Bosch Rexroth Controls and Mid-Frequency Transformers

FOR SALE from Weld Systems Integrators

Bosch Rexroth welding controls and mid-frequency transformers, FOR SALE from Weld Systems Integrators.  We maintain an IN-STOCK inventory of Bosch Rexroth resistance welding equipment at our Warrensville Heights, Ohio location for quick shipment and delivery.

Partner Logo - Bosch Rexroth | Weld Systems Integrators

Bosch Rexroth Controllers with Power Section

AC air and water-cooled and medium frequency / DC controllers designed for spot, projection and resistance seam welding applications. Bosch Rexroth welding controls offer repeatable high quality welds.

Bosch Rexroth Controllers with Power Section
Bosch Rexroth - PST-6000 AC-System | Weld Systems Integrators Bosch Rexroth - PSI-6000 MF-System | Weld Systems Integrators Bosch Rexroth - PRC-7000 MF-System | Weld Systems Integrators
Modular AC Resistance Welding Controller Series

PST 600E – Compact power packs for stationary machines and manual welding systems

PST 600E AC controllers from Rexroth have a compact, slim design which makes them up to 60 percent smaller and lighter for applications involving stationary welding machines and manual welding stations.

PST 600 E AC controllers were designed for applications up to 500 kVA:

  • Air cooled/water cooled
  • Parallel input/output box with coordinated scope of functions
  • High-precision primary current control without external current sensor – no more cables and connectors
  • Optional slot for fieldbus module (Ethernet)
  • Attractive replacement for older welding systems

PST 6000 – the cost-effective AC series for standard applications

The PST 6000 AC controllers are mechanically identical to the PSI 6300 inverter series. This also provides a low-cost migration path from AC to middle frequency at a later time. Naturally these control systems offer you the same flexibility in the I/O area and all the control functions of the entire PS 6000 system.

PST 6000 AC controllers were designed for applications up to 250 kVA:

  • Air cooled/water cooled
  • Optimum weld result by means of primary or secondary current control
  • Competitive solution for standard applications
MF-System - PSI 6000

Bosch PSI 6000 inverters have been specifically designed for spot, projection and resistance seam welding. The extensive control functions guarantee high process reliability. The PSI family offers a variety of additional functions for welding high-strength metals, aluminum and three-member joints. The 1,000 Hz medium frequency/DC technology has proved its particular economic efficiency in many applications in contrast to other processes:

  • Higher welding quality via more dynamic current control than for the AC system
  • Weldability of many materials increased by more intensive energy supply
  • Spatter reduced by decreased welding current and/or current time
  • Electrode life lengthened thanks to lower thermal and mechanical load on the electrode caps
  • Smaller and lighter transformers for integration in the electrode holders

Inverter PSI 62C0:  MF converter 9 – 54 kA, water cooled, 400 – 480 V, 50/60 Hz, preferably for connecting 100 KVA – 200 KVA transformers, with integrated control functionality, nominal current of 220 A (continuous thermal current), I/O module.

Inverter PSI 63C0: MF converter 6 – 36 kA (same design as PSI 6100), mains voltage of 400 to 480 V or 500 – 690 V, 50/60 Hz, air cooled, preferably for connecting PSG 6000 transformers, with integrated control functionality, nominal current of 110 A (continuous thermal current), I/O module.

Inverter PSI 64C0: MF converter 9 – 60 kA, water cooled, 400 – 480 V, preferably for connecting PSG 6000 transformers, nominal current of 220 A (continuous thermal current, I/O module.

Inverter PSI 65C0: MF converter 9.0 – 120 kA, water cooled, 400 – 480 V, 50/60 Hz, preferably for connecting PSG 6000 transformers, with integrated control functionality, nominal current of 660 A (continuous thermal current), I/O modules.

Features PSI6200/W1 PSI6300/L1 PSI6300/L2 PSI6300/W1 PSI6300/W2 PSI6400/W1 PSI6500/W1
Weight ca. 56 kg ca. 20 kg ca. 21 kg ca. 25 kg ca. 25 kg ca. 56 kg ca. 70 kg
Supply voltage range 400 – 480 V 400 – 480 V 500 – 690 V 400 – 480 V 500 – 690 V 400 – 480 V 400 – 480 V
Supply nominal current (max. thermal constant current) 220 A 110 A 110 A 110 A 110 A 220 A 330 A
max. primary current 1200 A 800 A 800 A 800 A 800 A 1600 A 2400 A
max. secondary current 54 kA 36 kA 36 kA 36 kA 36 kA 88 kA 120 kA
Required connection cross-section 95 mm² 35 mm² 35 mm² 35 mm² 35 mm² 95 mm² 2 to 4 wires; per wire 120 mm²
Controls and Monitoring

PSQ 6000 – for supreme quality in spot welding

The PSQ 6000 control system is designed to monitor quality performance in high-volume production operations. Intelligent current/voltage control maximizes process reliability and provides online verification of spot weld quality. The BOS 6000 operating interface includes logging and documentation features.

Rexroth Welding Controls and Monitoring | Weld Systems Integrators

Control and monitoring functions are integrated in the control system. The XQR control card is available as an upgrade for older PSI 6000 series systems.

Adaptive current/voltage control for perfect welding quality

The adaptive process control system gives you added flexibility for future requirements in the welding process. By measuring current and voltage, the course of resistance and energy can also be calculated, controlled and accurately evaluated during welding. The adaptive control algorithm ensures consistent quality and reduces spatter in demanding welding applications. Expensive rework is therefore considerably reduced.

Process monitoring

Tolerance limits can be set and monitored for a number of basic process parameters: current, phase angle, electrode voltage, resistance, current time cycle, power and energy. Two consolidated variables, which summarize the basic variables, are provided to simplify system handling:

  • PSF – the process stability factor indicates the stability of the welding process
  • UIP – the quality factor provides an indication of actual product quality

Q-Stop logic

Patented Q-Stop logic is a very useful extension of monitoring functionality. It enables users to analyze and optimize system productivity by defining how the system reacts to repetitive faults in a program or on a particular part.

Process overview

To provide the big picture, the status of all attached welding controllers is displayed on a bar graph.

Bosch Rexroth Mid-Frequency Transformers

Bosch Rexroth mid-frequency transformers are optimized for greater power and operating efficiency in resistance welding. PSG 6130 series compact, light mid-frequency transformers are optimized for all global robot applications up to 130 kVA.

Bosch Rexroth Mid-Frequency Transformers
Rexroth PSG-6130 Transformers | Weld Systems Integrators Rexroth PSG-6130 Mid-Frequency Transformers | Weld Systems Integrators Rexroth PSG-6000 Transformers | Weld Systems Integrators

PSG 6000 – Compact Mid-Frequency Transformers

The mid-frequency transformers in the PSG 6000 series are optimized for greater power and operating efficiency in resistance welding. They are characterized by a particularly compact design and low weight.

PSG 6130.XX.RSTK (MF 100) – The NEW Platform Transformer

The compact, light mid-frequency transformer series PSG 6130.xxRSTK is optimized for all global robot applications up to 130 kVA.

Mid-Frequency Transformer Models and Specifications
Mid-Frequency Transformer Models and Specifications
PSG 6130 Primary connection Output voltage Power supply (Bosch Rexroth converter)
6130.00AS via interface box 9.5 V 530 V
6130.00PS via MC 150 9.5 V 530 V
6130.00PTK via MC 150 9.5 V 530 V
6130.00PSTK via MC 150 9.5 V 530 V
6130.xxRSTK via single wire 9 V 530 V/ 645 V/926 V
PSG 6170 and PSG 6180 Primary connection Output voltage Power supply (Bosch Rexroth converter)
6170.00PTK via MC 150 9.5 V 530 V
6170.00PSD via MC 150 9.5 V 530 V
6170.68AT via interface box 9.5 V 530 V
6180.xxRSTK via single wire 14 V 530 V/645 V
PSG 6170 and PSG 6250 Primary connection Output voltage Power supply (Bosch Rexroth converter)
6170.00ASTK via interface box* 9.5 V 530 V
6250.00ASTK via interface box 14 V 530 V
PSG 6160 and PSG 6230 Primary connection Output voltage Power supply (Bosch Rexroth converter)
6160.00TS231 via PG 9 V 500 V
6160.00TS232 via PG 9 V 650 V
6160.00TS233 via PG 9 V 800 V
6230.00GM234 via PG 13 V 500 V
6230.00GM235 via PG 13 V 650 V
6230.00GM236 via PG 13 V 800 V

Contact Weld Systems Integrators

Weld Systems Integrators (WSI) is your complete source for standard and custom resistance welders, consumables, spare and replacement parts and value added services. We offer WORLDWIDE shipping from our Warrensville Heights, OH location.

CONTACT Weld Systems Integrators, or REQUEST A QUOTE for more information on our IN-STOCK welding equipment inventory. To speak with a WSI team member, please give us a call at 844-WSI-WELD or +1-216-475-5629.