶▶ Improved quality due to the production and mainte-
nance data saved. This facilitates preventive mainte-
nance of the welding gun for optimal, cost-efficient
production.
▶▶ Quick, reliable transfer of data to the welding controller
via the Ethernet-based interface

12
Welding aluminum in a cost-effective,

reliable manner
The automotive industry is increasingly concentrating on the potential of

lightweight, to reduce weight and thus consumption. The usage of alumi-
num required high process knowledge – therefore all this knowledge must
be coordinated and built up. Rexroth offers a full range of cost-efficient and
reliable welding solutions – including for aluminum.
Bosch Rexroth is the only market provider

worldwide which defines the requirements
for efficiency and reliability requirements for
welding aluminum. The welding process is
backed up by new control and monitoring
algorithm.
For the first time, automotive manufactures

has the possibility to work with a system
solution by Bosch Rexroth which can reliably
weld aluminum for automotive bodywork,
for the same costs like steel welding.

13
Inverter and transformers for aluminum welding

The PSI64CO adaptive welding inverter for aluminum is
developed to identify the physical characteristics of the
material. The comprehensive monitoring and the active
regulation of the welding procedure during the operational
process is now practicable for the first time. Therefore we
use the proven mid-frequency/direct current technology.
The material-specific properties of aluminum require higher

welding currents among shorter welding times. The PSG
6180 RSTK provided ideal prerequisites for aluminum weld-
ing and is thus one unit of many in Bosch Rexroth´s com-
prehensive line of transformers.
▶▶ The Bosch Rexroth

solution for aluminum
welding: The PSI
64CO inverter and
PSG 6180 RSTK
transformer (MF 180)

14
Transformers programm –
for maximum efficiency
and accuracy
The medium-frequency transformer series are an additional asset to our
successful PSI 6000 inverter system. Precisely coordinated and perfectly
compatible, these components facilitate optimum power transfer and
additional monitoring functions between the inverter and transformer,
resulting in greater profitability and enhanced precision in welding.
PSG 6000 –
compact medium-frequency transformers
The 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.
Features
▶▶ Process monitoring by
- Integrated current measuring coil
- Adaptive control of the welding control
▶▶ Component protection by
- Integrated temperature monitoring of the winding
package and the rectifier unit
- Programmable monitoring limit values in the
welding control
PSG 6000 transformer series PSG 6130 PSG 6170 PSG 6250
Output up to 20 % ED kVA 130 170 250
Nominal DC voltage V 9.5 9.5 14
Continuous on-state current kA 6.5 8 8
Cooling water flow I/min 6 8 8
Dimensions W x H x D mm 160 x 127 x 262 160 x 127 x 297 160 x 127 x 300
Weight kg 16 19 23

15
Benefits of middle frequency transformers from Rexroth

▶▶ Standardized platform transformer for the automo- ▶▶ Monitoring function that oversees interaction between
tive industry the inverter and transformer
▶▶ Optimal power transfer ▶▶ Optimal application possibilities thanks to a compact

construction and low weight
PSG 6130.xx.RSTK (MF 100) –

the new platform transformer
The compact, lightweight middle frequency transformers

from the PSG 6130.xxRSTK series are optimized for all global
robot applications up to 130 kVA.
Features
▶▶ For all robot applications
▶▶ Compliant with DIN EN ISO 22829 requirements and
welding gun specifications for the automotive sector
▶▶ Primary connection via single-conductor plug connector
▶▶ Common AIDA push-pull sensor connector for tempera-
ture, force, voltage, and current signals
▶▶ Suitable for primary, secondary, and adaptive welding
current controls
Platform transformer PSG 6130.xx.RSTK (MF 100)
Output kVA 130
Nominal DC voltage V 9
Continuous on-state current kA 6.5
Cooling water flow I/min 6
Dimensions W x H x D mm 106 x 150 x 332
Weight kg 16.8

16
An overview of the medium-

frequency transformers
PSG 6130 Primary Internal current measuring coil Nominal DC voltage Nominal primary voltage
connection and temperature monitoring
6130.00AS via interface box l 9.5 V 530 V
6130.00PS via MC 150 l 9.5 V 530 V
6130.00PTK via MC 150 9.5 V 530 V
6130.00PSTK via MC 150 l 9.5 V 530 V
6130.xxRSTK via single wire l 9V 530 V/645 V/926 V
PSG 6170 and Primary Internal current measuring coil Nominal DC voltage Nominal primary voltage
PSG 6180 connection and temperature monitoring
6170.00PTK via MC 150 9.5 V 530 V
6170.00PSD via MC 150 l 9.5 V 530 V
6170.68AT via interface box 9.5 V 530 V
6180.xxRSTK via single wire l 14 V 530 V/645 V
6170.00ASTK via interface box* l 9.5 V 530 V
6250.00ASTK via interface box l 14 V 530 V
* Both interface boxes as transformer accessory (TH 6000 MC and TH 6000 PG).
6160.00TS231 via PG l 9V 500 V
6160.00TS232 via PG l 9V 650 V
6160.00TS233 via PG l 9V 800 V
6230.00GM234 via PG 13 V 500 V
6230.00GM235 via PG 13 V 650 V
6230.00GM236 via PG 13 V 800 V

17
Transformers
Variants of primary connection
◀◀ Example:
PSG 6130.00 AS
Connection with
additional, individual
terminal box
◀◀ Example:
PSG 3075.10 PZ
Connection via
round plug connector
◀◀ Example:
PSG 6130.00 RSTK
Connection via
single-conductor
plug connector
◀◀ Example:
PSG 6160.00GM234
Connection via
PG fitting

18
STC Teach software function

(Sheet Thickness Combination) –
for expedited initial start-up
The new STC Teach software function makes it possible to optimize welding
procedures for different panel thickness combinations and materials in
advance by running tests in a laboratory. These parameters and the set-in
welding combinations used by the manufacturer were entered in a central
database to minimize the commissioning time for spot welds up to 90 %.
Features
▶▶ Welding parameters are determined in advance by carry-
ing out test welds in a laboratory
▶▶ The predetermined parameters allow production opera-

tion to take place immediately while actively monitoring
and regulating all spot welds
▶▶ Product derivatives can be quickly and easily communi-

cated (taught)
▶▶ Central data storage for welding parameters, reference

curves, and quality thresholds
▶▶ Parameter sets can be alternatively selected for every

panel thickness combination
1 Information about display diagram
▶▶ Easy assignment of the spot weld tables determined via

2 Display diagram
the BOS 6000 user interface
3 Drag-and-drop functionality for moving axes
4 Drag-and-drop functionality for moving cursor markers
5 Checkbox for maximum resistance and maximum force
6 Parameter group filter
7 Area for displaying welding sparks
8 STC curve mode

19
BOS 6000 – operation and

observation to perfection
The windows-based BOS 6000 user interface with built-in SQL database
function makes it very easy to operate the system and monitor performance.
You can operate both the welding controller and the process module on a
standardized BOS 6000 user interface. The BOS 6000 also provides con-
nectivity to higher-level data processing systems.
BOS 6000 – the integrated

user interface for weld control
and process module
IndraControl VCH 05 – versatile handheld console for IndraControl VPP 40 – compact PC system for industrial
mobile applications applications
The web-based IndraControl VCH 05 handheld console The robust VPP 40 industrial PC is the complete solution
allows you to operate any number of controllers on the go. for control, operation and visualization. It is specifically
No specialized knowledge is required as handling and use designed for use as a stand-alone or networked PC and can
are straightforward. State-of-the-art processor and commu- be integrated inexpensively in control cabinets. Depending
nication interfaces enable quick access to welding parame- on the operating requirements this PC can be supplied with
ters and diagnostic utilities. a touch screen or keyboard.

Bosch Rexroth AG
04_Body Straße
Berliner text U4_7.7 pt/3.84 mm
25
Address
64711 Erbach/Odw., Germany
www.boschrexroth.com/welding
IFind your local contact person here:

www.boschrexroth.com/contact
Further information
www.boschrexroth.com/welding
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
R999000051 (2013-10) derived from our information. The information given does not release the user
© Bosch Rexroth AG 2013 from the obligation of own judgment and verification. It must be remembered
Subject to revisions! that our products are subject to a natural process of wear and aging.

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PS 6000

LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

PS 6000 – powerful in medium

PS 6000 – the powerful system solution for the automotive

LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

System components Development/engineering

Adaptive current/voltage control

LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

PSI 6000 – the right inverter

Weight approx. 56 kg approx. 20 kg approx. 21kg approx. 25 kg approx. 25 kg approx. 56 kg approx. 70 kg

Max. secondary current* 54 kA 36 kA 36 kA 36 kA 36 kA 60 kA 120 kA

Mains voltage a1/w1: air-cooled, water-cooled 400 V to 480 V, 50/60 Hz

* Specific to the welding transformer used.

LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

PSI 62C0 inverter

PSI 63C0 inverter

PSI 64C0 inverter

PSI 65C0 inverter

Interfaces for the PSI 6000 series

LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

PST 6000 – cost-effective AC series

The AC controllers PST 6000 are designed for applications

◀◀ Left: Air-cooled version

Characteristic PST 6100L PST 6100W PST 6250L PST 6250W

Connection cross-section mm2 50 50 95 95

Weight kg 12.5 21 13 21.5

* without/with fan hood

LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

PST 600E – compact power packs

The AC controllers PST 600E are designed for applications

◀◀ Left: Air-cooled version for manual welding gun applications

Middle: Water-cooled version for manual welding gun and

Right: Water-cooled version for welding systems with high

Cooling Air Water Air Water Water

Connection cross-section mm2 50 50 95 95 240

Weight kg 8.6 7.9 13 9.1 11.2

* without/with fan hood

LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

PSQ 6000 – for supreme quality

The PSQ 6000 control system is designed to monitor quality performance in

▶▶ PSF – the process stability factor indicates the stability

LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

◀◀ BOS 6000 – the com-

◀◀ Q-Stop logic and the

LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

PSQ 6000 – for supreme quality

▲▲ Our user interfaces and

LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

Integrated servo gun controller for

Compact welding case series with Features

Gun data module GDM

LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

Welding aluminum in a cost-effective,

The automotive industry is increasingly concentrating on the potential of

Bosch Rexroth is the only market provider

For the first time, automotive manufactures

LSA Control S.L. www.lsa-control.com comercial@lsa-control.com (+34) 960 62 43 01

Inverter and transformers for aluminum welding

The material-specific properties of aluminum require higher