Rexroth Weld Tech Repair Process Overview PSI6XXX - XXX Platform

The Drive & Control Company
Welding Technology
Repair Process Overview
Bosch Rexroth PSI 6XXX.XXX Platform
REPAIR PROCESS OVERVIEW
WELDING TECHNOLOGY
BOSCH REXROTH PSI6XXX.XXX PLATFORM
REV: 1.3_7.2014
1
DCUS Welding Technology, Rev: 1.3_7.2014
Repair Process Overview / SFA & SVF Branch
www.boschrexroth-us.com CY2014
Welding Technology
This document has been drafted and reviewed in accordance with Bosch Rexroth Standard
Internal Procedures.
Purpose
The purpose of this document is to outline the general repair process and general criteria for the
line Bosch Rexroth PSI6XXX.XXX Platform Weld Inverter.
Scope
The contents of this document apply to PSI6XXX.XXX Platform Weld Inverter only. This guide
includes a summary of the minimum required tools, inspection steps, recommended repair
steps and repair report generation requirements for the Bosch Rexroth Aftermarket
Organization (Repair, Training & Field Service).
This document does not include information regarding Recalls, Campaigns or Product
Investigation (aka 8-D Report) Requests.
 Bosch Rexroth general information can be found on the internet at

www.boschrexroth.com
 Bosch Rexroth Weld Inverter information can be found at:
www.boschrexroth.com/welding
For additional information and technical details, please contact a member of the Bosch Rexroth
Aftermarket Support Team: +1 (847) 645-3600.
 Dave Wampfler, Bosch Rexroth – Senior Service Consultant (Detroit)

 Marlin Morales, Bosch Rexroth – Senior Service Consultant (Dallas)
 Tom Jones, Bosch Rexroth - National Service Manager (Chicago)
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Welding Technology
SECTION I: REQUIRED EQUIPMENT
1. Oscilloscope
2. Digital Multi-meter
3. Huntron Circuit Board Test Unit
4. Miyachi MM315A Real Time Weld Monitor / Checker
5. Bosch CPU Tester
6. PC with BOS 6000 Software
7. PSS 5000 Emulator Box
8. Assorted Communication and I/O Cables
 EtherNet
 ProfiNet
9. Load Shunt
10. Hand Tools as Needed
SECTION II: REPAIR PROCEDURE STEPS
1. Clean unit
2. If unit is water cooled check the heat sink for leaks
3. Print fault log
4. Check for latest version of firmware
5. Test CPU card with Bosch CPU tester
6. Tear down unit and perform static checks of all power components and
cards
7. Check for physical damage – frame, burn marks, etc
8. Check battery voltage for correct level
9. Replace or repair all defective parts
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Welding Technology
SECTION II: TEST PROCEDURE
1. Make all necessary power connections and coolant connections (as

needed)
2. Set and check date and time
3. Test all I/O and communication protocol for proper response
4. Load test program into inverter
5. Perform test with Bosch test program (checks internal / external current
monitoring circuits)
6. Perform 3000 minimum weld cycles (Time length: 60 – 75 minute cycle)
7. Monitor weld inverter output for proper current
8. Monitor analog output to gun solenoid for correct signal
9. Perform a memory reset
SECTION III: REPAIR REPORT GENERATION
1. Verify all Test Procedure Points were Checked and Tested.

2. Record all Complaint, Repair Steps and Findings data into the SAP
System
3. Verify Serial Numbers and Unit Build Date against SAP Records
4. Load Serial Numbers into SAP System
5. Complete the Repair Report with Comments, Root Cause Identification
(if any) and any other Points of Interest
6. Ready the Unit for Packing
7. Print Repair Report and transfer unit to Operations
4
Welding Technology
SECTION IV: VISUAL APPENDIX
Example Welding Inverter Repair Bench
Example Welding Inverter Repair Bench
5
Welding Technology
Example Typical Weld Inverter, Prior to Repair
Example Typical Weld Inverter, After Cleaning
6
Welding Technology
Example Typical Weld Inverter Load Test with Shunt
Example Chiller Unit for Weld Inverters (That Require Liquid Cooling)
7
Welding Technology
Example Air System Unit for Testing Heat Sinks for Leaks
Example Completed Standard Weld Inverter Repair Report
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Welding Technology
SECTION V: AFTERMARKET SERVICES SUMMARY
1. Hotline 1-800-REXROTH (1-800 739-7684)

2. Customer Consultation Support Services Available:
A. Application Engineering & Technical Services
B. Field Service
C. Spare Part Services (Sales & Contracts)
D. Repair & Exchange Services
E. Full range of Training classes
 On site at Customer Facility
 Bosch Rexroth Distributor Partner
 Bosch Rexroth Training Facility
G. Retrofit Planning & Implementation Assistance

H. After Hours Support and Extended Service Contracts
I. International Service Support
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Welding Technology
SECTION VI : DOCUMENT MANAGEMENT INFORMATION
REVISION STATUS:
 Any printed copy is an uncontrolled copy.
 The user shall verify with a Bosch Rexroth Aftermarket Management Associate(s) that
he/she is in fact using the appropriate version of the document for the specific project
he/she is working on.
 Any questions or comments with respect to this document should be directed to a Bosch
Rexroth Aftermarket Management Associate(s): +1 (847) 645-3600.
REVISION TRACKING LOG :
Revision Version Paragraph

Date No. Affected
Document Name Revision Revised By
Repair Process Overview,

Bosch Rexroth PSI Initial A.Mueller,
6/30/2014 1.1_7.2014 6XXX.XXX Platform Release All DCUS/SVF
Repair Process Overview, Visual
Bosch Rexroth PSI Appendix A.Mueller,
7/9/2014 1.2_7.2014 6XXX.XXX Platform Added Section VII DCUS/SVF
Repair Process Overview,
Bosch Rexroth PSI Reformat & R.Rusk,
7/15/2014 1.3_7.2014 6XXX.XXX Platform Editing All DCUS/SFA
10

Rexroth Weld Tech Repair Process Overview PSI6XXX - XXX Platform

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The Drive & Control Company

REPAIR PROCESS OVERVIEW

BOSCH REXROTH PSI6XXX.XXX PLATFORM

 Bosch Rexroth general information can be found on the internet at

 Dave Wampfler, Bosch Rexroth – Senior Service Consultant (Detroit)

SECTION I: REQUIRED EQUIPMENT

SECTION II: REPAIR PROCEDURE STEPS

SECTION II: TEST PROCEDURE

1. Make all necessary power connections and coolant connections (as

SECTION III: REPAIR REPORT GENERATION

1. Verify all Test Procedure Points were Checked and Tested.

SECTION IV: VISUAL APPENDIX

Example Welding Inverter Repair Bench

Example Welding Inverter Repair Bench

Example Typical Weld Inverter, Prior to Repair

Example Typical Weld Inverter, After Cleaning

Example Typical Weld Inverter Load Test with Shunt

Example Completed Standard Weld Inverter Repair Report

SECTION V: AFTERMARKET SERVICES SUMMARY

1. Hotline 1-800-REXROTH (1-800 739-7684)

G. Retrofit Planning & Implementation Assistance

SECTION VI : DOCUMENT MANAGEMENT INFORMATION

REVISION TRACKING LOG :

Revision Version Paragraph

Repair Process Overview,

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