Bosch L 309 Series, Technical Information

Page 1: ...Power Supply Module Technical Information L 309 150 L 309 250 104 Edition ...

Page 2: ... 078 131 104 00 05 GB Reg no 16149 03 E 1994 2000 This 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 DM 5 ...

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Page 4: ...ion of the power supply modules I 7 Retrofits and modifications by the user I 7 Maintenance repair I 8 Working safely I 8 1 Structure 1 2 Technical data 3 3 Dimensions 5 Types L 309 150 and L 309 151 5 Type L 309 250 6 4 Installation instructions 7 5 Connection instructions 9 5 1 Mains and welding transformer connection 9 5 2 Water connection 10 5 3 Connection to the timer module 11 5 4 Mains volt...

Page 5: ...Flexible Automation Type L 309 Power Supply Module 1070 078 131 104 00 05 GB ...

Page 6: ...this manual before installing connecting or commis sioning the product and store it in a place to which all users have access at any time Description of pictographs and symbols The following warnings and notes may be attached to the actual timer compo nents which are designed to inform the user on certain features Warning of dangerous voltages Components subject to electrostatic induction Disconne...

Page 7: ... term WARNING will be used wherever danger is imminent The possible consequences may be death or severe injury personal injury CAUTION The term CAUTION will be used wherever a dangerous situation is possible The possible consequences include severe or light injury personal injury damage to property or environmental hazards NOTE The term NOTE will be used for making recommendations on the use Non c...

Page 8: ...cardiac pace makers Danger DIN 40023 CAUTION When using manual welding guns the limit values may be exceeded for the ex tremities In this case additional work protection measures must be taken Intended use The power supply module is used for controlling the welding transformer The power supply modules in connection with suitable welding transformers and the PSS PSH timer modules serve for resistan...

Page 9: ...structed in operating installations in re sistance welding technology and who know the contents of the present docu mentation as far as operation is concerned WARNING An exception are persons with cardiac pacemakers Due to the strong magnetic fields arising from resistance welding the function of cardiac pacemakers may be disturbed This may cause the death or considerable health damages to the per...

Page 10: ...gh short circuits When drilling or sawing out openings within switch cabinets metal burr may get inside modules that have already been installed It is also possible that water may emerge during the installation of the cooling water lines and may enter the modules The possibility of short circuits and a destruction of the units cannot be entirely ruled out Therefore the modules should be well parti...

Page 11: ...nameplate of the product Appropriate electrical fusing equipment must be available on the mains side Danger of life through electrical voltage Changing the system voltage of the power supply module if necessary may only be performed when the system is de energized In any case suitable insu lated tools should be used for this purpose Danger of life through electrical voltage The power supply module...

Page 12: ...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 NOTE Damage to property through insufficient cooling of the modules The power supply modules must not be operated unless the cooling water cir cuit is active Damage to property through excessive welding current The maximum admissible welding current d...

Page 13: ...es must be operative in all modes of the system Releasing the EMERGENCY STOP facility must by no means result in an un controlled restart of the system CAUTION The right to perform repair maintenance work on the timer compenents is re served to the BOSCH service department or to repair maintenance units autho rized by BOSCH Only use spare parts replacement parts approved by BOSCH Working safely WA...

Page 14: ...s firing pulses to the thyristor power supply The integrated power supply unit generates the 27 V A C and 24 V D C synchro nization voltage for the weld timer The primary voltage of the welding transformer is measured and transmitted to the weld timer for evaluation and control UPR If the welding transformer or the thyristor power supply is overloaded a thermo static switch is released thus stoppi...

Page 15: ...Flexible Automation Type L 309 Power Supply Module Structure 2 1070 078 131 104 00 05 GB ...

Page 16: ...Hz set to 460 480 V when delivered Admissible voltage variations 15 20 Synchronization and supply for timer modules type PSH PSS 27 V A C voltage generation fused with M 1 25 A at F1 for triggering of inputs 24 V D C fused with M 2 5 A at F2 Percentage duty cycle ED independent from the possible thyristor switching currents limited by built in de ex citation resistor up to 400 V 100 duty cycle up ...

Page 17: ...pin plug in connector Cooling Water cooling without internal piping Water inlet temperature max 30 C Water throughput 4 liters min Differential inlet outlet 1 bar at 4 liters min Cooling thermostatically controlled Water connection Inlet outlet R 3 8 37 female taper Fault messages Thermostatic switch signal floating relay con tact it is evaluated by the timer which outputs the fault message Overte...

Page 18: ...00 mm installation clearance above and below the power supply module Front view Side view Top view Drill pattern Thyristor con nection V Connection of phase L2 Connection of phase L1 Tightness of the water connections can be achieved by using a 22 x 3 5 O ring Cooling water connection with 37 female taper 0 5 0 5 0 5 0 5 0 5 ...

Page 19: ...t 100 mm installation clearance above and below the power supply module Front view Side view Top view Drill pattern Thyristor con nection V Connection of phase L2 Connection of phase L1 Tightness of the water connections can be achieved by using a 22 x 3 5 O ring Cooling water connection with 37 female taper ...

Page 20: ... of injury at sharp metal edges You should therefore wear protective gloves Danger of damage to property through short circuits When drilling or sawing out openings within switch cabinets metal burr may get inside modules that have already been installed It is also possible that water may emerge during the installation of the cooling water lines and may enter the modules The possibility of short c...

Page 21: ...lts M6 The dimensions for the fastening holes are shown in the Dimensions section Since the cooling water connections are located at the back of the power supply module cooling water lines in the actual housing switch cabinet are not nec essary During installation it must be ensured that the contact surfaces are bare i e free from paint plastics coatings or dirt oxidation ...

Page 22: ...system voltage of the power supply module cf Mains voltage selection section if necessary may only be performed when the system is de energized In any case suitable insulated tools should be used for this purpose Danger of life through electrical voltage The power supply modules must be connected to the protective earthing PE circuit of the system Please ensure that a sufficient conductor cross se...

Page 23: ...lug for threaded bolts and a suitable bolt Connect outgoing welding transformer feeder V to the marked thyristor connec tion using a cable lug for threaded bolts and a suitable bolt NOTE Bolted cable lug connections must be properly tightened Use second wrench if necessary V L2 L1 X3 7 PE PE 5 2 Water connection The cooling water connections are located at the back of the power supply mod ule s ba...

Page 24: ... m 0 75 mm2 up to 75 m 1 5 mm2 L 309 X1 1 2 3 4 5 6 7 8 9 10 11 12 27 V A C 27 V A C operational earth floating relay contact thermostatic switch weld weld 24 V D C 0 V primary voltage feedback UPR1 to timer PSS PSH F1 M 1 25 A F2 M 2 5 A floating relay contact thermostatic switch floating relay contact thermostatic switch primary voltage feedback UPR2 CAUTION The X1 connection may only be made or...

Page 25: ...table insulated tools If necessary the customer himself may select the following voltages Types L 309 150 and L 309 250 400 V jumper between X3 1 and X3 2 state as delivered 415 440 V jumper between X3 1 and X3 3 500 550 V jumper between X3 1 and X3 4 Type L 309 151 400 V jumper between X3 1 and X3 2 460 480 V jumper between X3 1 and X3 3 state as delivered 575 V jumper between X3 1 and X3 4 X3 4 ...

Page 26: ...pply module from the mains before locating faults or replacing fuses CAUTION Danger of personal injury or damage to property Only use the fuse types and ratings specified Fuses must not be bridged The following fuses may be used F1 M 1 25 A 27 V A C output voltage X1 1 F2 M 2 5 A 24 V D C output voltage X1 8 F3 M 4 A rectifier input for generating the 24 V D C output voltage F4 FF 6 3 A 500 V 6 3 ...

Page 27: ...Maintenance Type L 309 Power Supply Module 14 1070 078 131 104 00 05 GB ...

Page 28: ...tion of the duty cycle ED in at max cooling agent temperature in _C and minimum water throughput in l min For determining the percentage duty cycle ED the weld time ts and the weld cycle time tsp must be known Weld time and weld cycle time ts tsp The duty cycle ED is calculated as follows ED ts tsp 100 Example In the figure above the weld time is 2 cycles and the weld cycle time is 4 cycles This r...

Page 29: ...L 309 150 and L 309 151 2500 Current carrying capacity IRMS in A 2000 1500 1000 500 ED in 0 2 5 10 20 50 100 0 Water cooling 4l min 30_C 150 kVA 100 kVA 30 cycles weld time max 50 ED L 309 150 L 309 151 1 Example Weld data of the machine 100 kVA Weld time ts 10 cycles 30 cycles Duty cycle ED 10 Current IRMS 600 A The intersection for ED 10 and IRMS 600 A found in the diagram is below curve 1 Thus ...

Page 30: ...09 Power Supply Module 17 1070 078 131 104 00 05 GB Load diagram of type L 309 250 2500 Current carrying capacity IRMS in A 2000 1500 1000 500 ED in 1 2 5 10 20 50 100 0 max 50 ED L 309 250 30 cycles weld time Water cooling 4l min 30_C ...

Page 31: ...Dimensioning instructions Type L 309 Power Supply Module 18 1070 078 131 104 00 05 GB ...

Page 32: ...pply fault will be output Possible causes Elimination not enough cooling water check water inlet and outlet thyristor rating too small calculate duty cycle check thyristor dimensioning on the basis of the load diagram please refer to section Dimensioning instructions Protective circuit against transient overvoltages In order to prevent the thyristor from being destroyed by overvoltages it is pro t...

Page 33: ...Fault messages Type L 309 Power Supply Module 20 1070 078 131 104 00 05 GB ...

Page 34: ... instructions 15 Dimensions 5 Drill pattern 5 Duty cycle ED 3 15 E Electrical connection I 6 4 EMERGENCY STOP facilities I 8 F Fault messages 19 Firing component 1 Fuse F4 19 Fuses 13 I Installation I 5 Installation instructions 7 Installation of power supply module 8 Intended use I 3 L Load diagrams 16 Load of the thyristor 15 M Magnetic fields I 3 Mains and welding transformer connection 9 Mains...

Page 35: ...ly voltage generation 3 Synchronization 3 T Technical data 3 Temperature monitoring 19 Terminal connector X1 11 Test procedures I 8 Thyristor off state voltage 4 Thyristor power supply 1 Thyristor load of the 15 Timer module connection 11 Training courses I 4 Type of construction 3 U Using manual welding guns I 3 V Voltage variations 3 W Water connection 4 10 Water inlet temperature 4 Water throug...

Page 36: ...A 1 1070 078 131 104 00 05 GB 1070 078 131 104 00 05 GB TI WS AT VWS Printed in Germany ...