Weld Package PlasmaTIG™Torch system with TIG dressing
Contact-free
ignition
without high
frequency
Solutions for: ABB • FANUC • KUKA • YASKAwA/MotoMAN
PlasmaTIG™ Weld Package: DCT Power source + Water cooler • Weld process controller • Robot interface • Wire feeder • Wire Guidance • PlasmaTIG™ Module • Cable bundle •
Ground cable • Control cable • Torch system • Cold Wire Feeding • Consumables • Goosenecks
Control cable
9
PlasmaTIG™ module
6
Cable bundle
7
DCT power source + Water cooler
1
4
Wire feeder
Robot interface
3
Cold wire feeding
11
8Ground cable
Torch system PlasmaTIG™
10 Torch system:Consumables
13 TCP drawings Checking fixtures14 Exploded
drawing
12
5
Wire Guidance
SKS Weld Package: System Design
SKS Weld Package: Overview
9
9
6
10
111
4
2a
37
Weld process controller + Software
2
This brochure contains information about the SKS Weld Package, the torch system PlasmaTIG™, as well as consumables and spare parts. There are various features of the welding machine components and torch systems available depending on the robot system and the welding task.The PlasmaTIG™ Weld Package can be used with common industrial robots. Please look for color coding to specify the robot types ABB, FANUC, KUKA and YaSKaWa/MOTOMan ( ).
Torch system PlasmaTIG™ with integrated cold wire feeding (TIG dressing)
SKS PlasmaTIG™ Weld Package
SKS Weld Package.
The PlasmaTIG™ Weld Package is designedfor the following welding processes, materials and power range:
Processes: TIG (Plasma)Wire materials: High-alloy steels, low-alloy steels, aluminum and copper alloys, nickel-based materialsWire diameter: 0.8 - 1.0 mmMax. power: 350 A - 60 % duty cycle/40 °C, water-cooled
Torch system with
TIG dressing
Contact-free
ignition
without high
frequency
Water cooler WK5
Stromquelle LSQ5
Direct Control Technology DCT
The LSQ5 ensures the optimum arc energy. It uniquely adjusts to different weld processes. Unlike
conventional power sources with inverter technology, the LSQ5 with Direct Control Technology
controls its switching transistors without any fixed clock frequency according to the needs of the
weld process. Without any delay, the energy needed for the process is provided instantly. The
flexible fine tuning is done by a central processor. The CPU continuously analyzes the weld process
and current/voltage values on the basis of data obtained and optimally drives the switching
transistors of the power section. This results in an extremely high efficiency and a low tempera-
ture development. The power source can be configured with only two buttons and four LED
indicators. For world-wide usage, voltages can be configured without opening the power source.
Power source and water cooler
Specifications:Description LSQ5-PT
Performance 420 A - 60 % duty cycle/40 °C
Processes PlasmaTIG™
Weight 49 kg
Primary voltage 3 x 400 (480)V
Wall mounting Yes (optional)
Conformities CE, CSA, UL
Dimensions L/W/H 450 x 400 x 540 mm
Option
Wall mount for LSQ5
Space-saving design that makes for
easy cleaning/maintenance.
The main benefits are:DCT provides a speed regulation up to ten times higher compared to conventional inverter
technology. This leads to excellent control behavior and shorter response times.
The weld properties are substantially improved. Software replaces hardware: Fewer components
also increase the reliability in continuous operation.
Water cooler WK5
The SKS water cooler WK5 perfectly integrates into SKS systems. With a cooling range for
TIG/MIG: 0-600W (dT=20 °C) it provides perfect cooling of the PlasmaTIG ™ torch system.
The cooler can be filled with max. 20 l, is equipped with a water level indicator, water flow
monitoring and can be filled/emptied with a button. The cooling unit is air-cooled. WK5 is
supplied with power over the SPW-bus – no additional power supply needed.
Power sourceDescription
LSQ5-PT
Part-no.77-1185-04
LSQ5 optionDescription
Wall mount
Part-no.77-1180-01
Water coolerDescription
WK5
Part-no.77-5000-00
1
Weld process controller2
Weld Process Controller Q84r/s
Innovative Control Concepts with Touch Screen.With the new Q84r and
the compact Q84s up to
four weld machines can be
controlled centrally.
New.
The new Q84r and Q84s are equipped with a touch screen, an innovative usability concept and an advanced visualization technology for much easier operating. The user interfaces have the look and feel of the Q8Tool4 software. Individual weld controllers are in card slots in the Q84r/s. This new weld controller concept can host up to four weld process controller cards. Each card independently controls a weld machine. As an alternative to the Q84r/s weld process controllers, the Q80 has been developed to control a single weld machine.
Weld process controller2
Controlling up to four weld machines at the same time
3
4 3 2 1
42
1
weld process controller Q84r
weld process controller Q84s
Weld process controller Q84r/s
The universal weld process controllers Q84r and Q84s calculate the optimal parameters for each welding process. Only basic data such as material, wire type, wire feed speed and type of gas must be entered. The Q84r is equipped with a 10" touch screen, the space-saving Q84s with a 7" touch screen. For wall mounting the display of the Q84s can be rotated by an angle of 180°.• Processes/features: TIG-DC, TIG-Pulse, Plasma, MIG/MAG (GMAW), I-Pulse, U-Pulse, KF-Pulse, Synchroweld™, RWDE™, NWDE™• Programs: 992 (x4)• General functions: Display and saving of readings, alarms• Monitoring functions: Weld current monitoring, auto compensation, arc and ignition monitoring, motor current, gas and water monitoring• Easy to network via Ethernet: Traceability• Ports: RJ45-Ethernet, SPW-Bus, SD card slot• Remote Control/Administration: Q8Tool, VNC clientOverview weld process controllerDescription Part-no. (Q84s) Part-no. (Q84r)Q84r/s with one weld card 77-7410-00 77-7310-00Q84r/s with two weld cards 77-7420-00 77-7320-00Q84r/s with three weld cards 77-7430-00 77-7330-00Q84r/s with four weld cards 77-7440-00 77-7340-00
Overview Q84r Mounting kits Description Part-no.Bracket for Q84r for mounting onto power source LSQ5 77-7240-01Bracket for Q84r for wall mounting 77-7240-02Bracket for Q84r mounting in the robot cabinet 77-7240-05
Overview Q84r/s Replacement Parts and accessoriesDescription Part-no.Touchpen for Q80 / Q84r/s weld process controller (replacement part) 77-7240-03Connection cable for Q84r/s 5m with open end for external power supply (option) 77-3305-00Plug for external power supply of Q84r/s (replacement part) 77-7240-96
microSD card (1GB) incl. SD card slot adapter for Q80 / Q84r/s weld process controller (replacement part)
77-7240-04
USB adapter for SD cards for Q80 / Q84r/s weld process controller 91-8-1Please note: The Q84r/s can be equipped
with up to four weld process
controller cards.
Weld process controller2a
Q8Tool software
The Q8Tool software provides accurate and comprehensive process monitoring. The user can
store weld parameters for documentation on a PC and/or administrate them. It offers basic
functions such as reading, modifying and documenting of weld parameters. Additionally, new
weld parameters can be created and transferred to the universal weld control Q8pt/w. The
Q8pt/w weld data is portable and the installation of further control units on new equipment is
easy. Also, the software allows reading and exporting of measurements and alarms. Graphical
and numerical recording of measures helps defining and optimizing parameters for new parts.
Users have a powerful tool for analyzing and documenting their weld results.
network The weld controller units can easily be networked via Ethernet ports: Time savings through
centralized administration of all controllers within the corporate network. There is a central
backup of all welding parameters, management of user rights and access, process monitoring
up to traceability. The Q8Tool software is provided free of charge with the Q8 series weld
controller. No additional hardware or software is required.
Software/IT2b
alternative
Weld process controller Q80
The Q80 is the alternative to the Q84r/s. It has the same functionality/features as a singleweld card of the Q84r/s - optimized for a single weld machine. With the universal Q80 all parameters and values needed for the weld task can be optimally calculated.• Processes/features/general functions see Q84r/s• Easy to network via Ethernet: up to traceability• Ports: RJ45-Ethernet, SPW-Bus, SD card slot• Wall mounting capability • Remote Control / Administration: Q8Tool, VNC-Client
overview weld process controllerDESCRIPtIoN PARt-No.Q80 77-7260-00
overview Q80 Replacement Parts and AccessoriesDESCRIPtIoN PARt-No.Touchpen for Q80 / Q84r/s weld process controller (replacement part) 77-7240-03
microSD card (1GB) incl. SD card slot adapter for Q80 / Q84r/s weld process controller (replacement part)
77-7240-04
USB adapter for SD cards for Q80 / Q84r/s weld process controller 91-8-1
weld process controller Q80 front view
weld process controller Q80 back view
or
A
Robot interface3
Perfect integration.Interfacing all
industrial robot types.
Interface UNI 5
Robot controllers or overall system controllers (e.g. PLC) use
digital or analog signals to communicate with the SKS weld
controller. The interface UNI 5 translates these signals for
the SKS welding machine. With just one interface, a variety
of digital encodings and analog levels can be processed. The
interface UNI 5 comes with a preconfigured connection kit
for easy installation.
Field bus systems exchange signals via serial communication.
The field bus master, usually the robot controller or overall
system controller, bundles and processes the signals of the
connected field bus, including the welding machine. Standard
field bus systems are e.g., Interbus-S, Profibus DP or Device-
Net. The SKS field bus interface FB5 translates the field bus
signals for the SKS welding machine using a standardized
protocol. It makes no difference which type of field bus sy-
stem is used. The signals are always at the same place on the
field bus. This makes the preparation of the robot or system
controller much easier.
Standard application Field bus application
With the universal interface solution from SKS, weld controllers can be connected with all industrial robot types. Users basically have two options for connecting robots with weld controllers: The connection can be realized with the SKS interface UNI 5 or by integrating into a given field bus environment with a field bus solution.
B
Robot interface UnI 5
The interface connects the welding equipment with all industrial robot types. With its high
degree of standardization, the UNI 5 is the perfect choice for connecting the weld controller
(e.g. Q8pt/w) with an industrial robot. The UNI 5 comes preprogrammed and configured for
different robot types. Configuration to a particular robot type is handled easily by programming
the interface with two buttons for the given robot type.
Robot interface3
Part-no.77-8011-08
Part-no.77-8001-84
Part-no.77-8011-08
Part-no.77-8013-00
Overview of robot interfacesFor robot type-aBB
Description
UNI 5A for IRC5
For robot type-FanUC
Description
UNI 5A for RJ3iC
For robot type-KUKa
Description
UNI 5A for KR C2
For robot type-YaSKaWa/MOTOMan
Description
UNI 5C for NX 100 / DX 100
A
alternative
Field bus connection
Various field bus types are supported (e.g. Profibus DP, DeviceNet). The field bus interface has
drilled bore holes for flexible mounting within the weld cell. Two additional mounting kits
provide easy installation at the power source or into the cabinet. Additionally, external power
can be connected to the interface. More details on SKS solutions for the specific field bus types
are available on request.
Overview FB 5 interfacesDescription
Interbus-S (copper line)
Profibus DP
DeviceNet
Part-no.77-3-377-3-577-3-8
Cabinet mountingDescription
Mounting kit for cabinet
Control cable with bracket
Part-no.77-1182-0277-3102-02
Optional power supply (24V)Description
Connection cable 2.0m (with open ends)
Part-no.77-1182-04
Power source mountingDescription
Mounting kit for power source
Part-no.77-1182-03
B
Wire feeder for cold wire feeding4
Wire feeder PF5-KD
Smaller and less weight accompanied by improved efficiency over conventional wire feeders
the PF5 follows the steady development of arc welding robots. Modern motor, gear and control
technology provide a strong performance and highest precision possible. The robust plastic
housing is electrically insulated. As a "lightweight" the PF5 is the perfect choice for the new
generation of robots with outer or inner cable dress.
Overview of PF5Description
PF5-KD
Part-no.10-2-7
Technical dataWeight 3.8 kg
Motor 70W
Wire feeding speed 2.5 - 25 m/min
Roll diameter 0.8 - 1.6 mm
Wire Feeder accessoiries4a
Connection cable PT/M5 to PF5-KDDescription
Connection cable PT/M5 to PF5-KD
Connection cable for PlasmaTIG™ Module PT/M5 to PF5-KD for cold wire feeding
With the connection cable wire stick monitoring is installed.
Center guides for PF5
Available in two versions:
For steel or aluminium wires
Part-no.10-1-7-10-1
Overview of center guidesDescription
Wire-ø < 2 mm for steel wire
Part-no.12-2-1-15
Wire Feeder accessoiries4a
Pressure roll
Pressure roll for wire feeder
Pressure rollDescription
Pressure roll
Part-no.12-2-3-0
Overview of drive rollsDescription
Wire-ø 0.8 mm, V-groove
Wire-ø 1.0 mm, V-groove
Part-no.12-2-3-0812-2-3-10
Drive roll for wire feeder
For wire diameters of 0.8 - 1.6 mm groove-type (V-groove for steel)
Wire Guidance5
2
3
4
Wire inlet body with quick
coupling at wire feeder
Connector for polymer conduit
Polymer conduit
Drum connector
With the new SKS polymer guidance, the high efficiency of the whole system extends
up to the drum.
advantages of polymer wire guidanceExtraordinary good glide properties reduces motor load
Minimized abrasive wear and reduced dirt in wire feeder and torch system
Lightweight design and a high inherent stability for easy installation
Length can be freely chosen by the customer
Cost optimized exchange: only the polymer conduit must be changed, connectors are reuseable.
Optimized materials for longer life and reduced downtimes
1
alternative
Wire inlet bodies for additional systems
Beside the wire inlet body for the SKS wire guidance, inlet bodies
for additional systems are available.
Overview of wire inlet bodies for additional systemsDescription
The PlasmaTIG™ Weld Package is designedfor the following welding processes, materials and power range:
Processes: TIG (Plasma)Wire materials: High-alloy steels, low-alloy steels, aluminum and copper alloys, nickel-based materialsWire diameter: 0.8 - 1.0 mmMax. power: 350 A - 60 % duty cycle/40 °C, water-cooled
Torch system PlasmaTIG™: TIG dressing10
Contact-free ignition without high frequency.
PlasmaTIG™ torch system with integrated cold wire feeding (TIG dressing)
The PlasmaTIG™ torch system comes with contact-free arc-ignition without high frequency. Known risks of electromagnetic noise from HF-waves to humans and machines are avoided and EMC- compatibility is guaranteed.Depending on the torch front end the user can vary between plasma- andclassic TIG-welding. The PlasmaTIG™ torch system consists of the Power Clutch safety clutch, the torch body for TIG and Plasma, a mounting flange for different robot types, the torch cable and the corresponding consumables.TIG dressing is especially for applications with open arc.
TIG dressing for
applications with
open arc.
Torch system: Collision protection10a
Collision protection Power Clutch 2™ for welding robots with outer cable dress
The SKS collision protection is based on the Power Joint™ concept, continuing the modular
structure of the SKS components. This ensures the same high precision TCP accuracy in the
Dual Wire Select™ as found in SKS PlasmaTIG™ systems.
Technical DataCollision protection deflection 10°
Reset accuracy ± 0.2 mm with TCP 400 mm
Weight 1.5 kg
Power Clutch 2™Description
Collision Protection
Part-no.71-17
Torch system: Torch body PlasmaTIG™10b
Torch body PlasmaTIG™
The TIG torch body has an integrated lifting unit to provide HF-free ignition. A cold wire
feeding unit can be attached to torch body, to increase the flexibility of the whole system.
Additionally, the torch body supports different electrode diameters.
Overview torch bodies, short, with quick-changeconnectors, consumables includedDescription
ø 2.4 mm
ø 3.2 mm
ø 4.0 mm
Part-no.57-2-42457-2-43257-2-440
Torch system: Torch mounting arm10c
PlasmaTIG™: Torch mounting arm
Precise torch mounting arm with adjustable skew correction
PlasmaTIG™Description
PlasmaTIG™ torch mounting arm
Part-no.62-5-4-130
Torch system: Torch cable/accessories10e
Overview of torch cablesLength
1.0 m
1.2 m
1.8 m
Torch cable for PlasmaTIG™ torch system
Highly flexible coaxial cable 72 mm2 with Power Pin and Power Clutch™ connector including
switch-off cable for the robot
Part-no.57-2-3-1057-2-3-1257-2-3-18
Torch system: accessories10f
PlasmaTIG™ adjustment tool for tungsten electrodes
With this special tool the lifting unit can be fixated; thus the exchange of
the clamping sleeve is much easier.
PlasmaTIG™ Spanner
With two fixed points in the tool, for welding or programming, the stickout of
the electrode can be correctly adjusted.
PlasmaTIG ™ adjustment tool for tungsten electrodesDescription
Adjustment tool for tungsten electrodes
PlasmaTIG ™ SpannerDescription
Spanner
Part-no.57-2-5-2
Part-no.57-2-5-3
Torch system: Installation10d
For robot type-KUKa
Model
KR5 arc
KR16
For robot type-YaSKaWa/MOTOMan
Model
SSF2000 / HP20
For robot type-aBB
Model
IRB1600
IRB2600
For robot type-FanUC
Model
M10iA / M20iA
PlasmaTIG™ robot flange
With the robot flange the PlasmaTIG™ torch system is mounted simply and
safely on the sixth robot axis.
Übersicht anschlussflansch
Part-no.63-4-1363-4-5
Part-no.63-4-8
Part-no.63-4-163-4-3
Part-no.63-4-1
Cold wire feeding
The wire feeding can be adjusted exactly with a knurled-head screw.
All necessary components for mounting included.
Cold wire feeding11
Cold wire feedingDescription
Cold wire feeding
Part-no.57-2-6
Cold wire elbow pipe
For wire feeding
Cold wire tip
With the exact calibrated bore hole, the way of the wire material is precisely defined.
Cold wire elbow pipeDescription
Cold wire elbow pipe, long, 45° /65 mm
Part-no.57-2-2-4
Overview cold wire tipsDescription
0.8 mm
1.0 mm
Part-no.57-2-2-857-2-2-10
Wire guidance conduit
Polymer materials for less abrasive wear and extraordinary good glide properties
Liner
From wire feeder to cold wire feeding
Wire guidance conduitDescription
4.19 x 8.9 / 2 m
Restricted Guidance (Spiral)Description
1.45 x 3.15 / 2 m
Part-no.44-8-200
Part-no.44-7-200
Cold wire feeding: accessoiries11a
Torch system: Consumables PlasmaTIG™12
Welding inset
For distribution of the center gas
Part-no.57-2-1-24057-2-1-24857-2-1-256
Overview Welding insetDescription
ø 4.0 mm for 2.4 mm electrode
ø 4.8 mm for 3.2 mm electrode
ø 5.6 mm for 4.0 mm electrode
Tungsten electrodes
Free from torium to avoide unwanted side effects
Part-no.57-2-1-8057-2-1-8157-2-1-82
Overview tungsten electrodesDescription
2.4 x 75 mm / 60 °
3.2 x 75 mm / 60 °
4.0 x 75 mm / 60 °
nut for clamping sleeve
To fixate the electrode and to clamp the clamping sleeve
Part-no.57-2-1-61
Overview nut for clamping sleeveDescription
2.4 mm / 3.2 mm / 4.0 mm
Ceramic center tube
For alignment (center) and isolation of the clamping sleeve
Part-no.57-2-1-7157-2-1-72
Overview Ceramic center tubesDescription
8 mm
33 mm
Clamping sleeve
To secure guidance of the tungsten electrode
Part-no.57-2-1-19057-2-1-19157-2-1-192
Overview clamping sleevesDescription
2.4 mm
3.2 mm
4.0 mm
Copper Gas nozzle
Copper-chrome-zirconium alloy for high lifetime
Part-no.57-2-1-3
Copper Gas nozzleDescription
Copper gas nozzle 18 mm
13 Torch sytem: TCP drawings
PlasmaTIG™ Part-no. 71-5-4-130-450
13a Torches: Checking fixtures
To check TCP of goosenecks and the complete torch system.
Checking fixtures are available for all listed goosenecks with PlasmaTIG™ torch system.
Please contact us for detailed information.
The center gas flows in to support the ignition. In the head of the torch the ignition takes place.
The arc takes the shortest way after the ignition: up to the part.
14 Torch system: Exploded drawing
Power source
LSQ50 … 420 A
Weld current
Center gas
Protective gas
Workpiece
S
Subject to change.
SKS Welding Systems GmbH | Marie-Curie-Strasse 14 | 67661 Kaiserslautern | GermanyPhone +49(0)6301/7986-0 | Fax +49(0)6301/7986-119
