PG RexRoth

Product Catalog
Resistance Welding
2 Product Catalog Restistance Welding | Introduction
Bosch Rexroth AG, R911382070/2017-08

R911382070/2018-04
Introduction | Product Catalog Restistance Welding 3
Introduction 5
Weld Controls PRC 15
Overview 16
Engineering Notes 18
Functional Overview 22
Ordering information, Handbooks 25
Options, Accessories, Spare Parts 24
Operating Software PRI 7000 25
System Components
for Communication, Gun Control and 27
Fieldbus Couplers and I/O-Modules 28
Fieldbus Couplers and I/O-Modules S20 29
Servo Drives HCS01 32
Safety Zone Module HZS01 35
Gun Data Modules GDM and MGDM 37
Welding Transformers PSG 39
Overview 40
Technical Data, Ordering information, Handbooks 46
PSG 3075 46
PSG 3100 48
PSG 6120 50
PSG 6130 52
PSG 6160 56
PSG 6170 58
PSG 6180 60
PSG 6230 62
PSG 6250 64
Options 67
Accessories 68
Primary Terminal Boxes 68
Counterplugs for Power and Signals 69
Protective FI Resistors 72
Abbreviations 74
Index 75

R911382070/2018-04, Bosch Rexroth AG


Introduction
Introduction 5
Resistance Welding 6
Why Welding with Medium Frequency? 8
Controls for Resistance Welding 14


Resistance Welding –
Efficient and in the Highest Quality
Welding processes in the automotive industry have to meet control and monitoring concept: users benefit from quicker
the strictest requirements regarding process safety and commissioning, maximum availability and energy efficiency,
quality. Weld controls PRC 7000 and welding transformers simple handling and maximum flexibility.
PSG 6000 from Rexroth – that is much more than a proven
Weld controls PRC provide:

▶▶ Up to 90 percent faster commissioning, in comparison ▶▶ Maximum energy efficiency through modern power
to conventional technology electronics: during welding the energy losses decrease
▶▶ Efficient handling and diagnostics with PRI 7000 by 30 %, and during production breaks even by 50 %,
software in comparison to conventional technology
▶▶ Optimized programming, control, and monitoring ▶▶ Open system architecture with integrated application
functionalities for maximum welding spot quality layer and servogun functionality
▶▶ Up to 10.000 weld jobs, flexibly programmable with ▶▶ Flexibly configurable hardware:
individual monitoring –– Two power classes available
–– Each with air and water cooling
–– Can be combined with various fieldbus modules,
expandable with bus couplers and I/O modules

Further system components from the Rexroth product

portfolio extend the functional possibilities of the weld
control:
▶▶ Fieldbus couplers and I/O-Modules allow connection of
operating and display elements and further digital and
analog signals
▶▶ Servo drives control servoelectric motors for gun stroke
and/or tip dresser
▶▶ The Safety zone module monitors the safety devices
and ensures a safe movement of the weld gun, if
required
▶▶ Gun data modules store data and possibly transmit
weld gun signals from/to the weld control
Welding transformers PSG complete the power pack:

▶▶ Standardized platform transformer for the automotive
industry
▶▶ Optimal power transfer with minimum losses
▶▶ Monitoring function coordinated between weld control
and transformer
▶▶ Optimal application possibilities thanks to a compact
construction and low weight
▶▶ Nine power classes from 94 … 250 kVA / 20 % D.C.
▶▶ DC output voltage 9.0 / 14.0 V
▶▶ Input supply voltage designed for 400 V … 690 V mains
▶▶ Different types of power and signal connectors

Why Welding with Medium Frequency?
Resistance welding requires current strength in the Medium frequency welding combines the advantages of
kiloampere range. For this purpose, a small voltage higher working frequency and direct current. A power
(e.g. 9 V) with a large current is generated from the mains inverter generates a controlled square-wave voltage in the
voltage (e.g. 400 V), with a welding transformer. kilohertz range from the mains voltage. This voltage is
For classic AC welding with mains frequency (50 or 60 Hz), transformed down by a welding transformer and rectified
current and weld time are controlled by a thyristor, by on the secondary side. The result is a nearly rectangular
means of phase shift. This has the disadvantage, that time current pulse with low residual ripple, which can be
and current can be varied with a minimum increment of adjusted in millisecond steps.
10 (resp. 8.3) msec. This is often too rough for precise
control. The phase shift control generates a sinusoidal
current with gaps. Direct current would feed the energy
more quickly and evenly into the material.

The welding inverter is connected to three phases of the As the frequency increases, the cross-section of an iron
mains, which is always loaded symmetrically – a further transformer core can be made smaller with the same power
advantage compared to the thyristor with AC welding. transmission.
Therefore, a medium frequency welding transformer is
At 1000 Hz operating frequency, the process control can significantly lighter and more compact than a mains
react to disturbances within a millisecond and adjust the frequency transformer.
current or the weld time in 1 msec steps. This is the
prerequisite for the use of an adaptive process regulation On the secondary side, the current is rectified.
(see below). Welding with direct current avoids inductive energy losses
Short weld times and steep current rise are possible. in the secondary circuit. The transformer power no longer
has to be dimensioned according to the size of the welding
window.

Controls for Resistance Welding
The weld control PRC is a process control and at the The system configuration for two typical applications is
same time a power inverter. It also controls various shown below.
technological processes: from opening and closing the
weld gun to the dressing of the electrode tips.
Robot cell with a servo-electric weld gun
System desgin
RC: Robot control WIC: Weld interface controller bus

PRI: Workstation with software PRI 7000 CB: Communication bus
PRC: Weld control PRC 7000 MGDM: Measuring gun data module
NFD: Mains filter for servo drives PSG: Welding transformer PSG 6000
HZS: IndraDrive safety zone module F(t), U(t), I(t): Analog feedback signals: force, voltage, current
HCS: IndraDrive servo module On, PC, T: Digital control and monitoring signals

The control components are installed in a compact control Servo modules HCS control the servo-electric drives for
cabinet (“welding box”) or mounted on the weld gun. weld guns and tip dressers.
The welding transformer PSG 6000 generates the The safety zone module HZS coordinates the safety
required high amperages and rectifies the welding current functions. It monitors the safety devices, such as protective
on the secondary side. doors or light barriers and ensures the safe movement
of the weld guns, if necessary.
The weld control PRC 7000 supplies the transformer with
a regulated 1000-Hz AC voltage, which is fed from the On the gun data module GDM, data for the operation of
3-phase mains. The inverter controls the resulting power the weld gun are stored, e.g. the actual electrode wear and
in the secondary circuit over the pulse width. an electronic type label. These are available to the process
control via the WIC bus.
The process control is integrated in the welding inverter. The measuring gun data module MGDM also serves as
It plays a central role in the execution, control and a converter for current, voltage, force and temperature
monitoring of the welding processes, as well as in the signals from the weld gun to the WIC bus.
communication with the system components. It exchanges
real-time signals with robot control, servo modules and The operating software PRI 7000 is the user interface
gun data module, the tip dresser, as well as the sensor of the process control for parameterization and quality
system. In addition, it realizes the data traffic with the monitoring of the welding process.
operating device(s). For this purpose, it is equipped with It is used to set the welding parameters and the regulator.
signal inputs/outputs and bus interfaces. Both online and offline programming are possible.
Using the operating software, actual values, error messages
The WIC (Weld Interface Controller) port of the weld and parameter changes can be displayed and documented.
control can be used to connect fieldbus couplers with
I/O modules and servo modules. This extends the
functional possibilities of the process control for the
respective application. If required, additional weld guns
and tip dressers can be connected.


Pneumatic manual weld gun
System design
PRC: Weld control PRC 7000 HIP: Hall installation plate for air and water
WIC: Weld interface controller bus MGDM: Measuring gun data module
S20-S3: Fieldbus coupler PSG: Welding transformer PSG 6000
S20-DO: Digital output module I(t), U(t): Analog feedback signals: current, voltage
S20-DI: Digital input module DO, DI, T: Digital control and monitoring signals
S20-AIAO: Analog I/O-module AO, AI: Analog control and monitoring signals

Fieldbus couplers Sxx-S3 and I/O modules Sxx-DI, Sxx-DO For other applications, such as:
and Sxx-AIAO, expand the signal input/output field of the –– robot cell with several servo-electric weld guns,
weld control by additional digital and analog inputs/ –– the robot controls the gun as “seventh axis”
outputs, e.g. for the connection of operating and display –– stationary welding machines,
elements as well as for enable, command and feedback the system configuration can also be optimally designed.
signals.
The programmable logic function of the weld control
Fieldbus couplers and I/O modules S20 are intended for (in preparation) configures the I/O signal mapping of the
installation in a control cabinet, whereas S67 modules can fieldbusses for the respective application.
be mounted on a weld gun.
It is also possible to connect several weld guns to a single

weld control: the system layout can be flexibly adapted to
the particular application, using fieldbus couplers and I/O
modules.

Which Current Source

for Which Welding Task?
We are offering weld controls in two power classes and for Welding transformers are available in nine power classes
two mains voltage ranges, each with air and water cooling. and two secondary voltage classes, in some cases for
The integrated process control is equipped with bus different primary voltages and with different connection
interfaces for the respective application and provides technology. For details and engineering notes, please refer
different special functions. to the chapter Welding Transformers.
You will find technical basic data and engineering notes on The power data of weld controls and transformers are
weld controls on page 15 et sqq. harmonized with one another. The following table shows
typical control-transformer combinations:
Control Transformer Secondary Secondary Max.

voltage class continous current secondary current 1
U2d [V] I2P [kA I2max [kA]
PRC 7300.xxx-X1 PSG 3075 9.0 5.0 15.8

PSG 3100 9.3 5.5 25.2
PSG 6130 9.0 6.1 17.3
PSG 6170 9.0 6.1 17.3
PSG 6180 14.0 4.2 20.9
PSG 6250 14.0 4.2 17.3
PRC 7400.xxx-X1 2 x PSG 6130 parallel 9.0 13.0 34.6
3 x PSG 6130 parallel 9.0 13.8 51.9
4 x PSG 6130 parallel 9.0 13.8 69.2
PSG 6180 14.0 5.7 35.5
2 x PSG 6180 parallel 14.0 9.5 60.8
PSG 6250 14.0 8.0 17.3
2 x PSG 6250 parallel 14.0 9.5 34,6
3 x PSG 6250 parallel 14.0 9.5 51.9
4 x PSG 6250 parallel 14.0 9.5 60.8
1
Max. secondary current: Peak loadability at 3 % D.C. and 50 msec weld time

Weld controls PRC | Product Catalog Resistance Welding 15
Weld Controls PRC
Weld Controls PRC 15

Overview 16
Functional Overview 22
Ordering information, Handbooks 23
Options, Accessories, Spare Parts 24
Operating Software PRI 7000 25

16 Product Catalog Resistance Welding | Weld controls PRC
Weld Controls PRC

Overview
Simlified Type Key
PRC7300–L 1–01VRS–0300–01–00001–CC–00
Power class Variant

300 = max. weld current* 33 kA CC = unpacked**
400 = max. weld current* 80 kA ST = packed
Cooling Function identifier

L – air e.g. 0300, 0401 see
W – water type-specific instruction
Range of mains voltage

1 = 400 … 480 V -15 %/+10 %
2 = 500 … 690 V -15 %/+10 %
** M
aximum secondary current of the welding transformer at turns ratio 55:1 (mains voltage range 1) resp. 72:1
(mains voltage range 2)
** U
npacked weld controls are intended for installation in a control cabinet at the manufacturer’s site. Packaged controls can be
ordered separately. This catalog contains only packaged controls.
Technical Data
Type PSG …
PRC 7300-W2-…1
PRC 7400-W2-…1
PRC 7300-W1-…
PRC 7400-W1-…
PRC 7300-L1-…
PRC 7300-L2-…
PRC 7400-L1-…
PRC 7400-L2-…
Electrical Data
Range of mains voltage V 400 … 480 500 … 690 400 … 480 500 … 690
Rated mains current A 110 80 250 180
(max. thermal continous current)
Output frequency Hz 1000
Max. primary current A 550 420 1600 1110
(output current to transformer)
Mechanical Data
Weight kg 13.8 13.1 13.8 13.1 30.8 28.1 30.8 28.1
Dimensions Height mm 320 496
Width mm 370 385
Depth mm 270 237 270 237 262 250 262 250
1
Particularity: PRC 7xxx-W2 in IT-mains: 500 … 580 V

Weld Controls PRC

Engineering Notes
Front view PRC 7300
XGSD1 +
XFU1 (covered)
XFE0
XDS1
XFE1
XGM1
XGM2 XFU0
XGM3 XFS1 + XFS2
XGM4 XGD1 +
XGD2 +
XGD3
The weld control PRC 7000 communicates with: Operation, programming and diagnostics are carried out by
▶▶ The robot control/PLC via I/O-interfaces means of a connected operating computer.
▶▶ The programming device(s) via data bus interface(s) A diagnostics module on the front side allows additionally:
resp. USB –– to display the status of PRC and its firmware version,
▶▶ Possibly servo drive module(s), the safty zone module –– to display and set the Ethernet configuration,
and gun data module via the WIC (Weld Interface –– to display and reset errors/warnings,
Controller) bus –– to re-start the control.
▶▶ Possibly operating and display elements and the
electrode tip dresser via digital I/O-signals Optionally, it is possible to access the control via
WebServer (in preparation).

Weld Controls PRC

Engineering Notes
Following signal interfaces are standard on board: Functionality of Weld Controls PRC 7000
▶▶ Secondary current, secondary voltage, transformer
temperature monitoring (XGM1) Below we are listing the functional scope, which is common
▶▶ Analog command and actual values of electrode to all weld controls.
pressure, digital feedback electrode pressure (XGM2) Additional functions for each control type are specified in
▶▶ Analog command and actual values of gun force, digital the following chapters. The functions of the process control
output Operate/Reset force sensor (XGM3) are reflected in the I/O signal mapping. For detailed
▶▶ 16 digital inputs 24 VDC (XGD1, XGD2) descriptions, refer to the type-specific instructions.
▶▶ 8 digital outputs 24 VDC (max. 100 mA) (XGD3)
Welding Tasks
Moreover –– Up to 10.000 different welding tasks (sheet thickness
▶▶ Two WIC ports (XFS1, XFS2) combinations) are programmable
▶▶ One Ethernet port for the connection of an operating –– Symbolic spot reference is possible
computer on site or via data network (XFE0)
▶▶ One USB port for local programming (XFU0) Welding Cycle
–– Universally adjustable
In addition, there are two analog inputs and outputs and –– Programming times in milliseconds
two digital high-speed inputs, which are not yet used –– Up to 10 sequences with separate blocks configurable
(XGM4). –– Block types: preconditioning, welding, post-conditioning
Optional function extensions can be enabled via SD card –– Specific current profile can be defined for each sequence
(XGSD1, behind the cover). block
The universal interface slot is equipped with an Anybus Regulation Modes

module which, depending on the application, implements –– PHA (phase shift)
a type-specific I/O signal interface (XFE1). –– KSR (constant current regulation)
Control types with different I/O interfaces are available: –– UIR (adaptive regulator, optionally see page 20)
–– ProfiNet The control modes can be set separately for each weld
–– Ethernet/IP time.
–– Others (in preparation)
Monitoring Functions
–– Reference currents can be programmed independently of
the commanded values
–– Percentage or absolute tolerance band, programmable
asymmetrically
–– Several monitoring functions can be set for each
sequence block
–– Automatic spot repetition when the current is too low,
configurable

Power Correction Protection Class, Mounting Position

–– Can be specified for each electrode separately Weld controls PRC 7000 have the protection class IP 20
and are intended for installation in a control cabinet. If
Weld Gun Management they, e.g., are installed in the rear wall of the cabinet,
–– Management of all guns used (number depending on the heat sink can be located outside.
control type)
–– Power increment (stepper function) Air- or Water-Cooling?
–– Electrode tip dressing incl. start dressing Weld controls PRC 7000 are available in two performance
–– Increment of the electrode force classes, each with air and water cooling:
–– Prewarning table with graphical representation of the
▶▶ PRC 7xxx-Lx … air cooling
electrode wear
▶▶ PRC 7xxx-Wx … water cooling
Control of Gun Force The thermal output power of each power class is the same
–– Force profile programmable for each sequence block, for both types of cooling. Controllers with water cooling are
–– Output as analog and/or digital correcting variable preferably used in high duty cycle applications, e.g. for roll
(depending on control type) seam welding.
–– Analog or digital feedback (depending on control type)
–– Force calibration for adjusting the force control variable Air-cooled controls require forced cooling by fans and allow
to the used actuators max. 45 °C cooling air temperature. We offer fan hoods as
accessories, see chapter “Weld Controls PRC Accessories”
Tip Dresser Management on page 24.
–– Management of all tip dressers used
–– Monitoring the milling cutter wear Water-cooled controls require a minimum flow rate of
–– Prewarning table with graphical representation of the 4 l/min and allow an inlet temperature between 18° and
milling cutter wear 30 °C, and max. 10 bar water pressure.
Calibration For further information on water-cooled controls, please

–– Of current (adjustment of the welding device to an refer to the application description:
external reference current meter) Rexroth PS6000 Wx / PRC7000 Weld Timer and Welding
–– Of force (adjustment of the welding device to an external Transformer with water cooling R911370699.
reference force measuring device)
Protocol Functions
–– Error/event protocol with logging of weld errors
–– Data change protocol
–– Protocol of current values
–– Electrode and milling cutter exchange protocol
Backup and Restore

–– Backup, auto-backup and restore of data

Weld Controls PRC

Engineering Notes
Mains Voltage Function

The controllers are connected three-phase to the TN, TT or 1. On the basis of a good welding with constant current
IT mains. regulation, the system determines the variation over
There are the PRC 7000 weld controllers for two mains time of electrode voltage and current and therefrom it
voltage ranges: calculates the resistance curve.
▶▶ PRC 7xxx-X1: 400 … 480 V; -15 %/+10 %; 50/60 Hz

▶▶ PRC 7xxx-X2: 500 … 690 V; -15 %/+10 %; 50/60 Hz
(Peculiarity: PRC 7xxx-W2 in IT mains
500 … 580 V; -15 %/+10 %; 50/60 Hz)
Adaptive UI Regulator (optional)
The adaptive UI (voltage/current) regulator ensures the

optimal introduction of the necessary heat quantity into the
spot during welding. It compensates for numerous
disturbances, such as:
▶▶ Electrode wear
▶▶ Bad electrode tips Typical current, voltage and resistance characteristics
▶▶ Variation of electrode force
▶▶ Electrode misalignment 2. A reference curve is created for the welding spot,
▶▶ Shunting from a series of resistance sequences thus obtained.
▶▶ Poor contact 3. Using the reference curve, the UI regulator can then vary
▶▶ Different coatings of material the welding current level and the weld time in such a
▶▶ Glue way that the required heat quantity is reliably inserted
▶▶ Edge welding into the welding spot, even if different disturbances
▶▶ Poor fitting occur.
▶▶ Mains voltage fluctuations
The adaptive regulator adjusts current and weld time for

each individual welding spot. This makes it possible to
process different material combinations with the same
welding program – a decisive advantage in manual welding.
The adaptive regulator detects splashes and can react
according to the specification.

Advantages of the UI regulator:

▶▶ Very wide bandwidth of compensable disturbances
▶▶ Significantly fewer user interventions when disturbances
occur
▶▶ Better and more precise monitoring of the welding
process, thanks to a variety of new monitoring
parameters: process stability, process quality et al.
▶▶ Simple and fast parameterization of the monitoring
functions by graphical representation of the actual
values’ distribution over time (histogram)
▶▶ Additional functions to improve the welding quality
(e.g. glue function, thin-sheet function, compensation of
gun resistance, Q-Stop-logics, monitoring of force) build
on the possibilities of the UI regulation
▶▶ Fast parameterization of the adaptive UI regulator after
sample welding of sheet metal strips (STC-Teach)
The adaptive UI regulator does not require any further

sensor technology, in addition to a primary or secondary
current measurement and a voltage tap on the arms of the
weld gun. A primary current sensor is included in all
PRC 7000 weld controls. Most PSG welding transformers
contain a secondary current sensor, see chapter “Welding
Transformers PSG”.
The adaptive UI regulator can optionally be retrofitted.

There are UI regulator options for steel and aluminum
sheets, see chapter “Weld Control Options”, on
page 24.

Weld Controls PRC

Functional Overview
Electrical and mecanical data see page 16
Type
PRC 7x00-x1-01VRS-0300-…
PRC 7x00-x1-01VRS-0401-…
PRC 7x00-x1-01VRS-0402-…
PRC 7x00-x1-01VRS-0403-…
Application
Control for manual weld guns — —  —
Control for pneumatic robot guns  — — 
Control for servo-electric robot guns  — —
Fieldbus module1
ProfiNet   — —
Ethernet IP — — — 
Digital Inputs /Outputs2
Inputs (control1) — 10 14 4
Inputs (extendible3) — 8 24 —
Outputs (control1) — 6 8 4
Outputs (extendible3) — 15 54 —
Analog Inputs /Outputs
Inputs (control1) 2 4 2 4
Inputs (extendible3) — – 2 —
Outputs (control1) — 1 1 1
Outputs (extendible3) — – 2 —
Special Features
Status codes via fieldbus —  — 
Functions gun life, tip dresser wear, visualization electrode status,  — — —
protocol of workpiece number
Functions servogun electric, tip dresser management —  — —
Functions electrode management for 2 guns, outputs for display — —  —
of status and program selection
 included with delivery — nicht enthalten
1 3
Contained in the control In/output field extendible by bus couplers and I/O-modules resp. MGDM
2 (see pages 28ff). The functionality, I/O-signal mapping and special features of
ctually used in/outputs, except transformer temperature, digital pressure
A
the each control type are described in the type-specific instructions,
feedback and mains circuit breaker trip
see page 23.

PRC 7xxx
Ordering information
Description Type Designation Ref. No.
550 A max, air-cooled, ProfiNet, for pneumatic robot guns PRC7300-L1-01VRS-0300-01-00001-ST-01 R911347586
550 A max, water-cooled, ProfiNet, for pneumatic robot guns PRC7300-W1-01VRS-0300-01-00001-ST-01 R911382992
1.600 A max, water-cooled, ProfiNet, for pneumatic robot guns PRC7400-W1-01VRS-0300-01-00001-ST-01 R911382489
1.600 A max, water-cooled, ProfiNet, for servo-electric robot guns PRC7400-W1-01VRS-0401-01-00001-ST-01 R911382491
1.600 A max, water-cooled, discrete I/Os, for manual weld guns PRC7400-W1-01VRS-0402-01-00001-ST-01 R911382493
550 A max, air-cooled, EthernetIP, for pneumatic robot guns PRC7300-L1-01VRS-0403-01-00001-ST-01 R911381919
1.600 A max, air-cooled, EthernetIP, for pneumatic robot guns PRC7400-L1-01VRS-0403-01-00001-ST-01 R911383151
1.600 A max, water-cooled, EthernetIP, for pneumatic robot guns PRC7400-W1-01VRS-0403-01-00001-ST-01 R911383153
Handbooks
Titel Ref. No.
Instructions Rexroth PRC 7000 R911172834 Download
Type-specific instructions Rexroth PRC 7x00-Lx/Wx-300 R911342600 Download
Type-specific instructions Rexroth PRC 7x00-Lx/Wx-401 R911373593 –
Type-specific instructions Rexroth PRC 7x00-Lx/Wx-402 R911381739 –
Type-specific instructions Rexroth PRC 7x00-Lx/Wx-403 R911381576 Download
Description of application Rexroth PS6000 Wx / PRC7000 R911370699 Download
Weld Timer and Welding Transformer with water cooling

Weld Controls PRC

Options, Accessories, Spare Parts
The following functions are optionally available for retrofitting the PRC controls:
▶▶ UI-regulator steel … adaptive voltage / current regulator (see page 20) for steel sheet
▶▶ UI-regulator steel+aluminum … same for steel and aluminum sheets
Type
PRC 7300-W1-01VRS-0300- …
PRC 7400-W1-01VRS-0300- …
PRC 7400-W1-01VRS-0401- …
PRC 7400-W1-01VRS-0402- …
PRC 7400-W1-01VRS-0403- …
PRC 7300-L1-01VRS-0300- …
PRC 7300-L1-01VRS-0403- …
PRC 7400-L1-01VRS-0403- …
Option
UI-regulator steel with force monitoring Option UIR steel and force 1070094217    — — — — —
monitoring
UI-regulator steel+aluminum with force monitoring Option UI-regulator 1070094218        
steel+aluminum and force
monitoring
Accessory
Air fan hood for PRC 7300 Fan hood PRC7300 R911173733  — — — —  — —
Air fan hood for PRC 7400 Fan hood PRC7400 R911174586 — — — — — —  —
1
Bag with 6 insert profiles for mains Insert profiles set R911174037        
inlet and transformer output
Current sensor with M12 connector SSR 81.20 1070081808        
for secondary current measurement
Spare Parts
Operating and diagnostic module Standard Controller R911293458        
Label for PRC Label set PRC7300 2 1070093582        
Interface module Ethernet-IP CFG-FBMODUL-AN-ETI-UP R911173991 — — — — —   
Interface module ProfiNet-Wire CFG-FBMODUL-AN-PNW-UP R911173824      — — —
Socket terminal board for XGD1, XGD2, XGD3 SET LED R911173800        
Socket terminal board for XDS1, XGM1, SET B2CF 3.50 REDUZ. R911173776        
XGM2, XGM3, XGM4
 included with delivery  accessory retrofittable  suitable — not suitable
1 2
Insert profiles for the power terminals are required for connecting conductors hree labels L1, L2, L3, PE, U, V for the terminals of the weld controls PRC 7300
T
with a cross-section of 35 mm2 or less, or with pin cable shoes, in order to and PRC 7400
ensure a secure connection.

Operating Software PRI 7000
The PRI 7000 software is used to program, operate and ▶▶ Certain events can be defined as “error” or “warning”,
diagnose the weld controls PRC 7000. as required
▶▶ The user interface provides an overview of all weld
▶▶ The welding process is universally configurable: each of
controls by means of a system diagram, a control-
the over 10.000 welding tasks can be built from up to
related overview based on various filter criteria and a
ten sequence blocks with their own power profile
status display of all input / output signals of the weld
▶▶ The regulation mode can be set separately for each
controls
weld time
▶▶ The data can be backed up and restored using the
▶▶ For each sequence block, current and other monitoring
Backup / Autobackup and Restore functions
can be individually selected
▶▶ Programming is possible online or offline
▶▶ For each weld control the measurement of current and
electrode force can be scaled to an external reference
measuring device System Requirements
▶▶ The power adjustment of electrode wear, the tip ▶▶ PC with min. 1 GHz processor
dressing, a force profile for each sequence block as well ▶▶ Operating system Windows 7 or 10,
as an individual power correction can be set for each Windows Server 2008 R2, Windows Server 2012
connected weld gun ▶▶ Net Framework 4.5.1 or higher
▶▶ The software provides extensive protocol functions acc. ▶▶ Memory:
to ISO 9000: –– RAM min. 4 GB
–– protocol of current values –– Hard disk 1 GB for PRI 7000 application, additional
–– protocol of errors/weld errors/events storage space for data
–– data change protocol ▶▶ Monitor resolution min. 1920 x 1080
–– electrode and milling cutter exchange protocol ▶▶ CD/DVD drive
▶▶ Ethernet card
Software DVD, single license PRI 7000 R911174535

26 Product Catalog Restistance Welding | System Components

System Components | Product Catalog Restistance Welding 27
System Components
for Communication,
Gun Control and
Safety
System Components 27
Fieldbus Couplers and I/O-Modules 28
Servo Drives HCS01 32
Gun Data Modules GDM and MGDM 37

Fieldbus Couplers and I/O-Modules
With fieldbus couplers and I/O-modules, the signal input/ The firmware of the weld control determines the function of
output field of the PRC weld controls is expanded by the inputs and outputs. For details, refer to the type-
additional inputs/outputs. An application example is shown specific instructions for each weld control.
on the overview diagram Pneumatic manual weld gun, on We are offering the modular I/O systems S20 and S67:
page 12.
I/O system S20 with protection class IP20 is the freely I/O system S67 with protection class IP67 allows you
scalable I/O system for cabinet installation. reliable, process-oriented and completely cabinet-free
installation – even in extreme environmental conditions.
▶▶ Easy installation thanks to toolless wiring
These modules may be mounted e.g. directly on the weld
▶▶ The S20 I/O-modules can be easily connected
gun.
decentrally via a bus coupler
▶▶ Robust design with a standard, expanded temperature ▶▶ Fast and toolless installation via the M8 and M12
range, minimal EMC emission and high vibration connectors as well as preassembled system cable
resistance ▶▶ Easy connection to the system via intelligent fieldbus
couplers
▶▶ High protection class IP67 for extreme operating
conditions with an expanded temperature range,
minimal EMC emission and high vibration resistance
A selection of fieldbus couplers and I/O-modules S20 and The brochure I/O systems S20 and S67 for flexible
S67, which are designed as system components in automation provides an overview of the entire program.
combination with weld controls PRC, are presented on the I/O systems for flexible automation
following pages. (Reference No. R999001321).

Fieldbus Couplers and I/O-Modules S20

for cabinet installation
The I/O system S20 is in modular design with protection The input module S20-DI-16/1 and the output module
class IP20, for cabinet installation. It is used to transfer the S20-DO-16/1 complete the I/O station.
process signals to a higher-level controller.
▶▶ 16 resp. 32 digital inputs or outputs
An S20 station consists of individual modules, which are
▶▶ Outputs 24 V DC, 500 mA, protected against short circuit
snapped onto a support rail.
and overload
The head of the station is a bus coupler. The I/O-modules
▶▶ Inputs 24 V DC, 2.4 mA
are connected to it.
▶▶ Connection of the sensors / actuators in 1-wire
The connection of the individual modules to one another
technology
and to the station head is realized by means of bus socket
▶▶ Minimum update time < 100 μs, bus-synchronous
modules. These are snapped together in the support rail
▶▶ Stored device type label
and form the local bus.
▶▶ Diagnostics and status displays
▶▶ Supplied with bus socket module
The bus coupler S20-S3-BK+ with a network connection
▶▶ Dimensions H × W × D = 126.1 × 35 × 54 mm
and an S20 local bus connection is the link between the
network and the S20 station as the head of an S20 station.
The analog input/output module S20-AIAO-2 connects
▶▶ Fieldbus protocol Sercos v1.3
additional signals from the weld guns to the weld control.
▶▶ 2 pcs. RJ45 connectors (with integrated switch)
▶▶ Rotary code switch for setting the Sercos address ▶▶ 2 analog inputs, 2 analog outputs,
▶▶ Up to 63 additional S20 users can be connected ▶▶ Voltage or current selectable individually: 0 … 20 mA,
▶▶ Electronic device type label 4 … 20 mA, ± 20 mA, 0 … 10 V, ± 10 V, 0 … 5 V, ±5 V
▶▶ Diagnostics and status indicators ▶▶ Connection of the sensors / actuators in 2-wire
▶▶ Dimensions H × W × D = 125.9 × 45 × 74 mm technology
▶▶ Delivery including bus socket module and connectors
▶▶ Dimensions: H × W × D = 126.1 × 35 × 54 mm
Please refer to the application description S20 System and

Installation for a detailed description of all components
(including bus socket modules and connectors) as well as
information on installation distances, conductor cross-
sections and connection technology
(Reference number R911335988).
Bus coupler Sercos S20-S3-BK+ R911173318
Module 16 digital inputs 24 VDC S20-DI-16/1 R911172543
Module 16 digital outputs 24 VDC S20-DO-16/1 R911172542
Module 32 digital outputs 24 VDC S20-DO-32/1 R911172535
Analog input-/output module: 2 analog inputs, 2 analog outputs S20-AIAO-2 R911173743

Fieldbus Couplers and I/O-Modules S67

for use in peripherals
The modular I/O system S67 consists of fieldbus couplers, The input module S67-DI8-M12 and the output module
I/O-modules and, if required, power distributors with S67-DO8-M12 extend the I/O field modularly.
protection class IP67. The total expansion per IndraControl
▶▶ 8 digital inputs and outputs, respectively
S67 node can be up to 500 meters, with a maximum
–– inputs 24 V DC, 7.3 mA
distance between the individual S67 components of 50 m.
–– outputs 24 V DC, 500 mA, protected against short
The fieldbus coupler and the I/O-modules are only
circuit and overload
connected via the S-BUS cable, for communication and
▶▶ Connection type: M12 connector, 3-pin
power supply.
▶▶ Diagnostics and status displays
▶▶ Dimensions: H × W × D = 117 × 50 × 36 mm
A general description of all components can be found in
the application description Rexroth S67 (Reference
Documentation: Application descriptions
number R911329572).
S67 Digital Module 8 Inputs (4×M12)
The manuals on the right provide detailed information on
(Reference number R911329550) and
configuration, commissioning and accessories.
S67 Digital Module 8 Outputs – 0.5 A
(Reference number R911342196).
The fieldbus coupler S67-S3-BK-DI8-M8 is the link to the
fieldbus and thus to the data exchange with the higher-level
control.
▶▶ 8 digital inputs
–– 24 V DC, 2.8 mA
–– connection type: M8 connector, A-coded, 3-pole
▶▶ USB port for service purposes
▶▶ Lockable control panel for the operating mode and
address switch (DIP switch)
▶▶ Diagnostics and status indicators
▶▶ Expandable by up to 64 external I/O-modules
▶▶ Parameterization and configuration using the
IndraWorks engineering tool
Documentation: application description

S67 Sercos Coupler 8 Digital Inputs (M8)
(Reference number R911338401)

Bus coupler S67 Sercos III S67-S3-BK-DI8-M8 R911172899
Module 8 digital inputs (M12) S67-DI8-M12 R911171788
Module 8 digital outputs (M12) S67-DO8-M12 R911171790

Servo Drives HCS01

for gun stroke and electrode tip dresser
The compact converters HCS01 are part of the Rexroth

IndraDrive Cs product family. They are used to operate
Rexroth IndraDyn motors or third-party motors.
The table on page 33 provides an overview of servo

drives which we recommend for our PRC 7000 weld
controls.
Following servo drives are available for resistance welding:

–– For control and regulation of gun stroke, in two power
classes
–– For control of tip dresser without regulation, in a single
power class
Servo drives for the gun stroke are available with the
options Safe Stop or Safe Movement. The Safe Movement
option, together with the HZS01 zone module, ensures that
the weld guns are moving with a safe speed, when e.g. the
door is open. See page 35 for more information.
For each servo drive, we provide the appropriate firmware,
which must be ordered separately. HCS01.1E-W0005, -W0028 and -W0054
We are offering Sercos cable assemblies – examples on Detailed technical data, notes on the mechanical and electri-
page 34. cal project planning, for servo motors, for documentation
and a description of the cables, accessories and additional
Mains filters NFD03.1 reduce radio interference and components are available in the following manuals:
network effects of the servo drives. They are used for the Rexroth IndraDrive Cs drive systems with HCS01;
disturbance suppression of three-phase drive control units project planning manual
up to 480 V for 1 … 6 axes and motor cable lengths up to a (Reference number R911322210)
maximum of 75 m single-axis / 120 m multi-axis. Rexroth IndraDrive drive controllers power sections
HCS01; operating instructions
Rexroth IndraDrive additional components and accessories;
project planning manual

Servo drives HCS01: Technical basic data, function overview, firmware and suitable mains filters
Type
W0028-A-03-B-ET-EC-NN-S5- …
W0054-A-03-B-ET-EC-NN-S5- …
W0005-A-03-E-S3-EC-NN-L3- …
W0028-A-03-B-ET-EC-NN-L4- …
W0054-A-03-B-ET-EC-NN-L4- …
HCS01.1E- …
Electrical Data
Mains connection 3-phase AC-network 200 … 500 V
Continous current A 2.0 11.5 11.5 21.0 21.0
Maximum current A 5.0 28.0 28.0 54.0 54.0
Output voltage V 3 × AC 0 … 500 V
Overall protection class IP20
Mechanical Data
Weight kg 0.72 1.7 1.7 4.22 4.22
Dimensions Height mm 215 268 268 268 268
Width mm 50 70 70 130 130
Depth mm 196 196 196 196 196
Functionality
Control of electrode tip dresser  — — — —
Control and regulation of gun stroke —    
Option Safe Stop   
Option Safe Movement  
Firmware
FWA-INDRV*-MPE-…  — — — —
for servodrives for electrode tip dresser control
FWA-INDRV*-MPB-… —    
for servodrives for gun stroke control and regulation
Mains Filter
for servodrives up to 30 A    — —
for servodrives up to 55 A — — —  
 included  suitable — not suitable

Servodrive electrode tip dresser up to 5 A HCS01.1E-W0005-A-03-E-S3-EC-NN-L3-NN-FW R911341015
Servodrive gun stroke with safe stop, up to 28 A HCS01.1E-W0028-A-03-B-ET-EC-NN-L4-NN-FW R911331611
Servodrive gun stroke with safe movement, up to 28 A HCS01.1E-W0028-A-03-B-ET-EC-NN-S5-NN-FW R911376620
Servodrive gun stroke with safe stop, up to 54 A HCS01.1E-W0054-A-03-B-ET-EC-NN-L4-NN-FW R911332723
Servodrive gun stroke with safe movement, up to 54 A HCS01.1E-W0054-A-03-B-ET-EC-NN-S5-NN-FW R911376621
Firmware for servodrive tip dresser FWA-INDRV*-MPE-xxVRS-D5-1-NNN-NN actual version
Firmware for servodrive gun stroke FWA-INDRV*-MPB-xxVRS-D5-1-NNN-NN on request
Sercos cable, 0,25 m long RKB0061/00,25 R911372773

Sercos cable, 2 m long RKB0062/002,0 R911372776
Mains filter for servodrives up to 30 A NFD03.1-480-030 R911286919
Mains filter for servodrives up to 55 A NFD03.1-480-055 R911286920

Safety Zone Module HZS01

for safe movement of the weld gun
The safety zone module HZS01 monitors the safety devices The safety zone module is controlled by the safety device
such as protective doors or light barriers and realizes, and, for its part, drives the servo drives via the
if necessary, the safe movement of the weld gun. communication bus. For this we offer ready-made bus
It provides the following security features: cables RKB0051 and RKB0052 (see below):
–– Safety Zone Acknowledge [SZA]
▶▶ Maximum total length of all cables in a safety zone:
–– Safety Zone Error [SZE]
2500 m
–– Safety Zone Input [SZI]
▶▶ Maximum length of a cable between two connection
–– Safe Door Locking [SDL]
points: 100 m
▶▶ Number of security zone nodes (without HSZ01):
▶▶ 2 × 8 digital inputs for 2-channel common selection of –– maximum of: 35
the safety functions at the safety zone nodes or 16 –– minimum: 1
inputs for 1-channel selection
▶▶ 2 × 1 digital dynamic output (1 output pair) for safety Technical specifications, detailed functional description,
zone acknowledgment, if all safety zone users display configuration notes as well as a description of the cables
safety and other accessories for the safety zone module are
▶▶ 2 × 1 digital dynamic output (1 output pair) Safety zone contained in the following manual:
error if at least one safety zone subscriber indicates an Rexroth IndraDrive Additional Components and
error Accessories Project Planning Manual
▶▶ 2 × 1 digital dynamic output (1 output pair) for (Reference number R911306140).
monitoring the wiring
▶▶ 2 × 1 digital output (1 output pair) for the control of the
safe protective door lock
▶▶ Galvanic isolation exists between the inputs and outputs
of the safety zone module and the other participants in
a safety zone
▶▶ Protection class: IP20

Safety zone module HSZ01.1-D08-D04-NNNN R911339573
Bus cable 0.25m RKB0051/00,25 R911341092
Bus cable 0.55m RKB0051/00,55 R911341093
Bus cable 1m RKB0052/001,0 R911341079
Bus cable 2m RKB0052/002,0 R911341083
Bus cable 5m RKB0052/005,0 R911341082

Gun Data Modules GDM and MGDM
On the gun data modules data from the weld gun are For this purpose, the gun data module GDM is used.
stored, e.g.: The measuring gun data module MGDM also collects the
–– an electronic type label, measured values occurring at the weld gun, including
–– the actual electrode wear. preparation and preprocessing.
The electronic type label is used e.g. in the gun workshop GDM and MGDM communicate with the weld control PRC
to identify the weld gun. If guns are used one after the via the WIC bus.
other at several weld controls, the current wear of the guns
and electrodes must be known to the controls.
The gun data module GDM has a WIC port, via which the The measuring gun data module MGDM moreover has
weld control or a service PC can access their respectively plugs for the following signals from the weld gun:
accessible memory range.
▶▶ 24 digital inputs/outputs 24 VDC, individually
The service PC can retrieve the electronic type label of the
configurable as input or output
gun, using a browser:
▶▶ Gun coding
▶▶ Serial numbers ▶▶ Actual value of a force sensor
▶▶ Information on gun design ▶▶ Actual value and calibration of another force sensor
▶▶ Information on welding transformer ▶▶ Actual value of secondary voltage
▶▶ Setpoint and actual value for a proportional valve
The weld control can read and write counter readings: ▶▶ Secondary current and temperature contact of two
electrode tip wear, dressing cycles, gun wear. welding transformers
Protection class: IP65 Protection class: IP65

Dimensions: H × W × D = 85 × 21 × 60 mm Dimensions: L × W × H = 200 × 167 × 22 mm
Further information in the description of application Further information in the Type-Specific Instructions
Rexroth GDM Gun Data Module Rexroth PRC7000 MGDM Measuring Gun Data Module
(Reference number R911339735). (Reference number R911381901).

Gun data module GDM.001 R911173166
Measuring gun data module MGDM.001 R911174536

Welding Transformers | Product Catalog Restistance Welding 39
Welding Transformers PSG
Welding Transformers PSG 39
Overview 40
Technical Data, Ordering information, Handbooks

PSG 3075 46
PSG 3100 48
PSG 6120 50
PSG 6130 52
PSG 6160 56
PSG 6170 58
PSG 6180 60
PSG 6230 62
PSG 6250 64
Options 67
Accessories 68
Primary Terminal Boxes 68
Counterplugs for Power and Signals 69
Protective FI Resistors 72

40 Product Catalog Restistance Welding | Welding Transformers
Welding Transformers PSG –

Overview
Simplified Type Key
PSG 6130.00 P ST K
Power class Special design

e. g. 130 = 130 kVA / 20 % D.C. ––see type-specific instructions
Variant Sensors
00, 01, 02 … 68 – see type-specific instructions S = with secondary current sensor
T = with temperature monitoring
Primary connection
A = without primary power and signal connectors
P = with primary power connector TAG
R = with primary power connector Robifix
Technical Data
Type PSG …
PSG 3075 …
PSG 6120 …
PSG 3100 …
PSG 6130 …
PSG 6160 …
PSG 6170 …
PSG 6180 …
PSG 6230 …
PSG 6250 …
Electrical Data
Frequency Hz 1000
Nominal power / 20 % D.C. S1N kVA 94 145 129 140 173 172 178 237 250
Secondary voltage class U2d V 9.0 9.3 9.0 9.0 9.0 9.0 14.0 14.0 14.0
Continuous output current / I2P kA 5.0 6.5 6.0 6.5 8.5 8.0 5.7 8.2 8.0
100 % D.C.
Output current / 20 % D.C. I2 kA 11.1 14.5 13.4 14.5 19.0 17.9 12.7 18.3 17.9
Mechanical Data
Mass kg 14.5 25.0 16.0 16.0 … 23.0 19.0/ 23.0 26.0 23.0
20.0 19.6
Dimensions without plugs Height mm 108 127 125 106 … 127 125/ 125 127 125
140 127
Width mm 150 160 160 150/ 171 160 160 171 160
160
Length mm 295/ 330/ 242 213 … 380 262 … 319 380 300
303 342 319 314


Engineering Notes
Welding inverter and transformer
U1N … primary voltage

U2d … secondary voltage
I2 … secondary current = weld current
Which Transformer for What Welding Task?

The welding transformer produces the intensity of current –– Afterwards it checks if the selected transformer can drive
required for resistance welding, by stepping down the the required weld current through the given secondary
output voltage of the inverter (e.g. 530 V) to a low voltage resistance.
(e.g. 9 V). Thus the secondary current is brought up in the –– Finally, the suitable design of power and signal
same proportion. connectors can be selected among different variants,
The secondary current is rectified, which enables low-loss if available.
DC welding. Welding transformer and rectifier form the
compact unit PSG.
–– The choice of welding transformer depends on:
–– the required secondary voltage
–– the required power
–– the available primary voltage
–– the required design of connectors.
–– In a second step, it is checked if the chosen transformer-
rectifier unit would suit with the required load cycle.


Engineering Notes
Secondary Voltage Sample welding task:

The secondary voltage of the transformer must be able to –– I2 = 18 kA, U2d = 9 V, D.C. = 10 %
drive the required welding current through the existing –– Power during weld time:
resistance of secondary circuit. S2 = I2 * U2d = 18 kA * 9 V = 162 kVA
We offer transformers in secondary voltage classes of 9 V –– Power related to 20 % D.C.:
and 14 V.
–– 9 V transformers are suitable for spot welding of steel D.C. 10 %
S2N = S2 * = 162 kV * = 115 kVA
sheets, e.g. with transformer guns. 20 % 20 %
–– 14 V transformers are recommended for spot welding of
aluminum sheets, as well as for all applications with Result:
higher secondary resistance, e.g. stationary projection Transformers PSG 6130 with 140 kVA nominal power are
welding machines. suitable for the given welding task.
Nominal Power (Rated power) Primary Voltage

The required welding power S2 is calculated from weld The output voltage of Rexroth welding inverters is in a fixed
current I2, secondary voltage U2d and duty cycle D.C. ratio to the mains voltage. The selected transformer must
The duty cycle is the percentage of weld time, with regard match with the given mains voltage.
to the thermal integration time of the component The primary connection plate of the transformers PSG
concerned, in this case the transformer (60 seconds). 6xxx.xx RSTK is marked in color accordingly.
For welding transformers the nominal power is specified for
Mains voltage UN Primary voltage U1N Color of
20 % D.C.
connection plate
The nominal power S1N of the transformer must be higher
400 V 530 V black
then the required welding power, also related to 20 % D.C.
480 V 645 V blue
The nominal power S1N of the transformer must be higher
690 V 926 V red
then the required welding power, also related to 20 % D.C.


Engineering Notes
Checking the Load of Transformer and Diodes Protective Measures Against Inadmissibly High Contact
In the course of dimensioning the transformer care must Voltages
be taken that neither winding nor rectifier diodes are Welding transformers of the PSG series correspond to
overloaded in operation. Due to the widely different protection class 1 in accordance with EN 61558-1.
thermal integration times of transformer (60 sec) and This means that protective measures as stipulated in
diodes (2 sec), their load cycles possibly must be EN 62135-1 must be provided to ensure protection against
considered separately. inadmissibly high contact voltages (in the event of an
insulation breakdown between the primary and the
The operating instruction “MF welding transformers secondary current circuit).
PSG xxxx” describes the procedure. In the type-specific
instruction of each transformer, the load diagrams of Possible protective measures in connection with medium-
transformers and diodes can be found. The duty cycles frequency transformers:
given in this catalog (e.g. “Output current / 20 % D.C.”) are
always related to the integration time of transformers (60 ▶▶ Direct Protective Conductor Connection
sec). The negative pole of the secondary circuit is grounded
using a protective conductor jumper. In this case the
scope of protection is limited to the secondary circuit.
Checking the Secondary Resistance
Furthermore it must be checked whether the required ▶▶ Fault-Voltage Protection (FV)
secondary current can really be achieved with the given Voltage-operated earth leakage protective switch
secondary resistance. (i.a.w. EN 62135-1): it monitors the secondary circuit.
For this purpose, the protective conductor jumper
For details, see operating instruction “MF welding (MPE bridge) of the transformer has to be removed. The
transformers PSG xxxx” and the relevant type-specific scope of protection is also limited to the secondary
instruction. circuit.
The transformers PSG 3075.11 PSV and PSG 3100.01
PSV have got a secondary tap from the minus pole for
the fault-voltage protection (FV).


Engineering Notes
▶▶ Earth Leakage Current Protection (FI) Temperature Monitoring,

Residual current protection circuit (i.a.w. EN 62135-1): Measurement of Secondary Current
It monitors the power inlet of the MF inverter by means The temperature of primary winding and rectifier diodes in
of a measuring current transformer. most transformers is monitored by temperature switches.
In this case, the MPE bridge of the welding transformer
has to be replaced by an appropriate ground fault The secondary current is measured by a toroid sensor. Both
protection resistor, see chapter Protective FI Resistors, signals are led out in the primary terminal space- pluggable
page 72. The scope of protection extends from the or by individual wires. For details see the relevant chapter
current transformer to all following system components. under “Options”.
For more detailed information on protective measures, see

the operating instruction “MF welding transformers PSG Measurement of Secondary Voltage,
xxxx” (Reference number 1070087062). Force Signal
The secondary voltage for the adaptive UI regulation can be
tapped either in the transformer, or the secondary voltage
Primary Power Connection tapped at the weld gun is lead through the terminal space
The primary power inlet (2pole+PE) can be connected of the transformer, same as possibly the force signal from
permanently or pluggable. an external force sensor.
The pluggable power connection is particularly suitable for
gun transformers. Most transformer types have got a power The signals are pluggable. For details see the relevant
connector Mulitcontact TAG or Robifix – for details see the chapter under “Options”.
relevant chapter and the chapter “Options”, page 67.
Examples of appropriate counterplugs are given in the
relevant chapter and in the chapter “Accessories”. Examples of appropriate counterplugs are given in the
relevant chapter and in the chapter “Accessories” on
A permanent power connection is suitable for e.g. page 68 .
stationary welding machines.
Transformers without pluggable power inlet come with
open primary terminal space (protection class IP00), they
must be adapted to the particular application by means of
terminal boxes, see chapter “Accessories”.


Engineering Notes
Water Cooling
For welding transformers PSG we recommend a closed
cooling circuit; open cooling circuits are to be avoided. In
the cooling system all components must be fitted with a
potential equalisation. The maximum water pressure must
not exceed 10 bar.
More details concerning suitable materials, dewing

protection, connection technology and maintenance of the
cooling circuit can be found in the Description of
application “Weld Timer and Welding Transformer with
water cooling”, (R911370699).
Dimensions, Hole Positions

The specified dimensions in this catalog are intended as
rough reference values for the design.
Scale drawings with hole positions for fixing can be found

in the relevant type-specific instructions.

PSG 3075 –
Technical Data
PSG 3075.10 PZ
Type PSG 3075.10 AZ PSG 3075.10 PZ PSG 3075.10 PSV PSG 3075.11 PSV

Electrical Data
Nominal power / 20 % D.C. S1N kVA 94
Primary voltage1 U1N V 530
Secondary voltage class U2d V 9.0
Continuous output current / 100 % I2P kA 5.0
Output current / 20 % D.C. I2 kA 11.1
Turns ratio n xx:1 55
Options
Primary power connection and signals pluggable    
Primary power connector [TAG 135] TAG 135 TAG 150 TAG 150
Temperature monitoring integrated    
Secondary current sensor integrated  –  
Secondary voltage tap / lead-through – – Lead-through –
Force signal lead-through – – – –
Protective FI resistor integrated – –  –
Mass, Color
Mass kg 14.5
Color RAL 7005 gray
Dimensions
Height mm 108
Width mm 150
Length without plugs mm 295 303 303 303
Length with plugs mm – 352 357 357
CAD Models
STEP Files Download Download Download
: included with delivery

 : accessory retrofittable
 — : not included
1
Primary voltage 530 V: Output voltage of weld inverter with 400 V mains

PSG 3075 –
94 kVA, without primary terminal box, with secondary current sensor PSG 3075.10 AZ 1070088509
94 kVA, primary connection pluggable TAG 135, without secondary current sensor PSG 3075.10 PZ 1070086612
94 kVA, primary connection pluggable TAG 150, with secondary current sensor PSG 3075.10 PSV R911170133
94 kVA, primary connection pluggable TAG 150, with secondary current sensor PSG 3075.11 PSV R911170744
Handbooks
Title Ref. No.
Operating instructions Rexroth PSG xxxx MF welding transformers 1070087062 Download
Description of application Welding Transformer with water cooling R911370699 Download
Type-specific instructions PSG 3075.10 AZ/PZ R911172816 Download
Type-specific instructions PSG 3075.1x PSV R911172346 Download
Accessories
Description Type Designation Ref. No. / PSG PSG PSG PSG
Manufacturer 2
3075.10 AZ 3075.10 PZ 3075.10 PSV 3075.11 PSV
Primary terminal box
for PG cable gland TH3000/PG 1070917826  – – –
for TAG connector TH3000/MC 1070917827  – – –
Counterplug for primary power
3
Power TSB 4 135, Ø 25 mm2 PSG-MC 135/25 R911171645 –  – –

Power TSB 4 150, Ø 25 mm2 PSG-MC 150/25 R911171646 – –  
Counterplug 3 for signals
1 Output current + voltage UT06128ST Souriau – –  –
5
Output current + FV tap – – – 
2 Output temperature B8141-0 Turck –   
3 Input voltage B8141-0 Turck – –  –
: suitable
 — : not suitable
2
Reference number/Manufacturer: We are giving Rexroth reference 4
Power TSB: Multicontact counterplug for the indicated cross
numbers or (if third-party product) the manufacturer and their type section
designation.
3
Counterplugs: We are giving examples of suitable counterplugs, 5
FV tap: Secondary tap from minus pole for fault voltage (FV)
further types can be found in the manufacturers’ catalogs. protection

PSG 3100 –
Technical Data
PSG 3100.00 PSV
Type PSG 3100.00 PSV PSG 3100.01 PSV PSG 3100.02 PSV PSG 3100.03 PSV

Electrical Data
1
Primary voltage U1N V 530
Options
Primary power connection and signals pluggable    
Primary power connector TAG 150 TAG 150 Robifix Robifix
Secondary current sensor integrated    
Secondary voltage tap / lead-through Lead-through FV tap Lead-through Lead-through
Force signal lead-through – – – –
Protective FI resistor integrated  –  
Mass, Color
Mass kg 25.0
Color RAL 1004 yellow
Dimensions
Height mm 127
Width mm 160
Length with plugs mm 384 384 380 380
CAD Models

 — : not included
1

PSG 3100 –
145 kVA, Primary connection pluggable TAG 150, with lead-through of secondary voltage PSG 3100.00 PSV R911170161
145 kVA, Primary connection pluggable TAG 150, with secondary tap for FV protection PSG 3100.01 PSV R911170745
145 kVA, Primary connection pluggable Robifix, with lead-through of secondary voltage, PSG 3100.02 PSV R911172136
additional shield connection for signal plug output current + voltage
145 kVA, Primary connection pluggable Robifix, with lead-through of secondary voltage PSG 3100.03 PSV R911173022
Handbooks
Title Ref. No.
Type-specific instructions PSG 3100.0x PSV R911172343 Download
Accessories
Description Type Designation Ref. No. / PSG PSG PSG PSG
Manufacturer 2
3100.00 PSV 3100.01 PSV 3100.02 PSV 3100.03 PSV
Counterplugs 3 for primary power

Power TSB 4 150, Ø 35 mm2 PSG-MC 150/35 R911171647   – –
Power Robifix B-35-FZEE Multicontact – –  
Counterplugs 3 for signals
1 Output current + voltage UT06128ST Souriau  –  
5
Output current + FV tap –  – –
2 Output temperature B8141-0 Turck    
3 Input voltage B8141-0 Turck  –  
: suitable
2
designation.
3
FV tap: Secondary tap from minus pole for fault voltage (FV)
further types can be found in the manufacturers’ catalogs. protection

PSG 6120 –
Technical Data
PSG 6120.00 RL
Type PSG 6120.00 RL
Electrical Data
1
Options
Primary power connection and signals pluggable 
Primary power connector Robifix
Temperature monitoring integrated –
Secondary current sensor integrated –
Secondary voltage tap / lead-through –
Force signal lead-through –
Protective FI resistor integrated –
Mass, Color
Mass kg 16.0
Dimensions
Height mm 125
Width mm 160
Length without plugs mm 242
Length with plugs mm 280
CAD Models
STEP Files Download

1

PSG 6120 –
129 kVA, Primary connection pluggable Robifix, lateral cooling water connection PSG 6120.00 RL R911172946
Handbooks
Title Ref. No.
Type-specific instructions PSG 6120.00 RL R911339825 Download
Accessories
Description Type Designation Manufacturer PSG 6120.00 RL
Counterplugs for primary power
Power Robifix B-35-FZEE Multicontact 
: suitable


PSG 6130
for Welding Machines
and Manual Guns –
Technical Data
PSG 6130.00 AS
Type PSG PSG PSG PSG PSG PSG PSG

6130.00 6130.00 6130.00 6130.00 6130.00 6130.01 6130.00
AS PS PSC PSK PSM PSM PTK
Electrical Data
1
Options
Primary power connection and signals pluggable       
Primary power connector [TAG150] TAG 150 TAG 135 TAG 150 TAG 150 TAG 150 TAG 150
Temperature monitoring integrated     –  
Secondary current sensor integrated       –
Secondary voltage tap / lead-through Tap Tap Lead-thr. Lead-thr. – Lead-thr. Lead-thr.
Force signal lead-through – – – – – – 
Protective FI resistor integrated – – –    
Mass, Color
Mass kg 16.0 15.4 15.3 20.0 19.0 19.0 17.0
Dimensions
Height mm 127 127 127 125 140 140 125
Width mm 160
Length without plugs mm 219 273 273 300 319 319 294
Length with plugs mm – 289 295 322 373 373 316
CAD Models
STEP Files Download

1

PSG 6130
for Robot Guns –
Technical Data
PSG 6130.00 RSTK
PSG PSG PSG PSG PSG PSG PSG PSG PSG PSG
6130.00 6130.00 6130.01 6130.02 6130.10 6130.11 6130.12 6130.20 6130.22 6130.30
PSTK RSTK RSTK RSTK RSTK RSTK RSTK RSTK RSTK RSTK
Electrical Data
140
530 530 645 926 530 645 926 530 926 530
9.0
6.5
14.5
55 55 66 95 55 66 95 55 95 55
Options
         
TAG 150 Robifix Robifix Robifix Robifix Robifix Robifix Robifix Robifix Robifix
         
         
Lead-thr. Lead-thr. Lead-thr. Lead-thr. Lead-thr. Lead-thr. Lead-thr. Lead-thr. Lead-thr. Lead-thr.
       – – 
         
Mass, Color
17.0 16.2
RAL 1004 yellow
Dimensions
125 106
160 150
295 285
317 332
CAD Models
Download Download Download Download Download Download Download Download Download Download

1
Primary voltage 530 V / 645 V / 926 V: Output voltage of weld inverter with 400 V / 480 V / 690 V mains

PSG 6130 –
140 kVA, without primary terminal box PSG 6130.00 AS 1070086613
140 kVA, Primary connector TAG 150 PSG 6130.00 PS 1070088554
140 kVA, Primary connector TAG 135 PSG 6130.00 PSC R911170054
140 kVA, Primary connector TAG 150, Special version BMW PSG 6130.00 PSK R911170132
140 kVA, Primary connector TAG 150, Special version Mercedes PSG 6130.00 PSM R911170128
140 kVA, Primary connector TAG 150, Special version Mercedes PSG 6130.01 PSM R911171823
140 kVA, Primary connector TAG 150, Special version BMW PSG 6130.00 PTK R911171139
140 kVA, Primary connector TAG 150, Special version BMW PSG 6130.00 PSTK R911173020
140 kVA, Primary connection Robifix, primary 530 V, Signal connector AIDA w/o Reset PSG 6130.00 RSTK R911172751
140 kVA, Primary connection Robifix, primary 530 V, Signal connector AIDA w. Reset PSG 6130.10 RSTK R911173181
140 kVA, Primary connection Robifix, primary 530 V, Signal connector Burndy PSG 6130.20 RSTK R911173295
140 kVA, Primary connection Robifix, primary 926 V, Signal connector Burndy PSG 6130.22 RSTK R911173296
140 kVA, Primary connection Robifix, primary 530 V, Signal connector Intercontec PSG 6130.30 RSTK R911174059
Handbooks
Title Ref. No.
Type-specific instructions PSG 6130.00 AS R911172341 Download
Type-specific instructions PSG 6130.00 PS / PSC R911344478 Download
Type-specific instructions PSG 6130.00 PSK R911344477 Download
Type-specific instructions PSG 6130.0x PSM R911337512 Download
Type-specific instructions PSG 6130.00 PTK R911172342 Download
Type-specific instructions PSG 6130.00 PSTK R911338021 Download
Type-specific instructions PSG 6130.xx RSTK R911172815 Download

PSG 6130 –
Accessories
Description Type Ref. No./
PSG 6130.30 RSTK
PSG 6130.0x RSTK
PSG 6130.1x RSTK
PSG 6130.2x RSTK
PSG 6130.00 PSTK
PSG 6130.00 PSM
PSG 6130.01 PSM
PSG 6130.00 PSC
PSG 6130.00 PSK
PSG 6130.00 PTK
Designation Manufacturer 2
PSG 6130.00 AS
PSG 6130.00 PS
For PG screw connection TH6000/PG R911172927  – – – – – – – – – – –
For TAG connector TH6000/MC R911172769  – – – – – – – – – – –
Counterplugs for primary power
3
Power TSB 4 135, Ø 25 mm2 PSG-MC 135/25 R911171646 – –  – – – – – – – – –

Power TSB 4 150, Ø 35 mm2 PSG-MC 150/35 R911171647 –  –      – – – –
Power Robifix B-35-FZEE Multicontact – – – – – – – –    
1 Output current + voltage CA- Coninvers – –   – – – – – – – –
Output voltage + force 07S1N1280DN – – – – – –  – – – – –
- 1619772
Output current + voltage + force – – – – – – –  – – – –
Output current + voltage + force UT06128ST Souriau – – – – – – – – – –  –
Output current + voltage IE-PS-V14MHYB- Weidmüller – – – – – – – –   – –
+ temperature + force 10P (AIDA)
ASTA015FR017 Intercontec – – – – – – – – – – – 
30235000
2 Output current + temperature B8141-0 Turck –  – – – – – – – – – –
Output temperature B8141-0 – –   – – – – – –  –
Output current + voltage BS8141-0 – – – –  – – – – – – –
Output current + temperature BS8141-0 – – – – –  – – – – – –
Input force B8141-0 – – – – – –    – – –
Input force + reset, BS8141-0 – – – – – – – – –  – 
power supply of force sensor5
3 Input voltage B8141-0 – –    –      
Output voltage B8141-0 –  – – – – – – – – – –
4 Output temperature B8141-0 – – – – – –   – – – –
: suitable
2
designation.
3
Input force + reset, power supply of force sensor: Signals from/to
further types can be found in the manufacturers’ catalogs. force sensor- force signal input, reset output, power supply.

PSG 6160 –
Technical Data
The PSG 6160 welding transformers are with terminal box.

The primary voltage can be supplied through cable glands
on four sides.
In transformers PSG 6160.00 TS23x the signals from
secondary current sensor and temperature monitoring can
be wired on terminals. The signal cables can be led out on
the end face.
PSG 6160.00 TS231
Type PSG PSG PSG PSG PSG PSG

6160.00 6160.00 6160.00 6160.00 6160.00 6160.00
TS231 TS232 TS233 GM231 GM232 GM233
Electrical Data
1
Primary voltage U1N V 530 645 800 530 645 800
Continuous output current / I2P kA 8.5
100 % D.C.
Turns ratio n xx:1 55 72 87 55 72 87
Options
Primary power connection and signals pluggable – – – – – –
Primary power connector – – – – – –
Temperature monitoring integrated    – – –
Secondary current sensor integrated    – – –
Secondary voltage tap / lead-through – – – – – –
Force signal lead-through – – – – – –
Protective FI resistor integrated – – – – – –
Mass, Color
Mass kg 23.0
Color Aluminum bright
Dimensions
Height mm 127
Width mm 171
Length mm 380
CAD Models
STEP Files Download Download Download Download Download Download

1

PSG 6160 –
171 kVA, for 530 V primary voltage, w. temperature monitoring and sec. current sensor PSG 6160.00 TS231 R911170944
171 kVA, for 530 V primary voltage, w/o temperature monitoring and sec. current sensor PSG 6160.00 GM231 R911170370
Handbooks
Title Ref. No.
Type-specific instructions PSG 6160.00 TS23x R911172347 Download
Type-specific instructions PSG6160.00 GM23x R911172817 Download

PSG 6170 –
Technical Data
PSG 6170.00 PSD
Type PSG 6170.00 ASTK PSG 6170.00 PSD PSG 6170.00 PTK PSG 6170.68 AT

Electrical Data
1
100 %
Options
Primary power connection and signals pluggable    
Primary power connector [TAG 150] Robifix TAG 150 [TAG 150]
Secondary current sensor integrated   – –
Secondary voltage tap / lead-through – – Lead-through –
Force signal lead-through – – Lead-through –
Protective FI resistor integrated –   –
Mass, Color
Mass kg 19.0 19.0 19.0 19.6
Dimensions
Height mm 125 127 125 125
Width mm 160
Length with plugs mm – 305 336 –
CAD Models

1

PSG 6170 –
172 kVA, without primary terminal box, with secondary current sensor PSG 6170.00 ASTK R911171455
172 kVA, with primary terminal box, with secondary current sensor PSG 6170.00 PSD R911171460
172 kVA, with primary terminal box, without secondary current sensor PSG 6170.00 PTK R911171939
172 kVA, without primary terminal box, without secondary current sensor PSG 6170.68 AT R911171677
Handbooks
Title Ref. No.
Type-specific instructions PSG 6170.00 ASTK R911338820 Download
Type-specific instructions PSG 6170.00 PSD R911172344 Download
Type-specific instructions PSG 6170.00 PTK R911338808 Download
Type-specific instructions PSG 6170.68 AT R911172818 Download
Accessories
Description Type Designation Ref. No./ PSG PSG PSG PSG
Manufacturer 2
6170.00 ASTK 6170.00 PSD 6170.00 PTK 6170.68 AT

For PG cable gland TH6000/PG R911172927  – – 
For TAG connector TH6000/MC R911172769  – – 
Power Robifix B-35-FZEE Multicontact –  – –
Power TSB 4 150, Ø 35 mm2 PSG-MC 150/35 R911171647 – –  –
1 Output force +voltage CA-07S1N1280DN Coninvers – –  –
- 1619772
2 Output current BS8141-0 Turck –  – –
Input force B8141-0 Turck – –  –
3 Input voltage B8141-0 Turck – –  –
4 Output temperature B8141-0 Turck –   –
: suitable
2
designation.
3
Counterplugs: We are giving examples of suitable counterplugs,
further types can be found in the manufacturers’ catalogs.

PSG 6180 –
Technical Data
PSG 6180.00 RSTK
Type PSG 6180.00 PSG 6180.01 PSG 6180.10 PSG 6180.11 PSG 6180.30 PSG 6180.32

RSTK RSTK RSTK RSTK RSTK RSTK
Electrical Data
Nominal power / 20 % D.C. S1N kVA 178 215 180 215 178 251
Primary voltage 1 U1N V 530 645 530 645 530 926
Continuous output current /100 % I2P kA 5.7 7.5 5.7 7.5 5.7 8.0
Turns ratio n xx:1 38 50 38 50 38 66
Options
Primary power connection and signals pluggable      
Primary power connector Robifix Robifix Robifix Robifix Robifix Robifix
Temperature monitoring integrated      
Secondary current sensor integrated      
Secondary voltage tap / lead-through Lead-through Lead-through Lead-through Lead-through Lead-through Lead-through
Force signal lead-through      
Force signal with reset – –    
Protective FI resistor integrated      
Mass, Color
Mass kg 23.0
Color RAL 8001 brown
Dimensions
Height mm 125
Width mm 160
Length with plugs mm 357
CAD Models
STEP Files Download Download Download Download Download Download

1

PSG 6180 –
178 kVA, Primary voltage 530 V, Signal connector AIDA PSG 6180.00 RSTK R911172752
178 kVA, Primary voltage 645 V, Signal connector AIDA PSG 6180.01 RSTK R911172902
178 kVA, Primary voltage 530 V, Signal connector AIDA, force signal with reset PSG 6180.10 RSTK R911174469
251 kVA, Primary voltage 926 V, Signal connector AIDA, force signal with reset PSG 6180.11 RSTK R911174470
178 kVA, Primary voltage 530 V, Signal connector Intercontec, force signal with reset PSG 6180.30 RSTK R911174332
251 kVA, Primary voltage 926 V, Signal connector Intercontec, force signal with reset PSG 6180.32 RSTK R911174333
Handbooks
Title Ref. No.
Type-specific instructions PSG 6180.xx RSTK R911337513 Download
Accessories
Description Type Designation Mat.-Nr./ PSG PSG PSG PSG
Manufacturer 2
6180.x0 RSTK 6180.x1 RSTK 6180.30 RSTK 6180.32 RSTK
Power Robifix B-35-FZEE Multicontact    
Counterplugs for signals
3
1 Output current + voltage + IE-PS-V14MHYB- Weidmüller   – –

temperature + force 10P (AIDA)
ASTA015FR Intercontec – –  
01730235000
2 Input force B8141-0 Turck    
3 Input voltage B8141-0 Turck    
: suitable
2
Counterplugs: We are giving examples of suitable counterplugs,
numbers or (if third-party product) the manufacturer and their type further types can be found in the manufacturers’ catalogs.
designation.

PSG 6230 –
Technical Data
PSG 6230.00 GM234
Type PSG 6230.00 GM234 PSG 6230.00 GM235 PSG 6230.00 GM236

Electrical Data
1
Primary voltage U1N V 530 645 800
100 %
Turns ratio n xx:1 38 50 61
Options
Primary power connection and signals pluggable – – –
Primary power connector – – –
Temperature monitoring integrated – – –
Secondary current sensor integrated – – –
Secondary voltage tap / lead-through – – –
Force signal lead-through – – –
Protective FI resistor integrated – – –
Mass, Color
Mass kg 26.0
Color Aluminum bright
Dimensions
Height mm 127
Width mm 171
Length with plugs mm –
CAD Models
STEP Files Download
— : not included
1

PSG 6230 –
237 kVA, for 530 V primary voltage PSG 6230.00 GM234 R911170929
Handbooks
Title Ref. No.
Type-specific instructions PSG 6230.00 GM23x R911172819 Download

PSG 6250 –
Technical Data
PSG 6250.00 ASTK
Type PSG 6250.00 ASTK

Electrical Data
1
Options
Primary power connection and signals pluggable 
2
Primary power connector [TAG 150 resp, TAG 250]
Temperature monitoring integrated 
Secondary current sensor integrated 
Secondary voltage tap / lead-through –
Force signal lead-through –
Protective FI resistor integrated –
Mass, Color
Mass kg 23.0
Color RAL 8001 brown
Dimensions
Height mm 125
Width mm 160
Length with plugs mm –
CAD Models
STEP Files Download

1

PSG 6250 –
250 kVA PSG 6250.00 ASTK R911171938
Handbooks
Title Ref. No.
Type-specific instructions PSG 6250.00 ASTK R911337513 Download
Accessories
Description Type Designation Ref. No. PSG 6250.00 ASTK
for PG cable gland TH6000/PG R911172927 
for TAG 150 connector TH6000/MC R911172769 
for TAG 250 connector TH6250/MC R911174776 
: suitable

1
2
Power connectors TAG 150 are designed for rated current up to 180 A, thus 6,84 kA continous secondary current.
For higher current, the terminal box TH6250/MC can be used. It is designed for power connectors TAG 250, which can be loaded corresponding
to the maximum continuous secondary current of PSG 6250.00 ASTK



Options
Primary Power Inlet and Signals Pluggable Temperature Monitoring Integated

Most transformer types come with pluggable power inlet Secondary Current Sensor Integrated
and with signal connectors for temperature monitoring, Most transformer types contain a temperature switch for
measurement of secondary current, tap or lead-through of monitoring the primary winding and rectifier diodes, and
secondary voltage for the adaptive UI regulation and lead- also a toroid sensor for measuring the secondary current.
through of force signal. The respective counterplugs are not
included. Both signals are led out at the primary-side terminal space
– pluggable or by individual wires.
Transformers without pluggable power inlet come with
open primary terminal space (protection class IP00), that
must be adapted to the particular application by means of
terminal boxes, see chapter “Accessories”.
Primary Power Connector Tap/Lead-through of Secondary Voltage

Pluggable primary power inlet with TAG- and Robifix Lead-through of Force Signal
connectors.
The secondary voltage for adaptive UI control is either
tapped in the welding transformer or the secondary voltage
tapped at the weld gun is lead through the terminal space
of the transformer, same as possibly the force signal from
an external force measuring device.
TAG 135 Robifix


Accessories
Primary Terminal Boxes
The transformer types PSG 3075.10 AZ, PSG 6130.00 AS, By this, the protection class of the primary-side terminal
PSG 6170.00 ASTK, PSG 6170.68 AT and PSG 6250.00 space increases from IP00 to IP55.
ASTK come without primary power and signal plugs.
They must be adapted to the particular application by
means of terminal boxes.
▶▶ Terminal box with PG cable glands: ▶▶ Terminal box for TSB plug:
The cable is lead in at the desired side through PG The included three pins are screwed into the terminals
glands and connected with cable lugs to the terminals U, U, V and PE. Then the TSB counterplug is inserted.
V and PE.
Dimensions:
TH3000/xx: H × W × D = 106 × 150 × 63 mm
TH6000/xx: H × W × D = 125 × 160 × 105 mm
We are offering terminal boxes of comp. Kempf as accessories.
Primary terminal box with PG cable glands for PSG 3075.10 AZ TH3000/PG 1070917826
Primary terminal box for Multicontact connector for PSG 3075.10 AZ TH3000/MC 1070917827
Primary terminal box with PG cable glands for PSG 6xxx TH6000/PG R911172927
Primary terminal box for TSB 150 connector for PSG 6xxx TH6000/MC R911172769
Primary terminal box for TSB 250 plug for PSG 6250 TH6250/MC R911174776


Accessories
Counterplugs for Power and Signals
The signals from the temperature monitoring and the For details, see the related chapter of this catalog.
secondary current sensor, the secondary voltage and the Hereinafter we are giving examples of suitable
force signal are lead in and out on the primary side of the counterplugs. Further types can be found in the
single transformer types differently. They are spread over manufacturers’ catalogs.
up to four plugs.
Counterplugs für Counterplugs for signals

Primär-Leistung 1 2 3 4
R911171645
R911171646
R911171647
Ref. No.
Rexroth
CA - 07S1N1280DN - 1619772
IE-PS-V14MHYB-10P (AIDA)
ASTA015FR01730235000
Robifix-B-35-FZEE
TSB 135/25
TSB 150/25
TSB 150/35
TSB 250/95
UT06128ST
BS8141-0
B8141-0
B8141-0
B8141-0
Type
Manufacturer
Multicontact
Multicontact
Multicontact
Multicontact
Multicontact
Intercontec
Weidmüller
Coninvers
Souriau
Turck
Turck
Turck
Turck
Transformer Ref. No.

PSG 3075.10 AZ 1070088509 [] [] – – – – – – – – – – –
PSG 3075.10 PZ 1070086612  – – – – – – – –  – – –
PSG 3075.10 PSV R911170133 –  – – –  – – –  –  –
PSG 3075.11 PSV R911170744 –  – – –  – – –  – – –
PSG 3100.00 PSV R911170161 – –  – –  – – –  –  –
PSG 3100.01 PSV R911170745 – –  – –  – – –  – – –
PSG 3100.02 PSV R911172136 – – – –   – – –  –  –
PSG 3100.03 PSV R911173022 – – – –   – – –  –  –
PSG 6120.00 RL R911172946 – – – –  – – – – – – – –
: suitable
 []
: suitable with appropriate terminal box — : not suitable
Explanation of signals on plugs 1 to 4: in the chapter on the respective transformer

Counterplugs for Counterplugs for signals

primary power 1 2 3 4
R911171645
R911171646
R911171647
Ref. No.
Rexroth
CA - 07S1N1280DN - 1619772
ASTA015FR01730235000
RobiFix-B-35-FZEE
TSB 135/25
TSB 150/25
TSB 150/35
TSB 250/95
UT06128ST
BS8141-0
B8141-0
B8141-0
B8141-0
Type
Manufacturer
Multicontact
Multicontact
Multicontact
Multicontact
Multicontact
Intercontec
Weidmüller
Coninvers
Souriau
Turck
Turck
Turck
Turck
PSG 6130.00 AS 1070086613 – [] [] – – – – – – – – – –
PSG 6130.00 PS 1070088554 – –  – – – – – –  –  –
PSG 6130.00 PSC R911170054  – – – – –  – –  –  –
PSG 6130.00 PSK R911170132 – –  – – –  – –  –  –
PSG 6130.00 PSM R911170128 – –  – – – – – – –   –
PSG 6130.01 PSM R911171823 – –  – – – – – – –  – –
PSG 6130.00 PTK R911171139 – –  – – –  – –  –  
PSG 6130.00 PSTK R911173020 – –  – – –  – –  –  
PSG 6130.00 RSTK R911172751 – – – –  – –  –  –  –
PSG 6130.01 RSTK R911172767 – – – –  – –  –  –  –
PSG 6130.02 RSTK R911172768 – – – –  – –  –  –  –
PSG 6130.10 RSTK R911173181 – – – –  – –  – –   –
PSG 6130.11 RSTK R911173926 – – – –  – –  – –   –
PSG 6130.12 RSTK R911173927 – – – –  – –  – –   –
PSG 6130.20 RSTK R911173295 – – – –  –  – –  –  –
PSG 6130.22 RSTK R911173296 – – – –  –  – –  –  –
PSG 6130.30 RSTK R911174059 – – – –  – – –  –   –
PSG 6160.00 TS231 R911170944 – – – – – – – – – – – – –
PSG 6160.00 TS232 R911170945 – – – – – – – – – – – – –
PSG 6160.00 TS233 R911170946 – – – – – – – – – – – – –
PSG 6160.00GM 231 R911170370 – – – – – – – – – – – – –
PSG 6160.00GM 232 R911170371 – – – – – – – – – – – – –
PSG 6160.00GM 233 R911170372 – – – – – – – – – – – – –
: suitable
 []
: suitable with appropriate terminal box — : not suitable
Explanation of signals on plugs 1 to 4: in the chapter on the respective transformer

Counterplugs for Counterplugs for signals

primary power 1 2 3 4
R911171645
R911171646
R911171647
Ref. No.
Rexroth
CA - 07S1N1280DN - 1619772
ASTA015FR01730235000
RobiFix-B-35-FZEE
TSB 135/25
TSB 150/25
TSB 150/35
TSB 250/95
UT06128ST
BS8141-0
B8141-0
B8141-0
B8141-0
Type
Manufacturer
Multicontact
Multicontact
Multicontact
Multicontact
Multicontact
Intercontec
Weidmüller
Coninvers
Souriau
Turck
Turck
Turck
Turck
PSG 6170.00 ASTK R911171455 – [] [] – – – – – – – – – –
PSG 6170.00 PSD R911171460 – – – –  – – – – –  – 
PSG 6170.00 PTK R911171939 – –  – – –  – –  –  
PSG 6170.68 AT R911171677 – [] [] – – – – – – – – – –
PSG 6180.00 RSTK R911172752 – – – –  – –  –  –  –
PSG 6180.01 RSTK R911172902 – – – –  – –  –  –  –
PSG 6180.10 RSTK R911174469 – – – –  – –  –  –  –
PSG 6180.11 RSTK R911174470 – – – –  – –  –  –  –
PSG 6180.30 RSTK R911174332 – – – –  – – –   –  –
PSG 6180.32 RSTK R911174333 – – – –  – – –   –  –
PSG 6230.00 GM234 R911170929 – – – – – – – – – – – – –
PSG 6230.00 GM235 R911170930 – – – – – – – – – – – – –
PSG 6230.00 GM236 R911170931 – – – – – – – – – – – – –
PSG 6250.00 ASTK R911171938 – – [] [] – – – – – – – – –
: suitable
 — : not suitable Explanation of signals on plugs 1 to 4: in the chapter on the respective transformer


Accessories
Protective FI Resistors
When using a residual current circuit (acc. to

EN 62135-1), the MPE bridge of the welding transfor-
mer has to be replaced by a suitable protective FI
resistor.
For transformers with integrated protective FI resistor

the MPE jumper must be removed and reconnected.
Thus, the protective FI resistor is activated.
For transformers without integrated protective FI resistor

we offer it as accessory. It can be mounted in place of the
MPE bridge. Depending on the space situation on the
primary side of the transformer, a protective FI resistor
with short or long connection cables can be used,
see page 73.

Protective FI resistor with short or long connection cables Possible installation situations
The protective FI resistor with short connection cables can For installation instructions, see “MF-Melding Transformers
be attached outside to transformers with pluggable power PSG xxxx”.
connection, the resistor with long connection cables is
suitable for installation in terminal boxes with limited space.
Protective FI Resistors –
Protective FI resistor with short connection cables R1K0/4W 1070081822
Protective FI resistor with long connection cables R1K0/4W/U 1070083996

74 Product Catalog Restistance Welding | Abbreviations
Abbreviations
AI Analog input NFD Type designation of Rexroth mains filters

AIDA Requirements of German automotive PE Protective earth
manufacturers PG Armored thread
AO Analog output
PHA Phase shift
CB Communication bus
PRC Type designation of Rexroth weld controls
DI Digital input
PRI Type designation of Rexroth operating software
DO Digital output
PSG Type designation of Rexroth welding transformers
D.C. Duty cycle
Q-Stop Quality-Stop
EMC Electromagnetic compatibility
RC Robot control
FI Failure current
Robifix Type designation of Multicontact power connectors
FV Failure voltage
PLC Programmable Logic Controller
GDM Gun data module
STC Sheet thickness combination
H × W × D Height × Width × Depth
STEP Standard for the Exchange of Product Model Data
HCS Type designation of Rexroth servodrives (CAD-data format)
HIP Hall installation plate TAG, TSB Type designation of Multicontact power connectors
HZS Type designation of Rexroth zone safety module UI-, UIR Voltage-current-(regulator)
I/O Input/output WIC Weld Interface Controller (serial bus system)
KSR Constant current regulation
L × W × D Length × Width × Depth
MF Medium frequency
MGDM Measuring gun data module
MPE Protective earth

Index | Product Catalog Restistance Welding 75
Index
▶▶ A ▶▶ O
Accessories PRC 24 Operating Software 25
Accessories PSG 68, 72 Options PRC 24
Adaptive UI Regulator 20 Options PSG 67
Overview PSG 40
▶▶ C
Cooling PRC 19 ▶▶ P
Counterplugs PSG 69 PRC 7300 16
PRC 7400 16
▶▶ D Primary Power Connection 44
Dimensions PRC 16 Primary Power Connector PSG 67
Dimensions PSG 45 Primary Terminal Boxes PSG 68
Direct Protective Conductor Connection 43 Primary Voltage PSG 42
Protective Measures PSG 43
▶▶ E PSG 307546
Earth Leakage Current Protection 44 PSG 310048
Engineering Notes PRC 17 PSG 612050
Engineering Notes PSG 41 PSG 613052
PSG 616056
▶▶ F PSG 617058
Fault-Voltage Protection 43 PSG 618060
Fieldbus Couplers 28 PSG 623062
Force Signal 44 PSG 625064
Functional Overview PRC 22
Function PRC 20 ▶▶ R
Resistors72
▶▶ G
Gun Data Modules GDM and MGDM 37 ▶▶ S
▶▶ H Secondary Resistance 43
Handbooks PRC 23 Secondary Voltage PSG 42
Hole Positions PSG 45 Servo Drives HCS01 32
Spare Parts PRC 24
▶▶ I
I/O system S20 28 ▶▶ T
I/O system S67 28 Tap/Lead-through of Secondary Voltage 67
I/O-Modules28 Technical Data PRC 16
Technical Data PSG 40
▶▶ L Temperature Monitoring PSG 44
Load of Transformer and Diodes 43 Type Key PRC 16
Type Key PSG 40
▶▶ M
Mains Voltage PRC 20 ▶▶ W
Measurement of Secondary Current 44 Water Cooling 45
Measurement of Secondary Voltage 44 Weld controls PRC 15
MGDM37 Welding Transformers PSG 39
▶▶ N
Nominal Power PSG 42

Bosch Rexroth AG
Berliner Straße 25
64711 Erbach, Deutschland
www.boschrexroth.com
Your contact with sales in Germany:

sales.resistance-welding@boschrexroth.de
For world-wide contacts see:

https://addresses.boschrexroth.com/EN/en_EN
The data indicated below is intended to describe the

product. Should information on its use be provided,
such information represents application examples
and suggestions only. Catalog specifications shall
not be deemed as warranted quality.
R911382070/2018-04 This information does not release the user from performing
© Bosch Rexroth AG 2018 his own assessments and verifications.
Subject to change without notice! Our products are subject to natural wear and aging.

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Product Catalog

Bosch Rexroth AG, R911382070/2017-08

 R911382070/2018-04, Bosch Rexroth AG

Bosch Rexroth AG, R911382070/2018-04

 R911382070/2018-04, Bosch Rexroth AG

Weld controls PRC provide:

Bosch Rexroth AG, R911382070/2018-04

Further system components from the Rexroth product

Welding transformers PSG complete the power pack:

 R911382070/2018-04, Bosch Rexroth AG

Why Welding with Medium Frequency?

Bosch Rexroth AG, R911382070/2018-04

 R911382070/2018-04, Bosch Rexroth AG

Controls for Resistance Welding

Robot cell with a servo-electric weld gun

RC: Robot control WIC: Weld interface controller bus

Bosch Rexroth AG, R911382070/2018-04

 R911382070/2018-04, Bosch Rexroth AG

Controls for Resistance Welding

Pneumatic manual weld gun

Bosch Rexroth AG, R911382070/2018-04

It is also possible to connect several weld guns to a single

 R911382070/2018-04, Bosch Rexroth AG

Controls for Resistance Welding

Which Current Source

Control Transformer Secondary Secondary Max.

PRC 7300.xxx-X1 PSG 3075 9.0 5.0 15.8

Bosch Rexroth AG, R911382070/2018-04

Weld Controls PRC

Weld Controls PRC 15

 R911382070/2018-04, Bosch Rexroth AG

Weld Controls PRC

Simlified Type Key

Power class Variant

Cooling Function identifier

W – water type-specific instruction

Range of mains voltage

Bosch Rexroth AG, R911382070/2018-04

Weld Controls PRC

Front view PRC 7300

XGM3 XFS1 + XFS2

 R911382070/2018-04, Bosch Rexroth AG

Weld Controls PRC

The universal interface slot is equipped with an Anybus Regulation Modes

Bosch Rexroth AG, R911382070/2018-04

Power Correction Protection Class, Mounting Position

Calibration For further information on water-cooled controls, please

Backup and Restore

 R911382070/2018-04, Bosch Rexroth AG

Weld Controls PRC

Mains Voltage Function

▶▶ PRC 7xxx-X1: 400 … 480 V; -15 %/+10 %; 50/60 Hz

Adaptive UI Regulator (optional)

The adaptive UI (voltage/current) regulator ensures the

The adaptive regulator adjusts current and weld time for

Bosch Rexroth AG, R911382070/2018-04

Advantages of the UI regulator:

The adaptive UI regulator does not require any further

The adaptive UI regulator can optionally be retrofitted.

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG

R911382070/2018-04, Bosch Rexroth AG