Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

R911172346
Rexroth PSG3075.1x PSV Edition 02

Mittelfrequenz-Schweißtransformator
Medium-Frequency Welding Transformer

DEUTSCH
Typspezifische Anleitung | Type-Specific Instructions

ENGLISH
 Bosch Rexroth AG
R911172346 | PSG3075.1x PSV 21/39

Contents

Contents

1 To this Documentation ............................................................................. 23

1.1 Validity of the documentation ............................................................ 23
1.2 Required and supplementary documentation .................................... 23
1.3 Display of information ....................................................................... 24
1.3.1 Safety instructions ............................................................ 24
1.3.2 Symbols............................................................................ 24
1.3.3 Designations ..................................................................... 24
1.3.4 Abbrevations .................................................................... 24
2 Safety instructions ................................................................................... 25
2.1 Protective conductor connection ....................................................... 25
3 General information on damage to property and products ........................... 26
4 Scope of delivery ..................................................................................... 26
5 Dimensions and locations......................................................................... 27
6 Circuit diagram ........................................................................................ 29
7 Load diagram .......................................................................................... 31
8 Technical data ......................................................................................... 33
9 Current / resistance characteristic............................................................. 35
10 Part numbers and accessories ................................................................. 37
11 Terminal box ........................................................................................... 38
12 Transformer selection with BOS ............................................................... 38
 R911172346 | PSG3075.1x
22/39 Bosch Rexroth AG PSV

Contents

Notes:
 Bosch Rexroth AG
R911172346 | PSG3075.1x PSV 23/39

To this Documentation

1 To this Documentation

1.1 Validity of the documentation

This documentation applies to Rexroth Medium-Frequency Welding Transformer
PSG 6xxx.
The content belong to
• Dimensions and locations
• Circuit diagram
• Load diagrams
• Technical data
• Current / resistance characteristic
• Part numbers and accessories
• Terminal Box
• Transformer selection with BOS
of the Rexroth Medium-Frequency Welding Transformer.

This documentation is designed for technicians and engineers with special

welding training and skills. They must have knowledge of the software and
hardware components of the weld timer, the power supply used, and the welding
transformer.

This documentation and the Instruction Manual contain important information on

the safe and appropriate assembly, transportation, commissioning, maintenance
and simple trouble shooting of Rexroth Medium-Frequency Welding Transformer.
 Read this documentation completely and particular the chapter "Safety
instructions", before working with the product.

1.2 Required and supplementary documentation

 Only commission the product if the documentation marked with the book
symbol is available to you and you have understood and observed it.

Tab. 1: Required and supplementary documentation

Title Document number Type of document

Rexroth PSI6xxx 1070 080028 Instruction Manual

Medium-Frequency Inverter
Instruction Manual

Rexroth PSG 3xxx/6xxx 1070 087062 Instruction Manual

Medium-Frequency Welding
Transformer

User Software BOS6000 Help 1070 086446 User Software

 R911172346 | PSG3075.1x
24/39 Bosch Rexroth AG PSV

To this Documentation

1.3 Display of information

In order to enable you to work with your product in a fast and safe way, uniform
Safety instructions, symbols, terms and abbreviations are used. For a better
understanding they are explained in the following sections.

1.3.1 Safety instructions

The safety instructions please look in Tab. 1: Required and supplementary
documentation.

1.3.2 Symbols
The following symbols mark notes that are not safety-relevant but increase the
understanding of the documentation.

Tab. 2: Meaning of the Symbols

Symbol Meaning

If this information is disregarded, the product cannot be

used and or operated to the optimum extent.

 Single, independent step

1. Numbered step:
2. The numbers specify that the Steps are completed one
3. after the other.

1.3.3 Designations
This documentation uses the following designations:

Tab. 3: Designations
Designation Meaning

BOS 6000 Bedienoberfläche Schweißen (Welding Software)

PSG xxxx Medium-Frequency Welding Transformer 1000 Hz

PSV Plug, current coil (Stromspule), V internal labeling

1.3.4 Abbrevations

For the abbreviations used in this documentation please look in Tab. 1: Required
and supplementary documentation.
 Bosch Rexroth AG
R911172346 | PSG3075.1x PSV 25/39

Safety instructions

2 Safety instructions

This section includes important information on the safe handling of the product
described.

Please look up the safety instructions under Tab. 1: Required and supplementary
documentation Rexroth PSG xxxx Medium-frequency welding transformers.

2.1 Protective conductor connection

The Rexroth PSG series medium-frequency transformers correspond to degree of

protection 1 according to EN 61558-1.
For degree of protection 1, additional protective measures as stipulated in
EN 62135-1 must be applied as protection against inadmissibly high contact
voltages in case of an insulation failure between primary and secondary circuit.
The plant supplier/operator is responsible for providing such protection.

WARNING
Dangerous electrical voltage in case of contact with the secondary connections,
the welding gun or the workpiece.
If these protective measures are not applied or are ineffective, there may be
danger of life!

 For degree of protection 1, additional protective measures as stipulated in

EN 62135-1 must be applied as protection against inadmissibly high contact
voltages in case of an insulation failure between primary and secondary
circuit.
 When delivered, the secondary circuit (negative pole) of the medium-
frequency transformers is connected with the protective conductor
connection by a removable protective conductor jumper (MPE). This
corresponds to the protective measure "direct protective conductor
connection" according to EN 62135-1.
 If another protective measure in accordance with EN 62135 is implemented
instead of "direct protective conductor connection", the protective conductor
jumper (MPE) must be removed. The removal of the protective conductor
jumper (MPE) must be permanently (in an indelible manner) indicated on the
plate provided on the transformer.
 As a further measure for degree of protection 1, the housing of the medium-
frequency transformers must be connected firmly with the protective
conductor connection of the transformer. This connection cannot be
removed.
 R911172346 | PSG3075.1x
26/39 Bosch Rexroth AG PSV

General information on damage to property and products

WARNING
Dangerous electrical voltage
Under certain circumstances, compensation currents ("crossover currents"
according to EN 62135-1) may flow through the MPE protective conductor
connections. This means that human lives may be in danger in the event of an
insulation failure!
 The compensation currents must generally be avoided because they may
interrupt the protective conductor connection through the protective
conductor jumper (MPE).
 An interruption of the protective conductor connection will render the "direct
protective conductor connection" protective measure inoperative.

3 General information on damage to property

and products
Please look up the general information on damage to property and products under Tab.
1: Required and supplementary documentation Rexroth PSG xxxx Medium-frequency
welding transformers.

NOTICE
The rectifier must not be used as load-bearing part.
The transformer housing must not be used as load-bearing construction element
of the welding gun.

4 Scope of delivery
Please look up the scope of delivery under Tab. 1: Required and supplementary
documentation Rexroth PSG xxxx Medium-frequency welding transformers.
 Bosch Rexroth AG
R911172346 | PSG3075.1x PSV 27/39

Dimensions and locations

5 Dimensions and locations

Fig. 1: Dimensions and locations PSG3075.10 PSV

 R911172346 | PSG3075.1x
28/39 Bosch Rexroth AG PSV

Dimensions and locations

Fig. 2: Dimensions and locations PSG 3075.11. PSV

 Bosch Rexroth AG
R911172346 | PSG3075.1x PSV 29/39

Circuit diagram

6 Circuit diagram

H
IS
L

ENG

Fig. 3: Circuit diagram PSG 3075.10 PSV

Tab. 4: Circuit diagram names

Name in circuit diagram Meaning

U, V Primary connection to PSI

PE Conductor connection

MPE Protective conductor jumper

T, pin 1 and 4 Connection of temperature sensor for monitoring the

primary winding and the rectifier

+, - Secondary connection to electrodes

U in pin 1, 2 Voltage input electrode

M pin A, B Current sensor connection

U out pin D, E Voltage output electrode

 R911172346 | PSG3075.1x
30/39 Bosch Rexroth AG PSV

Circuit diagram

Fig. 4: Circuit diagram PSG 3075.11 PSV

Tab. 5: Circuit diagram names

Name in circuit diagram Meaning

U, V Primary connection to PSI

PE Conductor connection

MPE Protective conductor jumper

T, Pin 1 and 4 Connection of temperature sensor for monitoring the

primary winding and the diode

+, - Secondary connection to electrodes

M Pin A, B Current sensor connection

U in Pin 1, 2 Voltage input electrode

S out Pin D, E Secondary pickup for FU- Monitoring

 Bosch Rexroth AG
R911172346 | PSG3075.1x PSV 31/39

Load diagra

7 Load diagram
Notice: The calculation of the duty cycle (ED) is in the operation manual Rexroth
PSG 6xxx Medium-Frequency Welding Transformer, please refer to
Tab. 1: Required and supplementary documentation.

Fig. 5: Load diagrams PSG 3075.xx PSV with 6 l/min, I sek (A), duty cycle ED (%)
 R911172346 | PSG3075.1x
32/39 Bosch Rexroth AG PSV

Load diagram

Notes:
 Bosch Rexroth AG
R911172346 | PSG3075.1x PSV 33/39

Technical data

8 Technical data

Tab. 4: PSG 3075.1x PSV – Technische Daten

Bezeichnung PSG3075.10 PSV PSG3075.11 PSV

Primary voltage U1N 500 V 500 V

Frequency 1000 Hz 1000 Hz

No-load DC voltage U2d 8,4 V 8,4 V

Continuous DC current I2P 5 kA with 100% duty cycle 5 kA with 100% duty cycle
(ED) (ED)

Continuous DC power 42 kW with 100% duty 42 kW with 100% duty

cycle (ED) cycle (ED)

Insulation class of welding F F

transformers

Sensitivity ratio 55:1 55:1

Weight 14,5 kg 14,5 kg

Color RAL 7005 grau RAL 7005 grau

Cooling water quantity 6 l/ min max.30 °C 6 l/min max. 30°C

Differential pressure ≤ 0,8 bar ≤ 0,8 bar

ENGLISH
Max. Temperature 70 °C, EN62135-1 70 °C, EN62135-1
Transformer housing

Max. Torque secondary 20 Nm 20 Nm

connection
 R911172346 | PSG3075.1x
34/39 Bosch Rexroth AG PSV

Technical data

Notes:
R911172346 | PSG3075.1x PSV Bosch Rexroth AG 35/39

Current / resistance characteristic

9 Current / resistance characteristic

Fig. 6: Current/ resistance characteristic PSG 3075.xx PSV, Rsek(µOhm), Isek (kA)
 R911172346 | PSG3075.1x
36/39 Bosch Rexroth AG PSV

Current / resistance characteristic

Notes:
R911172346 | PSG3075.1x PSV Bosch Rexroth AG 37/39

Part numbers and accessories

10 Part numbers and accessories

Tab. 5: Part numbers

Name Part number

PSG 3075.10 PSV R911170133

PSG 3075.11 PSV R911170744

Sensor cables; 1070 913494

LiYCY 2 x 2 x 0,75 mm²; shielded
Please specify designed length in order.

Mating plug (example)

B8141-0
company Turck for FSD4-0.5
UT 06128ST
company Souriau for UT00128PT
TSB 150/25
company MultiContact for TAG150
 R911172346 | PSG3075.1x
38/39 Bosch Rexroth AG PSV

Terminal box

11 Terminal box

The PSG3075.10 PSV for use with primary circuit plug-in connection with MC-
TAG150.

12 Transformer selection with BOS

1. Select the timer for which the transformer is to be defined.

2. Open the window containing the parameters for transformer selection:
BOS6000:
Programming  Electrode
3. Select the proper transformer PSG 3075.10 or PSG 3075.11 in field Type:
 Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Tel. +49 9352 18 0
Fax +49 9352 18 8400
www.boschrexroth.com/electrics

R911172346 DOK-PS6000-PSG30751PSV-IT02-D0-P