plasmatig™ weld package

PlasmaTIG™ Weld Package

Solutions for: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 //

Solutions for: ABB // FANUC // KUKA // MOTOMAN

Contact-free

ignition

without high

frequency

Torch system with TIG dressing

Document no.: DOC-0116EN | Revision: sks1109.en.2.g.ms

Control cable

9

PlasmaTIG™ module

6

Cable bundle

7

Weld process controller + Software

2DCT 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

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 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)Materials: Fe, CrNi, CuSiWire 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

The new Q84 is equipped with a 10 inch touch screen, an innovative usability concept and an advanced visualization technology for much easier operating. The user interface has the look and feel of the Q8Tool4 software.

The real weld controllers are in card slots in the Q84. This new weld controller concept can host up to four Q81 weld process controller cards. Every single Q81 card can independently control a weld machine.

Weld Process Controller Q84

Innovative Control Concept with Touch Screen.With the new Q84 up

to four weld machines can

be controlled centrally.

New.

Weld process controller2

Weld process controller Q84

The universal weld process controller Q84 calculates 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.

Processes/features: TIG-DC, TIG Pulse, Plasma, MIG/MAG (GMAW), I-Pulse, U-Pulse,

KF-Pulse, 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, micro SD

Remtote Control/Administration: Q8Tool, VNC client

Overview weld process controllerDescription

Q84 with 1 Q81 weld process controller card

Q84 with 2 Q81 weld process controller cards



Overview Q84 Mounting kits Description

Mounting on Power Source LSQ5

Wall mounting

Part-no.77-7240-1077-7240-2077-7240-3077-7240-40

Part-no.77-7240-0177-7240-02

Controlling up to four weld

machines at the same time

4 3 2 1 4

3

2

1

Please note:

The Q84 can be equipped with up to

four Q81 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.

Weld process controller Q8pt and Q8pw

The Q8pt is the alternative to the Q84. It has the same functionality/features as a single weld

card of the Q84. The illuminated LCD display shows clearly all parameters and values needed for

the weld task or program selection.

Processes/features: TIG-DC, TIG Pulse, Plasma, MIG/MAG (GMAW), I-Pulse, U-Pulse,

KF-Pulse, RWDE™, NWDE™

Programs: 992

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:up to traceability

Ports: RS232, USB, RJ45-Ethernet, SPW-Bus

Overview weld process controllerDescription

Q8pt

Q8pw

Part-no.77-7210-0077-7220-00

Alternative

Weld process controller Q8pt

Weld process controller Q8pw

Same functionality as Q8pt but in

a wall mount version (-w)

Software/IT2b

or

A

B

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.

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-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.77-3-177-3-277-3-3

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

Overview of center guidesDescription

Wire-ø < 2 mm for steel wire

Wire-ø < 0.8-1.0 mm for steel wire

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

Part-no.12-2-1-1512-2-1-17

Wire Feeder accessoiries4a

Drive roll for wire feeder

For wire diameters of 0.8 - 1.6 mm and different groove-types (V-groove for steel and

U-groove for aluminum wires)

Overview of drive rollsDescription

Wire-ø 0.8 mm, V-groove

Wire-ø 1.0 mm, V-groove

Wire-ø 1.0 mm, U-groove

Part-no.12-2-3-0812-2-3-1012-2-3-110

Pressure roll

Pressure roll for wire feeder

Pressure rollDescription

Pressure roll

Part-no.12-2-3-0

Wire Guidance5

3

2

4

1

2

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

M10 with internal thread for ESAB

UNF 3/8x24’’ with external thread

with 9.6 mm bore hole

with 13 mm bore hole

for cold wire feeding

with PG9 thread

Part-no.10-2-0-5010-2-0-5110-2-0-5210-2-0-5310-2-0-5410-2-0-56

Wire Guidance5

1

2

3

4

Wire inlet body with quick couplingDescription

Wire inlet body with quick coupling

Polymer wire conduitDescription

Polymer wire conduit, blue

Connector for wire drumDescription

Connector for wire drum

Wire inlet body with quick coupling

Wire inlet body for PF5 with quick coupling

Polymer wire conduit

Polymer wire conduit (sold by meter)

Connector for wire drum

Quick connector with ceramic-inlet

Part-no.10-2-0-61

Part-no.44-9-1

Part-no.44-40-1

Connector for polymer conduit Description



Connection nipple for polymer conduit

Part-no.44-40-3

Please note: Two connectors necessary.

PlasmaTIG™6

PlasmaTIG™ Module 5

The PlasmaTIG™ Module is mounted on the wire feeder bracket, in front of the wire feeder for a

good accessibility. The control electronics for the HF-free ignition is in the module. Additionally,

a flowmeter for gas and gas monitoring is integrated. For a perfect mounting of the torch cable,

torch connectors for the PT350 PlasmaTIG™ torch system is integrated into the module.

PlasmaTIG™ Module 5Description

PlasmaTIG™ Module 5

Part-no.10-1-7

Technical DataWeight 2.7 kg

Features HF-free ignition/gas flow control

and monitoring

For robot type-ABB

Model

IRB1600

IRB2600


Model

M10iA

M20iA

For robot type-KUKA

Model

KR5 arc / KR16


Model

SSF2000 / HP20

Wire feeder bracket

Wire feeder bracket for PF5: with bore holes and screws, ready to install

Part-no.14-9-4on request

Part-no.on request

on request

Part-no.14-9-2

Part-no.14-9-2

Overview Wire Feeder Brackets for PT-M5

Cable bundles7

Cable bundles: Power source to wire feeder PF5

Coaxial power cable 72 mm2 with internal gas flow, control cable L-700,

disconnect cable, corrugated tube and cable holder. Water-cooled version.

Overview of cable bundlesDescription

3 m

5 m

7 m

10 m

12 m

15 m

Part-no.20-3-0320-3-0520-3-0720-3-1020-3-1220-3-15

Clamping set7a

For robot type-ABB

Model

IRB1600

IRB2600


Model

M10iA

M20iA

For robot type-KUKA

Model

KR5 arc

KR16


Model

SSF2000

HP20

Mounting cable bundle: Clamping set

Provides perfect installation of the cable bundle for all different robot types. Undefined cable

movements are prevented. This results in higher lifetime.

Part-no.91-3-0-61-391-3-0-61-4

Part-no.on request

on request

Part-no.on request

on request

Part-no.on request

on request

Overview of cable bundle clamping sets

Ground cable

Overview of ground cablesLength

3 m

5 m

6 m

10 m

15 m

20 m

25 m

Ground cable with 70 mm2

connector and cable plug

Cables with larger diameters are available on request.

8

Part-no.228078103 228078105228078106228078100228078115228078120 228078125

Control cable: L-700/SPW-bus

Standard control cable to connect the

components: Weld controller, power source,

robot interface, wire feeder.

Control cable 9

Overview of control cablesLength

0.5 m

1 m

2 m

3 m

5 m

7 m

10 m

12 m

15 m

Part-no.541031050541031001541031002541031003541031005541031007541031000541031012541031015

The PlasmaTIG™ Weld Package is designedfor the following welding processes, materials and power range:

Processes: TIG (Plasma)Materials: Fe, CrNi, CuSiWire 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™ 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™Description

Collision Protection

Part-no.71-5

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


Model

SSF2000 / HP20

For robot type-ABB

Model

IRB1600

IRB2600


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



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

Protective gas

Protective gas

Workpiece

S

plasmatig™ weld package

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