SKS System - B - Q4 LSQ5 UNI5 PF5 - V1.0 - EN

Version 1.
0-EN
Issue 25.06.09 Operating Manual
Q4 Overall system
Q4
LSQ5
UNI5
PF5
SKS Welding Systems GmbH Austraße 2a D-66849 Landstuhl

Tel. +49(0) 6371 9267-0 www.sks-welding.de info@sks-welding.de
Table of contents
0 Important notes for owners and operators! .......................................................... 4
1 Guide to this operating manual ............................................................................ 7
1.1 Intended use ....................................................................................................... 8
1.2 Electromagnetic compatibility ............................................................................. 8
1.3 Name of the buyer when reselling ...................................................................... 8
1.4 Copyright ............................................................................................................ 8
2 Safety at work .....................................................................................................10
2.1 General information .......................................................................................... 10
2.2 Safety symbols ................................................................................................. 11
2.3 Personnel qualifications.................................................................................... 13
2.4 Intended use ..................................................................................................... 13
2.5 Safety instructions ............................................................................................ 14
3 Operation of the Q4 robot welding system .........................................................17
3.1 Characteristics .................................................................................................. 17
3.1.1 Concept ..................................................................................................... 17
3.1.2 Technology ................................................................................................ 17
3.2 Components of the Q4 robot welding system ................................................... 19
3.3 Q4 Process control ........................................................................................... 20
3.3.1 Power source ............................................................................................. 21
3.3.2 Wire feeder ................................................................................................ 27
3.3.3 Interface to the robot .................................................................................. 28
3.3.4 SPW-BUS connections / L700 cable.......................................................... 29
4 Scope of supply ..................................................................................................30
4.1 Customer service.............................................................................................. 30
4.2 Packaging, Storage .......................................................................................... 30
5 Commissioning the Q4 robot welding system.....................................................31
5.1 Location ............................................................................................................ 31
5.2 Preparing the Q4 robot welding system for operation....................................... 32
5.2.1 Connecting the components ...................................................................... 33
5.2.2 SPW bus .................................................................................................... 33
5.2.3 Welding current cable ................................................................................ 34
5.2.4 PC .............................................................................................................. 34
5.2.5 Safety shutdown ........................................................................................ 34
5.2.6 Wire feeder ................................................................................................ 34
5.2.7 Inert gas, wire feed hose, welding torch..................................................... 34
5.2.8 Mains connection ....................................................................................... 35
5.3 Interface selection and set-up .......................................................................... 35
5.3.1 Installation instructions ............................................................................... 37
5.3.2 Cables and pin assignment ........................................................................ 37
5.3.3 Field bus .................................................................................................... 37
6 Operating the Q4 robot welding system .............................................................38
6.1 Safety instructions ............................................................................................ 38
6.2 Preparing for welding........................................................................................ 39
6.2.1 Switching on and testing the robot welding system.................................... 39
6.2.2 Troubleshooting ......................................................................................... 40
6.3 Operating the Q4 .............................................................................................. 41
6.4 Setting up programs and welding parameters .................................................. 45
6.4.1 Using standard programs / selecting stored data sets ............................... 45
6.4.2 Q4 display .................................................................................................. 47
6.4.3 Q4 control keys: ......................................................................................... 47
6.4.4 Key switch .................................................................................................. 67
6.5 The Q8-Tool4 system software ........................................................................ 68
7 Shutting down the Q4 robot welding system ......................................................70
8 Maintenance and care of the Q4 robot welding system ......................................71
8.1 Power source ................................................................................................... 71
8.1.1 Retesting in accordance with VDE 0702 and BGV D1 (formerly VBG 15) . 71
8.2 Wire feeder ....................................................................................................... 73
8.2.1 Centre guide .............................................................................................. 73
8.2.2 Capillary tube ............................................................................................. 73
8.2.3 Adjusting the water monitor ....................................................................... 74
8.2.4 Checking the water flow ............................................................................. 75
8.2.5 Cleaning ..................................................................................................... 76
8.2.6 Repair work ................................................................................................ 77
8.2.7 Displays of the firmware versions .............................................................. 77
9 Transport and storage of the Q4 robot welding system ......................................78
10 Data records stored in the Q4 on delivery .......................................................79
11 ALARM CODE LIST ........................................................................................80
12 Index and table of figures ................................................................................94
12.1 Index ............................................................................................................. 94
12.2 Table of figure ............................................................................................... 96
13 Confirmation ....................................................................................................97
0 Important notes for owners and operators!

Thank you very much for purchasing a Q4 complete system for robot welding from SKS
Welding Systems GmbH.
We at SKS wish you every success when working with this unit.
Please observe the following points:
Keep the operating manual in a place where it is always accessible to the operator.
Have the operator sign that he has read and completely understood the operating
manual before starting the machine.
This operating manual applies only to the Q4 control system.
Safeguard the system against unauthorised use.
The system must only be operated by trained and qualified personnel.
Have an electrician check whether the wall socket where you want to connect the
equipment is appropriately fused and properly earthed.
Inform our customer service in the event of malfunction.
In case of accident, inform a doctor and the responsible official body.
Dear customer,
The components of your welding system may differ in some details from the illustrations
in this manual. However, this has no effect on the operation of the units.
Should you have questions about this manual or if you want to order more copies,
please provide the item numbers, which you will find on the nameplates of the
respective units.
Important reminder:
The data and information in this manual have been put together with the greatest care.
Although everything has been done to ensure that the information in this document was
up-to-date and correct at the time of delivery, there is no guarantee that it is absolutely
free of errors.
If you should find any errors or mistakes when reading through this manual, please
contact us.
SKS Welding Systems GmbH

Austraße 2A
D-66849 Landstuhl
http://www.sks-welding.de
Phone: +49 (0) 6371 92670

Fax: +49 (0) 6371 926719
E-mail: info@sks-welding.de
4
As the operator or owner, you are obliged

– to restrict hazards to an unavoidable minimum,
– to inform your personnel clearly about any existing danger.
THREAT TO LIFE
Welding systems work with high current and high heat.
Improper operation of such systems is life-threatening.
THREAT TO LIFE
Persons fitted with a heart pacemaker must not operate the welding system.
and should not stay in the vicinity of the equipment during
operation. During welding, strong electro-magnetic fields are generated which
may affect the proper function of a pacemaker.
The system may only be used by trained personnel in accordance with EN 1418.
Inform any employee about this operating manual before the employee operates the
system for the first time. Give him sufficient opportunity to read the entire operating
manual thoroughly.
Before starting up the machine, have the operator sign the confirmation that he has
read and fully understood the operating manual. You will find an appropriate
declaration form after the table of figures on Page Fehler! Textmarke nicht
definiert..
Instruct all persons concerned before every use of the machine.
Repeat the instructions at reasonable intervals. Even persons who only work
temporarily with the machine must be trained.
Only allow the robot welding system to be operated by persons who
– have been appropriately trained;
– are physically and intellectually suitable;
– can be expected to reliably fulfil the tasks assigned to them;
5
Create an operating instruction manual especially for your company. This company-
specific operating instruction manual must take into account both the most important
items of this operating manual and the special situation of your company. It should
contain information about
–specific hazards associated with the robot welding system,
– safety instructions,
– actions in case of accidents and malfunctions,
– the most important operating steps.
Make sure that operators of the welder are provided with personal protective
equipment (gloves, safety goggles, protective apron etc.).
Ensure that a 2 kg CO2 fire extinguisher is provided within reach of the welding
workstation, and that this is kept operational at all times (periodic testing).
Safeguard the robot welding system against unauthorized use.
In case of accident, inform a doctor and the responsible official body.
Unauthorized interference with the robot welding system as well as unauthorized

alteration of the robot welding system of any kind will result in the loss of any right to
guarantee and liability claims in the event of personal or material damage.
6
1 Guide to this operating manual

This operating manual is written for owners and users of the robot welding system with
Q4 process control.
Please read the entire operating manual before you start working with the robot welding
system.
This operating manual provides you with all the necessary information to operate the Q4
system.
The following subjects are included
Operation of the Q4 robot welding system in Chapter 3
Scope of supply in Chapter 4
Commissioning the robot welding system in Chapter 5
Working with the robot welding system in Chapter 6
Maintenance and care in Chapter 8
Fault finding in Chapter 6
Shutting down in Chapter 7
Storage and transport in Chapter 9
Data records stored in the Q4 on delivery in Chapter 10
Alarm list in Chapter 11
Other information on the power source in Appendix A1
on the interface/fieldbus in Appendix A2
relating to the wire feed unit in Appendix A3
There is a THREAT TO LIFE and serious risk of material damage if the robot welding
system is not used properly. Therefore observe all instructions in this operating manual.
The symbols used in this operating manual have the following meanings:
There is an immediate threat to life and health of personnel. Danger

is imminent if the warning is not observed.
There is a possible threat to life and health of personnel.
There is a risk of an undesirable situation arising, which could lead to

minor personal injury or considerable material damage.
7
1.1 Intended use
The equipment may be damaged if the warning is not observed.
Disregarding this information will interfere with product handling,

which may lead to minor material damage in exceptional cases.
General information and notes on the optimum use of the product
Sections marked with "" are handling instructions and operational prompts:
Make sure that this operating manual is always kept close to the robot welding
system.
1.1 Intended use

The Q4 robot welding system is designed to control a welding process, to provide and
record process parameters, and to monitor faults. Any other use is regarded as not
being in accordance with the intended purpose.
1.2 Electromagnetic compatibility

The robot welding system is mainly intended for use in an industrial environment. Due
to its principle of operation, strong electromagnetic fields are generated during electrical
welding, which may interfere with other electrical systems and machines. Such
interference must be minimized by proper installation (see Chapter 3) and by taking
appropriate care when commissioning (see Chapter 5).
1.3 Name of the buyer when reselling

If you resell the robot welding machine, please let us know the name and postal
address of the new owner.
1.4 Copyright
Copyright of this operating manual remains with SKS Welding Systems GmbH.
These documents must neither be passed on to third parties nor copied, and their
content must neither be used nor communicated, even in part, unless by express
agreement.
All rights reserved.
8
1.4 Copyright
The information contained in this document is regularly checked, and corrections are
included in subsequent issues.
SKS Welding Systems GmbH

Austraße 2A
D-66849 Landstuhl
http://www.sks-welding.de
Phone: +49 (0) 6371 92670

Fax: +49 (0) 6371 926719
E-mail: info@sks-welding.de
As we work continuously on improvements, we reserve the right to make changes

without prior notice.
9
2 Safety at work
2.1 General information
2 Safety at work
Dear customer,
Safety instructions are an important subject and it is essential that they be observed.
For your own sake you should know the safety instructions for operating your robot
welding unit inside out. Since the Product Liability Act [1] came into force in December
1989, safety instructions have acquired additional importance.
As well as protecting your health and the capital value of the company, safety
instructions have the task of clarifying the responsibilities that are incurred by owning
and operating an item of equipment.
In this section of the operating manual, we would like to provide you with the
information, which you need in order to work safely with your SKS robot control system,
in an easily understandable form.
2.1 General information

Welding units work with high currents.
There may therefore be hazards for the operator.
You are obliged,
– to restrict hazards to an unavoidable minimum,
– to inform other users in a clear way about any existing danger,
– to protect the components against ingress of liquids and foreign bodies,
– to isolate the power unit from the mains supply if liquids or foreign bodies have
found their way into a unit and to have the unit checked by a qualified person,
– to observe the safety instructions.
We ask you to observe the following points:

Keep the operating manual in a place where it is always accessible to the operator.
Before you start working with the system, read the entire operating manual
carefully.
Pay particular attention to the safety instructions.
Have the operator sign to confirm that he has read and completely understood the
operating manual before starting the machine.
Do not commence welding before you have understood all operating procedures.
Contact the responsible SKS service technician if there are any doubts on certain
operating procedures.
This operating manual applies only for the Q4 robot welding system.
The system must only be operated by trained and qualified personnel.
Safeguard the system against unauthorised use.
Inform our customer service in the event of malfunction.
An operating instruction manual and a maintenance instruction manual for your
company must be produced based on this manual.
The internal instruction manual must take into account the particular conditions of use in
your company.
10
2 Safety at work
2.2 Safety symbols
The owner is responsible for ensuring that operating personnel wear personal protective
equipment, e.g. safety goggles, safety shoes, gloves, ear defenders etc.
The owner is responsible for ensuring that the system components are used only as
directed.
If in doubt, refer to the information in this operating manual for all work such as
transportation, erection, assembly, manufacturing operation, maintenance etc.
2.2 Safety symbols

Please observe the following safety symbols:
There is an immediate threat to life and health of personnel. Danger

is imminent if the warning is not observed.
There is a possible threat to life and health of personnel.
There is a risk of an undesirable situation arising, which could lead to

minor personal injury or considerable material damage.
There is a risk of minor or moderate material damage.
Disregarding this information will interfere with product handling,

which may lead to minor material damage in exceptional cases.
General information and notes on the optimum use of the product
The following symbols point to special hazards:
Warning of dangerous electrical voltage
Warning of electromagnetic fields
11
2 Safety at work
2.2 Safety symbols
Prohibition signs mean:
Persons fitted with a heart pacemaker are prohibited
Symbols relating to personal protective equipment mean:
Wear protective clothing
Wear safety goggles
Wear ear defenders
Wear head protection
12
2 Safety at work
2.3 Personnel qualifications
2.3 Personnel qualifications

Only allow the system to be operated by persons who:
– are appropriately trained in the field of welding
– have been appropriately instructed
– are physically and intellectually suitable
– can be expected to reliably fulfil the tasks assigned to them.
2.4 Intended use

The relevant standards and accident prevention regulations have been taken into
account in the development of the overall Q4 system. The system has been
manufactured in line with the latest developments in technology and is regarded as safe
to operate.
The Q4 control is designed for:
Welding processes:
- Arc welding using the GMAW, pulsed arc and GTAW welding processes
Power sources:
- Inverter power sources in the LSQ series
Robots:
- Commercially available robots for arc welding
Intended exclusively for industrial indoor use.
You can connect the following equipment to the Q4 control system:
- SPW bus cable to SPW93 standard
- All assemblies to SPW93 standard (interface, wire feeder, power source)
- Service PC via USB interface
- Welding torch with SKS Power Pin, Euro, or Dinse central connection.
Any other use is regarded as not being in accordance with the intended purpose. The
manufacturer is not liable for damage resulting from the units not being used as
directed. Any risk is carried by the user.
Observing this operating manual also constitutes "use as directed".
13
2 Safety at work
2.5 Safety instructions
Disregarding the following safety instructions can be life-

threatening!
Observe the regulations for the prevention of accidents.
Operation is restricted to those persons who have appropriate knowledge in the use of
arc welding equipment.
Wear protective clothing, eye protection and ear defenders as specified in UVV 26.0,
VBG 15. Protect the eyes and face with a safety mask.
Hot sparks and molten drops!

Hot sparks and molten drops are produced and fly out during
welding.
Flying sparks and molten drops can cause fires and explosions.
Remove containers with inflammable or explosive liquids from
the working area. Do not heat explosive liquids, dusts or gases
by welding or cutting. There is also a risk of explosion with
apparently harmless substances, which can build up excess
pressure in enclosed containers when they are heated.
Wear approved working and protective clothing, e.g. welding
apron, gloves, protective goggles etc.
Strong electric and electromagnetic fields!

Severe electromagnetic radiation is produced by the welding
equipment when welding.
The operation of heart pacemakers can be adversely affected in
the vicinity of the welding equipment. Electronic equipment (e.g.
IT equipment) may malfunction in close proximity to the welding
station.
Make the welding system inaccessible to persons with heart
pacemakers. Do not use electronic equipment near the welding
system or take measures to avoid EMC problems.
Radiation!
Arcs emit UV radiation.
Unprotected parts of the body may suffer burns and blinding is
possible. Wear protective goggles or erect protective walls.
Protect exposed body parts (hands, face) from radiation.
Protect personnel not involved against optical radiation and risk
of glare by means of curtains and protective walls
14
2 Safety at work
Risk of burns!
Contact tip, nozzle holder, gas nozzle and gooseneck may be
hot.
Burning possible if touched.
Wear heat-protecting gloves. Allow to cool before carrying out
maintenance work.
Electrical voltage!
Contact tip, nozzle holder, wire and workpiece can be live.
Electric shock possible if touched.
During the actual welding process, do not touch the torch, the
torch holder or any electrically conductive parts in their vicinity.
Disconnect the power source before carrying out maintenance
work or changing parts, and secure against reconnection.
Switching off or removing the fuse does not provide adequate
electrical protection.
Electric shock may be life-threatening!

Connect the units only to properly earthed socket outlets.
Use the system only with an intact supply cable with an earth conductor and
safety plug.
Improperly repaired plugs or damaged supply cable insulation may cause
electric shock.
Only authorised specialists may open the units.
Remove the mains plug from the socket before opening. Wait for 2 minutes
until the capacitors have discharged.
Even if you touch low voltages you may be startled and in consequence cause an
accident, therefore:
Handle feed cables, torch and workpiece properly.
Do not touch electrically live parts with bare skin.
Do not use torches or cables with damaged insulation.
Vapours from chlorinated hydrocarbons can be converted into poisonous phosgene by

ultraviolet radiation.
Fumes and gases!

Poisonous fumes and gases may be produced when welding.
Inhaling these can lead to shortness of breath and poisoning.
Do not inhale fumes and gases. Make sure that there is
adequate fresh air. Keep vapours and solvents away from the
radiation area around the arc.
15
2 Safety at work
If necessary, ventilation or extraction systems must be provided to ensure that the MWC
values are not exceeded (MWC = Maximum Workplace Concentration of materials
that are hazardous to health).
Noise!
High noise levels can arise during welding.
Noise which exceeds 70 dBA can cause permanent damage to
hearing.
Wear suitable ear defenders or earplugs. Make sure that other
personnel in the working area are not inconvenienced by noise.
High pressure!
Gas bottles and gas supply systems are under high pressure.
There is a risk of explosion if not handled correctly.
Follow the handling instructions provided by the gas
manufacturer, and the compressed gas regulations. Secure gas
bottles. Place shielding gas containers in provided collets and
secure with retaining chain. Do not throw or heat gas bottles,
and safeguard them against falling. Remove the gas bottle from
the welding unit when transporting by crane.
Operator errors
Incorrect operation and maintenance can lead to malfunctions
and material damage.
Pay attention to the operating instructions for the individual
welding components, such as power source, wire feeder and
cooling unit. Do not exceed the load limits.
Handling
Torch cables and other cables.
Incorrect handling of the torch cable can damage the insulation
and thus render it unusable.
Never pull the cable assembly over sharp edges, and never lay
in the spatter area or on hot workpieces.
Warning against unauthorised conversion or modification.

Unauthorised conversion or unauthorised modification is not
allowed and will result in the loss of any right to guarantee
claims. The manufacturer must be informed in all
circumstances.
16
3 Operation of the Q4 robot welding system
3.1 Characteristics

3.1 Characteristics
3.1.1 Concept
The heart of the overall Q4 robot welding system is the fully adjustable and automated
Q6p controller for specifying parameters and monitoring when welding with fully
mechanised robot systems.
It is a machine concept, which is based on performance, high availability, flexibility and
compatibility. The control enables perfect interaction of the individual components of the
system. Modern inverter equipment with a fully digital control unit guarantees
reproducibility and transferability of the machine settings. Power source characteristics
are independent of the hardware (e.g. transformer), as all dynamic and static properties
are provided by software. The fully digital control unit calculates the ideal power source
characteristics for the GMAW, short arc and spray arc welding processes.
Furthermore, it controls the dynamic current rise behaviour, the maximum current, and
the droplet transition during the pulsed arc process. Whether steel, CrNi steel,
aluminium, bronze or special materials: excellent welding properties are assured. The
power sources are designed to accept mains voltages of 400 Volts and a permissible
supply voltage tolerance of +/- 10%. They have the required IEC certification.
A general-purpose interface to the robot and/or the robot controller/PLC forms the
dividing line between the overall system and other devices of the welding installation. If
you have any questions relating to the robot or its control, please refer to the relevant
operating manuals.
3.1.2 Technology
The Q4 controller contains the following features as standard.
Welding programs:
There are 186 welding programs that can be called directly by the robot. An unlimited
number of welding programs are available on the service PC. Welding programs can be
optimized on site. Data is backed up in the Q4 controller or in the PC.
Welding process monitoring:

Special monitoring parameters are allocated to all welding programs. Limit value
responses are assigned to the monitoring parameters.
All alarm messages for operator and system are displayed.
Changes to welding programs carried out by operating personnel are stored.
Operator guidance:
Linked parameters change simultaneously in the display (one-button-operation).
This linking can be bypassed by means of detailed adjustment features.
The operating language can be selected from 9 languages at the press of a button.
17
3.1 Characteristics
Interfaces:
Looped-through SPW field bus node with T-branch for connecting the following
components:
¾ Q4 Process control
¾ Power source
¾ Wire feeder
¾ Interface/field bus
Front-mounted USB interface without galvanic isolation for service PC.
Supported field bus modules:

All modules to SPW93 standard (interface, wire feeder, power source).
All modules to SPW99 standard
Expansion modules to SPW9x standard (external displays)
Axis control to SPW9x standard (traverse unit)
Welding processes:
GMAW pulse, soldering
18
3.2 Components of the Q4 robot welding system
3.2 Components of the Q4 robot welding system
The overall Q4 system comprises the following individual components:
Q4 process controller
Wire feeder
Torch
Power source
SPW bus
Interface
3.2-1 Overview of system components
Wire feeder, Q4, welding power source, SPW bus, robot interface. Please note that the
welding torch has its own operating manual and is not included in this document.
19
3.3 Q4 Process control
The Q4 process controller serves as a data memory and information system, and is also
used for entering the welding parameters. The front side accommodates a key switch,
the soft-touch operating panel and the LCD display. The USB interface for connecting a
service PC is also here.
3.3-1 Q4 process controller, front view
20
3.3.1 Power source

All power sources in the SKS range are suitable for use as the welding power source,
especially the LSQ 3.
Welding cable
sockets
Q4 controller
Control keys
and LED
SPW-bus connections
Fuse
3.3-2 LSQ 5 power source
21
TECHNICAL DATA LSQ 3

Adjustment range:
Welding current / Welding voltage
GMAW 11 A / 14 V – 400 A / 38 V
Duty cycle at 40°C

Ambient temperature:
60% duty cycle 340 A
Duty cycle 10 min (60%: 6min ON, 4min OFF)

No load voltage 70V
Mains voltage (tolerances) 3x400 V (-10%, +10%)
Frequency 50/60 Hz
Mains fuse (slow-acting fuse) 35 A
Mains cable 4x4 mm²
max. connected power 19 kVA
cosϕ / Efficiency >0.95 / 91%
Insulation class / Protection class H / IP23
Ambient temperature <45°C
Cooling Air
Workpiece cable 70 mm²
Dimensions L / W / H [mm] 450x330x540
Weight: 37 kg
Manufacturing standards EN 60974 / IEC 60974 / VDE 0544
EN 50199 / VDE 0544 Part 206 /
SPW99
CE mark EN 60974 / IEC 60974 / VDE 0544
[S] mark EN 50199 / VDE 0544 Part 206
As a universal power source, the LSQ 3 with 340 A (60% duty cycle), 270 A (100% duty
cycle) is suitable for the following processes:
¾ GMAW
¾ I-pulse
¾ U-pulse
¾ KF-pulse
22
GMAW:
The classic method for short and spray arc welding with automatic parameter setting:
¾ Arc generation
¾ Static characteristic curve
¾ Dynamic behaviour (MAG-M, MAG-C)
¾ Welding voltage
Advantage: Easy handling, single-button operation, wire speed Æ welding voltage

Disadvantage: Some spatter formation
I-pulse (power pulse)

An easy-to-use, universal pulse process with automatic parameter setting:
¾ Arc generation
¾ Static characteristic curve
¾ Current rise (pulse upslope)
¾ Pulse current
¾ Pulse current time
¾ Current decay (pulse down slope)
¾ Base current
I-pulse
Downslope U
Upslope
IP
US
IG
tP tG t t
3.3-3 I-pulse process schematic
The base current time tG is automatically selected to give the required welding voltage
US.
Advantage: Uncomplicated handling, single-button operation, wire speed Æ
welding voltage
Disadvantage: Poor short circuit behaviour
The process can be used for steel, CrNi steel, aluminium and bronze.
23
U-pulse:
The classic pulse process with changeover from pulse voltage to base current with
stored parameter settings:
¾ Arc generation
¾ Pulse voltage
¾ Pulse time
¾ Base current
¾ Base current time
All parameters have to be optimised manually.
U-pulse
Downslope
UP Upslope
IG
tP tG t
3.3-4 U-pulse process schematic
Advantage: Good short circuit behaviour

Disadvantage: Process sensitive to changes in distance between torch and
component
24
KF-pulse:
Special pulse process with changeover from pulse voltage to base current with stored
parameter settings:
¾ Arc generation
¾ Pulse voltage
¾ Pulse time
¾ Characteristic field (KF) variable
¾ Base current
¾ Base current time
KF-pulse
Characteristic Downslope
field (KF)
Upslope
tP tG t
3.3-5 KF-pulse process schematic
The characteristic of the current source changes automatically at the limits of the
characteristic field. The selectable characteristic field dynamics ensure good bridging of
the gap. All parameters have to be optimised manually.
Advantage: Good short circuit behaviour, good gap bridging

Disadvantage: Complicated handling, process sensitive to changes in distance
between torch and component
The process can be used for aluminium, CrNi steel and bronze.
The process is sensitive to changes in the system resistance. Parameters

can therefore only be transferred from one system to another to a limited
extent.
Solution: Readjust pulse voltage if there are problems when transferring
parameters.
25
The LSQ 3 supports many types of controller and has to be configured for older
control systems. You will find the configuration in the Appendix under 'LSQ 3
operating modes'.
26
3.3.2 Wire feeder

Any of the wire feeders in the SKS product range can be connected: Q591D (with air-
cooled torch) and Q590D (with water-cooled torch) as well as all versions of the Power
Feeder 5. The following methods are available for connecting the torch: Euro, Dinse,
and Power Pin.
27
3.3.3 Interface to the robot

The interface connects the Q4 controller to the robot or to the PLC control system. The
interface used here is a universal interface, which can be adapted to suit all
commercially available controllers. It processes all signals, levels and codes. The
specific connection is programmed directly on the interface.
3.3-6 Universal robot interface
The interface must only be operated in connection with a PLC control configuration or
an appropriate robot controller. Suitable interface configurations are available ex works
for all common types of robot.
The interface is supplied by the power source with 42 VAC via the system cable L-703.
It does not need an external power supply.
28
3.3.4 SPW-BUS connections / L700 cable

Bus connections are provided for connecting the individual components. These are in
the form of an SPW field bus with T-branch. The cables are wired complete with plugs
and sockets and cannot be confused, as they are interchangeable. The total length of
the cable per installation must not exceed 100 m.
3.3-7 SPW bus connection

3.3-8 SPW bus cable L700
29
4 Scope of supply
4.1 Customer service
4 Scope of supply
On delivery, the whole system is once again checked for correct operation and an
inspection mark is attached. On receipt, the delivery must be checked for damage and
completeness. Any transport damage or missing components must be notified to the
manufacturer or to the haulier.
4.1 Customer service

If you want to make use of customer service for your system, please contact your local
dealer or one of the SKS Welding Systems subsidiaries in your area of the world
directly.
You will find a list of SKS partners on the Internet on the following website:
http://www.sks-welding.de/d/kontakt/partner.html
4.2 Packaging, Storage

Keep the packaging safely. Ship the units in their original packaging only.
If the system is not put into operation immediately after delivery, the following points
must be observed:
¾ All components must be stored in a secure place.
¾ All components must be protected against humidity, dust and metallic dirt.
If you should resell the system, please provide us with the name and postal address of
the new owner so that we can replace any chapters of the operating manual that may
have changed.
30
5 Commissioning the Q4 robot welding system
5.1 Location

5.1 Location
If possible, do not weld in rooms which have a height of less

than 3 metres. Special regulations apply for confined rooms in
accordance with BGV 1D [7] .
The units can be operated under the following conditions:
Temperature range of ambient air:

for welding: 0°C to +40°C
for transport and storage: -25°C to +65°C
Relative humidity:
up to 50% at 40°C;
up to 90% at 20°C.
Ambient air must be free from excessive dust, acids, corrosive gases or substances
etc., in as far as these are not produced during welding.
Examples of unusual working conditions:
¾ Unusually corrosive fumes

¾ Steam
¾ Excessive oil fumes
¾ Unusual vibrations or shocks
¾ Excessive dust (e.g. grinding dust)
When installing the equipment, make sure that air can flow freely to and from the unit.
The units are tested to protection class IP23:
¾ Protection against ingress of solid bodies >12mm,

¾ Protection against splash water up to an angle of 60° from the vertical.
¾ Ensure that the room is adequately ventilated.

¾ Weld only at a sufficient distance from combustible materials or liquids.
¾ Before starting to weld, remove all combustible articles and liquids from the vicinity
of the workplace.
¾ Make sure that fire extinguishers are available at the workplace.
¾ Do not weld in rooms where there is a risk of explosion.
¾ Do not set up the robot in the vicinity of any equipment or apparatus which is
sensitive to welding spatter.
31
5.2 Preparing the Q4 robot welding system for operation
Choose a safety distance, which is sufficiently large to ensure that there

is no danger due to welding spatter, and screen the welding area using
shields or curtains.
Noxious vapours and airborne particles may be produced during welding.
¾ Set up the system components:

- on a stable, clean, and level surface
- in such a way that no-one is endangered or injured by welding spatter
- in such a way that all cables and connections are protected against damage.
¾ Protect the units from severe vibration.
¾ Avoid heat build-up inside the units.
¾ Protect the power unit from excessive dust and dirt.
¾ Make sure that the air can circulate freely around the cooler.
¾ Protect the units against ingress of fluids or foreign bodies.
¾ Disconnect the units immediately from the mains supply in the case of ingress of
fluids or foreign bodies.
¾ Have the units concerned checked by a qualified technician.
¾ Provide for proper UV protection by means of sliding doors or curtains; also take into
account the possibility of glare due to reflection from smooth surfaces.

Select the set-up location of the Q4 so that the operator always has sight of the
controller and is able to reach it. The Q4 is not suitable for outdoor use.
The power source must not be located within the working range of the robot or in the
welding spatter area. Position the power source in such a way that no welding fumes
can penetrate. The operator controls must be freely accessible.
You may install the wire feeder on the robot. For this purpose, use the brackets, which
are available from SKS for all common types of robot. You can also locate the wire
feeder next to the robot. In all cases, secure the wire feeder in case of possible dynamic
loading.
The interface is installed in the PLC or robot controller. To do this, feed the 7-core SPW
bus cable through the wall of the control cabinet.
The same rules as for the power source apply to the location for setting up the cooling
unit.
32
5.2.1 Connecting the components
5.2.2 SPW bus
5.2-1 SPW connection of components
The SPW bus connects all components of the welding system to one another, and
supplies them with power. Data are also exchanged between robot interface, controller,
wire feeder, power source, water cooler, etc. by this means.
All modules are galvanically isolated from one another. The total cable length can be up
to 100 m. For reasons of immunity to interference and the type of cable, the data
transmission rate is only 16 kbit/s.
Use the SPW bus cable supplied to make the following connections:
- Power source - wire feeder (integrated into the intermediate cable assembly)
- Power source interface (UNI interface or field bus)
The cables are standardized and can be freely interchanged.
33
5.2.3 Welding current cable
5.2-2 Set-up GMAW/Pulse
Connect the welding current cable:

+ cable usually between power source and wire feeder (intermediate cable assembly)
- cable between power source and welding device
For special materials or GTAW welding processes, use the opposite
polarity!
5.2.4 PC
The connection between the Q4 and the PC is made using a USB
slave cable
5.2.5 Safety shutdown

For the safety shutdown circuit, use the cable with the 4-pin AMP or M8 plug between
the wire feeder and the robot controller, and between the safety shutdown circuit and
the wire feeder.
5.2.6 Wire feeder

Due to the high current consumption, only one wire feeder per power unit must feed a
wire. However, several feeders may be present but only one of them is active. With
standard SPW cable, the total cable length between power source and wire feeder must
not exceed 15 m. Thicker cables are available for longer distances.
5.2.7 Inert gas, wire feed hose, welding torch

When connecting the ½" diameter inert gas hose, please check the connection to
ensure that there are no leaks.
34
5.3 Interface selection and set-up
First fix the wire feed hose to the spool and then to the drive of the wire feeder. You
must insert the wire electrode manually as far as the drive; the machine will then
transport the wire through the wire feeder as far as the welding torch.
For installation and connection of the welding torch, please refer to the operating
manual for the torch.
5.2.8 Mains connection

¾ Compare the mains voltage indicated on the nameplate with the voltage of your
mains supply. The nameplate is located on the side of the power source.
Mains voltage Tolerance Min Max Series transformer

400V ±10% 360V 440V ---
480V ±10% 432V 528V 3x480V Æ 3x400V ---
575V ±10% 518V 633V 3x575V Æ 3x400V
As mains voltages can sometimes vary considerably, a series transformer should be
used for mains voltages above 520V.
Never connect the units to a mains supply with a voltage, which

does not correspond to that indicated on the nameplate.
Connecting the power source to an unsuitable mains voltage
can cause damage to the power source or have an adverse
effect on its operation.
¾ Compare the current consumption indicated on the nameplate with your mains
supply fuse.
¾ Have an electrician check that the wall socket where you want to connect the
equipment is properly earthed.
¾ Set the mains switch at the side of the power unit to "0".
¾ Plug the mains plug into the tested socket.
If the unit is to be switched on by means of a contactor in the electrical cabinet, contacts

for C-load must be used.

The interface is programmed in the factory for your robot controller before delivery.
It is characterised by the following features:
¾ Programmability
¾ Analogue/digital mode
¾ Workpiece contact function (binary)
¾ Negative logic, for which you will need the additional electronic board UNI NEPOS
in certain cases (FANUC).
¾ Rotation mode
¾ Provision of an analogue value to control the speed of an external axis.
35
If a replacement should be required, however, you can program each

interface in such a way that your control can be addressed, regardless of
whether the system is working in analogue or digital mode.
It is essential to use the correct version of the interface,

otherwise the robot will not work or may respond in an
uncontrolled manner.
36
5.3.1 Installation instructions

Clip the interface onto a mounting rail in the electrical cabinet.
Now fix the L-703 system cable with flange plug to the electrical cabinet and connect
the tinned cable ends to the interface. If available, the interface will be delivered with a
wired plug, and needs only to be plugged into the socket provided for the purpose in the
controller. Otherwise, the connections must be configured manually. Please refer to the
instructions for your individual interface in the Appendix as to whether further wiring is
required.
5.3.2 Cables and pin assignment

You will find further details relating to system configuration, circuit diagrams, and
terminal allocation in the Appendix under your individual interface.
5.3.3 Field bus

The welding system can also be connected to the robot by means of the field bus. The
field bus interface is required for this purpose.
You will find further information on the field bus coupler in the Appendix relating to the
field bus interface.
37
6 Operating the Q4 robot welding system

Strong electric and electromagnetic fields! .

Severe electromagnetic radiation is produced by the welding
equipment when welding.
The operation of heart pacemakers can be adversely affected in
the vicinity of the welding equipment. Electronic equipment (e.g.
IT equipment) may malfunction in close proximity to the welding
station.
Make the welding system inaccessible to persons with heart
pacemakers. Do not use electronic equipment near the welding
system or take measures to avoid EMC problems.
Electrical voltage!
Contact tip, nozzle holder, wire and workpiece can be live.
During the actual welding process, do not touch the torch, the
torch holder or any electrically conductive parts in their vicinity.
Hot sparks and molten drops!

Hot sparks and molten drops are produced and fly out during
welding.
Flying sparks and molten drops can cause fires and explosions.
Remove containers with inflammable or explosive liquids from
the working area. Do not heat explosive liquids, dusts or gases
by welding or cutting. There is also a risk of explosion with
apparently harmless substances, which can build up excess
pressure in enclosed containers when they are heated.
Wear approved working and protective clothing, e.g. welding
apron, gloves, protective goggles etc.
38
6.2 Preparing for welding
Fumes and gases!

Poisonous fumes and gases may be produced when welding.
Inhaling these can lead to shortness of breath and poisoning.
Do not inhale fumes and gases. Make sure that there is
adequate fresh air. Keep vapours and solvents away from the
radiation area around the arc.
Radiation!
Arcs emit UV radiation.
Unprotected parts of the body may suffer burns and blinding is
possible. Wear protective goggles or erect protective walls.
Protect exposed body parts (hands, face) from radiation.
Protect personnel not involved against optical radiation and risk
of glare by means of curtains and protective walls
Do not use solvents for cleaning components, as they may damage the
surface of your equipment.
Have any repair and maintenance work on electrically live parts and
inside the power source carried out only by your own responsible service
technician or by the SKS customer service department.

6.2.1 Switching on and testing the robot welding system
After correct completion of the wiring, switch on the system with the mains switch of the
power source. The system first carries out a self-test to determine the system condition.
All components of the system are tested and their interaction is simulated. If any
incompatibility should be detected, an error or alarm message is generated. If no error
or alarm message is output, the system is ready for operation.
G0 T2 P2 ALARM: 02
---------------------------------------- ----------------------------------------
MULTIPROCESS_Q4 MULTIPROCESS_Q4
Version: 6.30 Version: 6.30
Leipold + CO GmbH 2006 Leipold + CO GmbH 2006
on behalf of SKS on behalf of SKS
---------------------------------------- ----------------------------------------
CONTROL CODE: 9
LCD-DISPLAY LCD-DISPLAY
6.2-1 System properly installed
6.2-2 System faulty
39
6.2.2 Troubleshooting
It may happen that an error message is output when starting up the system. The
following error messages may occur:
Error code table SINGLE-WIRE system
CODE Power source Wire feeder Interface Type of

system
1 o.k. missing/defective missing/defective Standard
2 missing/defective o.k. missing/defective configuration
3 o.k. o.k. missing/defective
8 missing/defective missing/defective o.k.

9 o.k. missing/defective o.k.
10 missing/defective o.k. o.k.
11 o.k. o.k. o.k.
CODE Power source Wire feeder Interface Type of

system
5 o.k. missing/defective missing/defective GTAW
6 missing/defective o.k. missing/defective system
7 o.k. o.k. missing/defective
12 missing/defective missing/defective o.k. the value 4 is

added
13 o.k. missing/defective o.k. to the standard-
code
14 missing/defective o.k. o.k.
15 o.k. o.k. o.k.
Alarm messages are generated if a malfunction occurs during operation of the welding
system. Identify the cause of the alarm using the alarm code list (see Appendix), and
follow the instructions to rectify the cause of the fault.
40
6.3 Operating the Q4
The Q4 provides a robot with suitable welding parameters on demand. Individual

parameter combinations are put together to form programs, which are then stored in the
controller, where they can be selected at any time. The programs constitute individual
welding seams.
For reasons of clarity, 6 welding programs are combined to form a main parameter set
(file number). Each main parameter set (file number) is assigned its own start program,
3 welding programs, an end filling program and an end program. Up to 31 main
parameter sets (file numbers) can be defined for different components.
31 Main parameter sets (file numbers)

31 Start programs
31 End filling programs
31 End programs
3 x 31 Welding programs
The following is an example of a welding program:
Welding programs:
PROGRAM SELECT
P2
Wire : 5.0 m/min P2 P3 P4
Us : 18.8 V Ko:0.0
P3
Wire : 6.0 m/min
Us : 20.2 V Ko:0.0
6.3-2 Key selection
P3
Wire : 8.0 m/min
Us : 22.2 V Ko:0.0
¾ 3 different welding programs
¾ 3 different parameter sets
6.3-1 Welding program - example
¾ 1 type of welding process (e.g.
MIG or U-pulse)
A start program is always carried out at the beginning of a weld in order to optimise the
ignition process. In doing so, the gas pre-flow time is included in the cycle time of the
system. The wire feed speed is normally slower than with normal welding.
Start program:
41
P1 START ¾ The start program is automatically executed

Gas pre-flow: 0.20 s
Wire : 4.0 m/min
after each "welding on" signal.
Us: 17.4 V Ko:0.0 V ¾ Optimised parameters for safe arc ignition.
Duration: 0.2 s ¾ Duration: after ignition, the start program lasts
for the set duration (in this case 0.2 seconds),
then switches to a selected welding program.
PROGRAM SELECT
START
6.3-3 START program
After starting, the program selected by the robot is called up. If the robot has not
selected a program, then the next normal welding program will be called up.
P2/3/4 ¾ Wire feed speed in metres per minute

Wire : 5.0 m/min ¾ The Q4 calculates the welding voltage Uw
Us : 18.8 V Ko:0.0
(single-button operation)
¾ Optimisation of welding behaviour by means of
voltage correction ± 5 V (arc length correction).
PROGRAM SELECT
P2
6.3-4 Welding program
42
At the end of the weld, a specific program is carried out to complete the welding.
END (P8)
Burnback: 2 mm
Gaspostflow: 0.20 s
¾ Automatically carried out after each "welding
Endfilling (P7): 0 off" signal
¾ Optimum wire burn-back
¾ Check for sticking
PROGRAM SELECT
¾ Gas post-flow is not included in the cycle time.
END
6.3-5 END-Programm
If the "Endfilling" function is activated in the END program, a program for carrying out
end filling will be executed before the END program.
FILL (P7)
Wire : 5.0 m/min
Us : 18.8 V Ko:0.0
¾ Automatically carried out after every "Welding
off" signal if activated in END program
¾ Parameters are reduced to the values in the
FILL program
PROGRAM SELECT
¾ Carries out the end fill
FILL
6.3-6 FILL program
43
By way of explanation, the complete process sequence is shown again here, in the way
that it is organised by the Q4.
P1
Welding on
START ¾ Gas pre-flow
¾ Ignition process (arc generation)
P2
¾ Check for stable arc → robot starts
Welding with P4
P3 ¾ Selection by robot
P4
Welding off
¾ Wire burn-back
END ¾ Check for sticking
¾ Gas post-flow
START P4
END
6.3-7 Process sequence
Part number :
The file number relates to a component, and contains the relevant data for the up to 3
subsequent welding programs plus start and end program.
Part number: 1
Part number: 1
A file number contains data
Welding process : MAG M
Operating mode : Robot
Welding process : MAG M Basic data
Operating mode : Robot related to - Wire

- Material
:
:
1.0 mm
FE
Basic data ¾ Welding process - Inert gas
- Base material
:
:
82Ar18CO2
FE
- Wire : 1.0 mm
- Material : FE
¾ the operating mode P1 (START)
- Inert gas :82Ar18CO2 ¾ basic data of a
- Base material : FE
component P2
6.3-8 Q4 display: File number
P3
Basic data:
Be sure to check this P4
Wire diameter
information before welding starts,
Welding filler P7 (FILL)
as the settings directly influence
Inert gas composition
the subsequent welding programs.
P8 (END)
6.3-9 File number - welding programs
44
6.4 Setting up programs and welding parameters
The 6 welding programs are now combined to form one file number.
31 file numbers can be defined for different components.
P1 (START) P1 (START) P1 (START) P1 (START)
P2 P2 P2 P2
P3 P3 P3 P3
P4 P4 P4 P4
P7 (FILL) P7 (FILL) P7 (FILL) P7 (FILL)
P8 (END) P8 (END) P8 (END) P8 (END)
6.3-10 31 file numbers
Before welding, the robot must select the particular program concerned, which is then
made available by the Q4, in the sequence Group - File number - Welding program, in
order to call up the welding parameters. Another welding program consisting of these
file numbers can be called during welding. Welding must be switched off if the file
number is to be changed.

6.4.1 Using standard programs / selecting stored data sets
On delivery, many sets of welding data are stored in the Q4 controller ready for use. In
Chapter 10 on Page 79 you will find a list of the data sets provided ex works.
These data sets in the Q4 controller are organised as follows:
- 31 file numbers with 3 welding programs each plus start, fill and end program
File number and program are continuously shown in the top line of the LC display.
Each data set (file number) contains a complete description of the relevant welding job:
¾ Welding process GMAW/PULSE/GTAW etc.

¾ Operating mode Timer/External
¾ Material, wire and inert gas
¾ 3 welding programs plus start, fill and end program with parameters
¾ Various monitoring functions
45
Display Operating keys
6.4-1 Front of Q4
USB connector
Key switch
46
6.4.2 Q4 display
Navigation
The navigation and status
G0 T01 P1 EDITMODE line lines remain unchanged in
Cursor GASPREFLOW: 0.20s
WIREFEED1 4m/min
almost all displays. Between
Uweld 22.2V Ko 0.0V them there are 6 lines for
PROG-TIMER: 0.2s various tasks.
P1 - PAUSE- Status
LCD-DISPLAY line
6.4-2 Q4 display
Navigation line: Here you can see the Group (always 0), File number and Program,
which were last processed by the operator, and which Group
(always 0) and File number the robot has used last.
Edit mode: Edit mode is switched on and off depending on the
position of the key switch (ON/OFF). When edit mode is switched
on, you can alter the presets for the selected program.
Status line: The status line displays the currently used program 'P'; the group and
file numbers can be found in the navigation line. Possible displays:
Break: No welding
Start: The control system has recognized the command 'Welding ON'
Motor: Welding wire is being fed
Arc-relay: Arc is stable (as soon as Arc-relay is displayed, the relay is
switched to the interface to make the robot move).
The current welding program is only displayed during welding.
6.4.3 Q4 control keys:

The CURSOR keys
⇓: Change page
↑: Move the cursor up on the current page
⇓
“+”, “-“: Change values at the current cursor position
- +
CURSOR
6.4-3 Cursor keys
47
The PROGRAM SELECT keys

PROGRAM SELECT
Selection of welding programs, entry of
welding parameters (several pages may be
START P2 P3 P4 available)
The cursor can also be moved by pressing

FILL END the program key, file number, or Q4 key.
Please note that the cursor moves to the
6.4-4 Program keys
next page after the last line.
The DISPLAY keys
A Pressing this key displays the actual values during welding

First and second page digital
DISPLAY Third and fourth page analogue
6.4-5 Display key
48
The SELECT key
PAR
The 'PAR' key on the SELECT keypad gives you access to 3 pages in the
display window.
1. Page:
G0 T01 P1 PRESETS
This is a free information page
----------------------------------------------------- where the user can specify any
PAR MAGM FE 0.8MIX
MIG
FE 2s
EXTERNAL
1.0mm
content via a PC.
Ar>9% CO2 G00 T01
-----------------------------------------------------
SKS does not accept
P1 - PAUSE- any guarantee for
LCD-DISPLAY
SELECT the contents of this page!
G0 T01 P1 EDITMODE
FILE-NUMBER: 4
FILE-NUMBER AUTOMAT 2. Page:
OP-MODE: EXTERNAL
EDIT MODE: 1 Here you can make the following
TEXT IN GERMAN
LCD-CONTRAST: 9 selections:
P1 - PAUSE-
LCD-DISPLAY
File number: Specify the file
number for the file to be
processed.
G0 T01 P1 CAREFUL!
PROCESS MIG/MAGM File number:
SHIELDGAS: Ar>9%CO2
MATERIAL: FE 2-S - manual selection
WIRE-DIMENSION: 1.0mm
Standardvalues: ? - automatic selection via
P1 - PAUSE-
interface (external)
LCD-DISPLAY Operating mode:
6.4-6PAR select key
- external program selection
(robot, PLC)
- timer (time controlled program
selection)
Manual pre-selection of a file/group

If external selection of a file and group is selected, this selection cannot be carried out
manually.
However, manual selection is often necessary for adjustment work.
If the "File number by hand" function is switched on, external selection by robot or PLC
will be deactivated. Any file and group can now be selected manually.
If the key switch is turned to 'OFF', the system changes automatically to

external selection. Operating modes
49
Operating modes
EXTERNAL:
In this operating mode, the ignition program is carried out under the control of a timer.
"0" (= external program selection) is selected as the next program.
The entire welding sequence is now controlled by robot/PLC.
At the end of welding, the robot deletes the starting signal and the control automatically
terminates the welding process with "P8=END". An end filling routine can also be
activated in END.
TIMER:
The programs " P1=START" to "P7" can be carried out under the control of a timer. This
is achieved by entering the program duration and the subsequent program. Loops of all
kinds are permitted.
Special features:
Time = 0:
The program runs as long as the robot or PLC "Start" (Welding ON) is active.
Next program = 0:
Use program selected by robot/PLC (without external selection: => P2)
Next program = 8: Program 8 ("END") terminates the welding process.
Any mixture of external preset and internal timer control can be programmed in this
way.
Example:
Ignition via timer control, then welding controlled by externally selected programs.
Finally, a program with timer control is called-up externally, which welds an overlap.
"P8" is entered as the next program, which terminates the welding process.
50
Edit mode
0: Reduces all setting options to the unavoidable minimum
1: Opens the complete menu
Almost all functions are now enabled for modification by the user. As a result, very
many parameters are displayed, which a well-trained user requires.
Assignment:
[PAR]: Workpiece-related parameters (process, material,...)
[START]: Ignition parameters and general welding parameters
[P2..4]: Parameters for the special welding program
[FILL]: Parameter for end filling
[End]: Parameters for burn-back and break parameters
2: For service personnel, only accessible by entering a password on the PC
Text in
Selection of language version
LCD contrast
Adjustment range from 1 to 9, where 9 is the strongest degree of contrast.
3. Page:
Selection of:
- Welding process
- Gas type
- Welding filler (wire material)
- Wire diameter
Important: After any change on the 3rd page, you must move the cursor
to 'Standard values' and press the + key, otherwise the standard values
will not be recalculated.
51
Welding processes:
MIG/MAGM: Metal inert gas welding and metal active gas welding for all common mixed
gases. The MAG/CO2 process should be used when using 100% CO2.
MAG/CO2: Metal active gas welding with 100% CO2 as the active gas.
You will find further information on the welding processes in Chapter 3, Pages 23 ff.
Gas types:
Many different gases are currently used in welding technology. These can be divided
into parameter groups of a maximum of nine basic gases.
Description Description
For the correct gas setting, the gas
99.999Ar 99,999% Argon
used should be assigned to one of
Ar+O2 Argon + Oxygen
the adjacent classes.
Ar+ O2+CO2 Argon + Oxygen + CO2
Ar+CO2+ O2 Argon + CO2 + Oxygen
Example:
Ar<9%CO2 Argon with less than 9% CO2
You are using a gas composed of
Ar>9%CO2 Argon with more than 9% CO2
80% Argon and 20% CO2.
Ar+He+ Argon + Helium
When using this gas, you should
100%CO2 100% CO2
select Ar>9%CO2.
100%He 100% Helium
6.4-7 Gas parameter groups
Welding filler (wire material):

Selection of the wire material from the standard materials Fe, CrNi, Al, CuSi, AlSi5 and
Cr-flux. The endings L and S (1-L and 2-S) indicate different process characteristics for
the same wire material.
(1-)L: For wire diameter 1.2 mm and above, or base material thickness > 3mm
(2-)S: For wire diameter 1.0 mm and below, or base material thickness < 3mm
Special characteristics have been determined for certain types of material and recorded
in material lists. With these materials, a dedicated material must be selected for different
wire diameters and different welding processes.
52
G0 T01 P1 CAREFUL!
PROCESS MIG/MAGM Order of settings
SHIELDGAS: Ar>9%CO2 1. Welding process
MATERIAL: FE 2-S 2. Type of inert gas
WIRE-DIMENSION: 1.0mm
Standardvalues: ? 3. Wire diameter
P1 - PAUSE- 4. Material
LCD-DISPLAY
5. Recalculate (for activation)
Material Process ∅ in mm Material number AWS code Description

Ferritic filler
IM 01 1,2 I-pulse/GMAW 1,2 1.4509; 1.4510; 1.4511 AWS 5.9 (No AWS code)
wire
KF- pulse/ U- Ferritic filler
KU 01 1.2 1,2 1.4509; 1.4510; 1.4511 AWS 5.9 (No AWS code)
pulse wire
AWS 5.9-93 ER 430 Ferritic solid
IM 02 1.0 I-pulse/GMAW 1,0 1.4509; 1.4510; 1.4511
(mod) wire
KF- pulse/ U- AWS 5.9-93 ER 430 Ferritic solid
KU 02 1.0 1,0 1.4509; 1.4510; 1.4511
pulse (mod) wire
Austenitic solid
IM 03 0.8 I-pulse/GMAW 0,8 1.4370 AWS 5.9-95 ER 307Si
wire
KF- pulse/ U- Austenitic solid
KU 03 0.8 0,8 1.4370 AWS 5.9-95 ER 307Si
pulse wire
Austenitic solid
wire
KU 03 1.0 1,0 1.4370 AWS 5.9-95 ER 307Si
pulse wire
Austenitic solid
wire
KU 03 1.2 1,2 1.4370 AWS 5.9-95 ER 307Si
pulse wire
Ferritic filler
IM 04 1,6 I-pulse/GMAW 1,6 1.4509; 1.4510; 1.4511 AWS 5.9 (No AWS code)
wire
KF- pulse/ U- non/low-alloy
KU 04 1,01 1,0 1.5125; 1.5130 AWS 5.18-96 ER 70S-6
pulse solid wire
non/low-alloy
IM 05 1.02 I-pulse/GMAW 1,0 1.5125; 1.5130 AWS 5.18-96 ER 70S-6
solid wire
non/low-alloy
IM 06 1.01 I-pulse/GMAW 1,0 1.5125; 1.5130 AWS 5.18-96 ER 70S-6
solid wire
6.4-8 Special materials
1
: Use with shield gas 92%argon 8%CO2
2
: Use with shield gas 82%argon 18%CO2
53
The program keys
Ignition process End program

G0 T01 P8 EDITMODE
G0 T01 P1
GASPREFLOW:
EDITMODE
0.20s
END ENDFILLING(P7)l:
BURNBACK:
T-ENDPULS:
0
2.0mm
2.2ms
START WIREFEED1
Uweld 18.8V
5m/min
0.0V
ENDPULS-CURR:
GASPOSTFLOW:
370A
0.20s
PROG-TIMER: 0.2s TESTFEED: 5.0m/min
NEXT PROGRAM: 0 P1 -PAUSE-
P1 -PAUSE- LCD-DISPLAY
LCD-DISPLAY
G0 T01 P1 EDITMODE G0 T01 P8 EDITMODE

I-IGNITION: 400A ARC-RELAY: NO
T-IGN.PULSE: 8 control, ALARM TIMER: 2.00s
VOLT.DROP: 4.92V/100A WATERPUMP: OFF
STARTFILTER: 2.00s GAS-OBSERVAT: YES
ARC-OBSERVAT: HALT GASFLOW 8.0l/min
ARC_FILTER: 1.00s PROGRAM (ROBOT): 3
P1 -PAUSE- P1 -PAUSE-
LCD-DISPLAY
LCD-DISPLAY
G0 T01 P1 EDITMODE
ARC-RELAY: YES
FAST ARCRELAY: NO
VOLT.DROP: AUTO G0 T01 P8 EDITMODE
MOTOR1/2: MOT1 mm/inch: -mm-
mm/inch: -mm- LIFT STICK? OFF
E_FUNCTION: ON
P1 -PAUSE- POWER START: OFF
LCD-DISPLAY LIFT TO START: OFF
P1 -PAUSE-
LCD-DISPLAY
Welding program P2-P4

G0 T01 P8 EDITMODE
G0 T01 P2 EDITMODE WIDTH WINDOW: 0.0%
WIREFEED1 5.0m/min *COM PROTOCOL: PRO2
P2 Uweld 22.6V 0.0V WK5 STATUS: 0.0A
SYNCHROWELD: OFF
F0
CURRENT-PRV: 180A
VOLT.DROP: 4.92V/100A
P1 -PAUSE-
P1 -PAUSE- LCD-DISPLAY
LCD-DISPLAY
G0 T01 P2 EDITMODE
ARC-OBSERVAT: YES
ARC_FILTER: 0.60s
CURR.WINDOW: 0A
MOTOROBSERVAT: YES
MOTOR-LIMIT 2.0A
MOTOR_FILTER: 2.00s
P1 -PAUSE-
LCD-DISPLAY
G0 T01 P2 EDITMODE
ARC-RELAY: YES
ACO-OBSERVAT: YES
ACO-INTERRUPT: HALT
AUTOCOMP-LIMIT: 3.0V
AUTOCOMP-FILT: 0.20s
P1 -PAUSE-
LCD-DISPLAY
6.4-9 Example of use of program keys
54
START
The 'START' key on the SELECT keypad gives you access to 3 pages of
the START program.
The individual content of these pages may vary depending on the design of the system
and the selected welding process. This is an overview of the usual settings:
1. Page:
Gas pre-flow:
PROGRAM SELECT G0 T01 P1 EDITMODE
GASPREFLOW: 0.20s
START P2 P3 P4 WIREFEED1 5m/min
Uweld 18.8V
PROG-TIMER:
0.0V
0.2s
Protection for the welding seam must be
guaranteed before the actual welding
NEXT PROGRAM: 0
V_WELD: 0.90m/min
FILL END P1 -PAUSE-
LCD-DISPLAY process begins by ensuring that gas is

flowing before welding starts. The time
G0 T01 P1
I-IGNITION:
EDITMODE
400A
G0 T01 P1
ARC-RELAY:
EDITMODE
YES
between opening the gas valve and
T-IGN.PULSE:
VOLT.DROP:
8.0ms
4.92V/100A
FAST ARCRELAY:
VOLT.DROP:
NO
AUTO igniting the arc can be set by means of
STARTFILTER: 2.00s MOTOR1/2: MOT1
ARC-OBSERVAT:
ARC_FILTER:
HALT
1.00s
mm/inch: -mm- the gas pre-flow time.
P1 -PAUSE- P1 -PAUSE-
6.4-10 START program key Wirefeed1:
Wire speed during the START program.
Uweld:
Voltage setpoint during the START
program.
Prog-Timer:
Duration of the START program after ignition in order to stabilise the arc.
The wire is initially fed in at Wirefeed1 and is then ramped up to the wire feed
speed settings for the selected welding program over the time Prog-Timer.
Next program:
The program, which is executed after the START program. If Next program = 0, the next
program is specified externally.
Values from 0-8 can be entered here. Program 7 is the FILL program, and
Program 8 the END program. If 5 or 6 is set as the next program, the control
system will indicate Alarm 93 (invalid program) when the program is executed.
These values should NOT be set.
55
V_Weld:
Proposed welding speed for the robot (TCP speed) for the synchro weld function.
Currently the Synchroweld function is only possible in combination with the NX100
control from Motoman Yaskawa. More information about Synchroweld can be found at
www.synchroweld.de and www.synchroweld.com or you can request this directly from
us.
Base time (T-base):

Duration of the base current in the U-pulse and KF-pulse process (cf. Chapter 3, Page
24 and 25).
Work area:
The KF-pulse process uses a characteristic field (work area) in order to achieve a better
short-circuit behaviour. The characteristic of the power source changes at the
boundaries of the characteristic field in order to cleanly resolve a short circuit. The
boundary of the characteristic field can be reduced in order to reduce spatter in the
event of a short circuit. In doing so, however, it should be noted that the process will be
destabilised if the working area is restricted too much (cf. Chapter 3, Page 25).
GTAW/E-current:
Setting for the current in the tungsten electrode.
UP-Slope:
With the GTAW-DC process, it is sensible to limit the rate of rise of current in order to
prevent damage to the weld pool. The duration of the transition between the starting
current and the electrode current can be adjusted.
2. Page:
I-ignition:
The current for the start pulse can be set here.
T-ign.pulse:
The length of the start pulse can be set here.
Volt drop:
In order to stabilise the welding process, the welding voltage is reduced with increasing
welding current. The volt drop characteristic determines by how much the voltage is to
reduce for an increase in current of 100 A. An automatic preset can be selected.
Startfilter:
If an arc has not been established within the time specified by 'Startfilter', the starting
process is terminated and an alarm message is output.
56
Arc-observat:
The welding system is able to detect a break in the arc. If "YES" is selected, then the
welding process will be stopped if an arc break is detected. If the setting is "NO", only
an alarm will be output.
Arc_filter:
A filter is incorporated to prevent transient arc faults from immediately initiating an
alarm. This parameter determines the minimum time that a fault must be present in
order to initiate an alarm.
Pulsecurrent:
Pulse current setting for the I-pulse process (cf. Chapter 3, Page 23).
Pulse-voltage:
Pulse voltage setting for the U- and KF-pulse processes (cf. Chapter 3, Page 24)
Pulse-timer:
Length of the pulses in the I-, U- and KF-pulse processes (cf. Chapter 3, Pages 24 ff).
Basecurrent (I-base):
Magnitude of the current outside the pulse time in the I-, U- and KF-pulse processes (cf.
Chapter 3, Pages 24 ff).
Puls-Upslope:
The transition from the base current to the pulse current is controlled by an e-function.
The rate of rise coefficient is automatically preset and can be adjusted manually. Larger
values accelerate the rate of rise (cf. Chapter 3, Pages 24 ff).
Puls-Downslope:
The transition from the pulse current to the base current is controlled by an e-function.
The rate of decay coefficient is automatically preset and can be adjusted manually.
Larger values accelerate the rate of decay (cf. Chapter 3, Pages 24 ff).
Workarea-dynamic:
The dynamic behaviour of the power source can be affected by the "Workarea-dynamic"
parameter. The characteristic field is modified under the control of a timer. This
achieves a good bridging of the gap by controlled variation of the arc length.
3. Page:
Arc-relay ("current flowing" signal)

Setting for whether the enable signal is transmitted to the robot as soon as the arc is
stable.
Fast arcrelay:
57
The transmission of the enable signal can be brought forward with the YES setting,
even when all start conditions have not yet been fulfilled.
Volt drop auto (DV) or manual

Switches the automatic preset for the characteristic on or off (cf. "Volt drop" when
STARTing on the second page).
Motor1/2:
Selection of the wire feeder, which is controlled by this Q4. For systems with one wire
feeder, this is always MOT1.
mm/Zoll:
Changeover of the units of measurement between the metric and imperial system.
In modes
Analog-output: (in TIMER mode only)

The Q4 system has an analogue output, which can be set in the programmes. Its main
use is to set the welding speed for different applications. You can define the polarity and
the 100% value at the interface.
P2
Keys P2 to P4 on the program block are used to navigate to the welding program pages
The individual content of these pages may vary depending on the design of the system
and the selected welding process. This is an overview of the usual settings:
1. Page:
Wirefeed1:
Wire speed for this program.
WIREFEED1 5.0m/min
START P2 P3 P4 Uweld 22.6V 0.0V
CURRENT-PRV: 180A
VOLT.DROP: 4.92V/100A
FILL END P1 -PAUSE-

Uweld:
LCD-DISPLAY Welding voltage setpoint for this
program.
G0 T01 P2 EDITMODE G0 T01 P2 EDITMODE
ARC-OBSERVAT: YES ARC-RELAY: YES
ARC_FILTER:
CURR.WINDOW:
0.60s
0A
ACO-OBSERVAT:
ACO-INTERRUPT:
YES
HALT Current-prv:
MOTOROBSERVAT: YES AUTOCOMP-LIMIT: 3.0V
MOTOR-LIMIT
MOTOR_FILTER:
2.0A
2.00s
AUTOCOMP-FILT: 0.20s Expected value for the current. This is
P1 -PAUSE-
LCD-DISPLAY
P1 -PAUSE-
LCD-DISPLAY
purely an information field. It is not
6.4-11 Program keys P2-P4 possible to enter a current at this point.
58
V_Weld:
Proposed welding speed for the robot (TCP speed) for the synchro weld function.
www.synchroweld.de and www.synchroweld.com or you can request this directly from
us.
Volt drop:
In order to stabilise the welding process, the welding voltage is reduced with increasing
welding current. The volt drop characteristic determines by how much the voltage is to
reduce for an increase in current of 100 A. An automatic preset can be selected.
Work area:
The KF-pulse process uses a characteristic field (work area) in order to achieve a better
short-circuit behaviour. The characteristic of the power source changes at the
boundaries of the characteristic field in order to cleanly resolve a short circuit. The
boundary of the characteristic field can be reduced in order to reduce spatter in the
event of a short circuit. In doing so, however, it should be noted that the process will be
destabilised if the working area is restricted too much (cf. Chapter 3, Page 25).
Pulsecurrent:
Pulse current setting for the I-pulse process (cf. Chapter 3, Page 23).
Pulse-voltage:
Pulse voltage setting for the U- and KF-pulse processes (cf. Chapter 3, Page 24).
Pulse-timer:
Length of the pulses in the I-, U- and KF-pulse processes (cf. Chapter 3, Pages 23 ff).
Basecurrent (I-base):
Magnitude of the current outside the pulse time in the I-, U- and KF-pulse processes (cf.
Chapter 3, Pages 23 ff).
Base time (T-base):

Duration of the base current in the U-pulse and KF-pulse process (cf. Chapter 3, Page
24 ff).
Prog-Timer: (in TIMER mode only)

Duration of welding program. The system switches to the "Next program" when the time
has expired.
Next program: (in TIMER mode only)

Welding program, which is executed at the end of the current program. The building of
loops is possible.
59
Values from 0-8 can be entered here. Program 7 is the FILL program, and
Program 8 the END program. If 5 or 6 is set as the next program, the control
system will indicate Alarm 93 (invalid program) when the program is executed.
These values should NOT be set.
GTAW/E-current:
Setting for the current in the tungsten electrode.
UP/DOWN-Slope:
With the GTAW-DC process, it is sensible to limit the rate of change of current in order
to prevent damage to the weld pool. The duration of the transition between the
electrode currents in the individual welding programs can be adjusted.
2. Page:
Arc-observat:
The welding system is able to detect a break in the arc. If "YES" is selected, then the
welding process will be stopped if an arc break is detected. If the setting is "NO", only
an alarm will be output.
Arc_filter:
A filter is incorporated to prevent transient arc faults from immediately initiating an
alarm. This parameter determines the minimum time that a fault must be present in
order to initiate an alarm. The filter is also used for filtering the value of current used for
the "current range" and "window width" settings (see following items).
60
Current window (welding current monitoring)
The Q4provides a facility for monitoring the

current during the welding process. A suitable
mean value for the expected welding current can
be determined from welding tests. This mean
value can now be entered under the "Current
window" value. An appropriate window width must
be entered in the "END program" (cf. "Width
window" Page 61). The window width (specified in
6.4-12 Example of measurement recording
%
of the “Current window” value now specifies a
range around the “Current window” value. If the
welding current exceeds or falls below the limits
of this range, then the welding process is stopped
and an alarm message is output.
Example: Test welding gives a mean value of

158A.
Current window: 158A
Width window: 8% Æ ±12A
Æ (An alarm is output and welding stopped at
values of current below 146A or above 170A.
6.4-13 Mean value and window width
The monitoring function is also filtered with an arc filter to prevent minor disturbances
and current peaks from interrupting the welding process. The current window monitoring
can be deactivated by entering "0%" for the window width.
Motorobservat:
The current of the wire feeder motor can be monitored in order to detect problems with
the wire feed. The monitoring is activated with "YES" and deactivated with "NO".
Motor-Limit:
If the measured motor current exceeds the set limit, an alarm message is output at the
end of the welding process.
Motor_Filter:
The monitoring is filtered to ensure that minor disturbances do not initiate an alarm.
"Motor_filter" specifies how long the motor current must exceed the limit in order for an
alarm to be output.
3. Page:
Arc-relay:
You can specify whether the "Arc-relay" signal is sent to the robot or PLC in each
program.
61
Aco-observat:
In the GMAW and I-pulse processes, the autocompensation function automatically
controls the welding voltage when the distance between the torch and the component
changes. This automatic welding voltage correction can be monitored by entering
"YES".
ACO-interrupt:
This can be used to specify how the Q4 responds to the set autocompensation limit
being exceeded (see "Autocomp-limit").
HALT stops the welding process and outputs an alarm message.
INFO outputs an alarm message at the end of the weld; the welding process is not
stopped.
Autocomp-Limit:
As it is only appropriate to control the welding voltage within certain limits, it is possible
to enter a maximum permissible value of voltage for the automatic welding voltage
correction. If this value is exceeded, the actions specified in "ACO-interrupt" are taken.
Autocomp-Filt:
The monitoring is filtered to ensure that minor disturbances do not initiate an alarm.
This parameter specifies how long the autocompensation limit has to be exceeded in
order to initiate a response.
Analog-output: (in TIMER mode only)

The Q4 system has an analogue output, which can be set in the programmes. Its main
use is to set the welding speed for different applications. You can define the polarity and
the 100% value at the interface.
62
END
The "END" key ' gives you access to 4 pages in the END program. In the End program
are the parameters for completing the welding seam, as well as general entries for the
file number (applicable to all welding programs P2-P4). The individual content of these
pages may vary depending on the design of the system and the selected welding
process. This is an overview of the usual settings:
1. Page:
Endfilling (P7):
If an end crater is to be filled, a value
ENDFILLING(P7)l: 0
START P2 P3 P4 BURNBACK: 2.0mm
T-ENDPULS:
ENDPULS-CURR:
2.2ms
370A between 1 and 5 must be entered here. The
GASPOSTFLOW: 0.20s
FILL END
TESTFEED:
P1 -PAUSE-
5.0m/min larger the value, the slower the reduction to
LCD-DISPLAY the parameters of the FILL program. The
crater is filled using the FILL program.
G0 T01 P8
ARC-RELAY:
EDITMODE
NO
G0 T01 P8
mm/inch:
EDITMODE
-mm- Entering “0” disables this function.
ALARM TIMER: 2.00s LIFT STICK? OFF 6.4-15 Endfilling
WATERPUMP: OFF E_FUNCTION: ON
GAS-OBSERVAT: YES POWER START: OFF
LIFT TO START: OFF
GASFLOW 8.0l/min
P1 -PAUSE- m/min
PROGRAM (ROBOT): 3
P1 -PAUSE- Welding off
Parameters
P2-P6
Slope 1-5
G0 T01 P8 EDITMODE
WIDTH WINDOW: 0.0%
*COM PROTOCOL: PRO2
WK5 STATUS: 0.0A F0
SYNCHROWELD: OFF
Parameter
P7
P1 -PAUSE-
LCD-DISPLAY
6.4-14 END program key Duration (P7) t
P2-P6 P7
Gaspostflow:
The gas valve can remain open for a short
time at the end of the welding process in
order to maintain gas protection of the still
hot weld pool crater and wire end. The
length of the gas post-flow can be set here.
63
Burnback:
Up to Q8p(t/w) firmware 6.43:
Specifies the amount by which the wire is burnt back at the end of the weld.
In GTAW welding processes with cold wire feed, the wire is retracted by this amount at
the end of the weld.
From Q8p(t/w) firmware 6.44 onwards:

Burn-back has no effect.
With the setting LIFT-STICK: Enter the retraction length at the end of the weld.
See also Lift-Stick Page 66
T-Endpuls:
An end pulse is used to release the last drops adhering to the wire at the end of the
weld. Pulse height is automatically preset, but can be changed manually.
From Q8p(t/w) firmware 6.44 onwards an optimised end routine is used. As all
parameters are set automatically in this case, this setting has no effect.
Endpuls-Curr:
The magnitude of the end pulse current is automatically preset, but can be changed
manually here. The pulse current is used automatically in pulse processes.
From Q8p(t/w) firmware 6.44 onwards an optimised end routine is used. As all
parameters are set automatically in this case, this setting has no effect.
Testfeed:
As standard, the new welding wire is threaded into the cable assembly at 5 m/min. The
value can be reduced here for particularly sensitive wires.
DOWN-Slope:
With the GTAW-DC process, it is sensible to limit the rate of decay of current in order to
prevent damage to the weld pool. The duration of the transition between the electrode
current of the last welding program and the switch-off current can be adjusted.
Sw.off current:
At the end of the welding process, the current is reduced to the switch-off current over
the time set in DOWN-Slope, and then switched off.
2. Page:
Arc-relay:
You can specify whether the "Arc-relay" signal is sent to the robot or PLC in each
program. As the robot/PLC is normally stationary in the end program, "NO" is the default
value here (robot is not enabled).
64
Alarm timer:
Time for which the fault relay is set in the case of an alarm.
Waterpump:
In water-cooled processes, this activates the external water pump (circulating air cooler,
coolant recooler) and the water flow monitoring.
Gas-observat:
If a gas monitoring device is connected (e.g. gas pressure switch) then this signal (Gas
OK or Gas not OK) can be monitored. You will find more information on connecting gas
monitoring devices in the Appendix relating to your wire feeder in the description of the
motor card.
Gasflow:
This function is currently inactive.
Program (Robot): (in EXTERNAL mode only)

Indicates the program currently selected by the robot/PLC (group and file number are
not displayed). This is helpful when setting up to see which parameters on the current
component are assigned to a welding seam.
Analog-pause: (in TIMER mode only)

The value of the analogue output when no welding program is active can be set here.
3. Page:
mm/Zoll:
Changeover of the units of measurement between the metric and imperial system.
65
Lift-Stick:
The welding wire is retracted from the welding pool in a controlled manner at the end of
the weld using the “Lift Stick” function. This function can be executed instead of a burn
back. The retraction length can be set under the Burnback parameter.
From Q8p(t/w) firmware 6.44 onwards the end routine has been optimised. This
requires retracting the wire from the welding pool. For this reason this function should,
as a general rule, be activated as of firmware 6.44.
E_function:
This function changes the dynamic behaviour of the power source for the GMAW and
GMAW/CO2 welding processes. The values for the PULSE-UPSLOPE and PULSE-
DOWNSLOPE from the END program are used instead of the default values.
Activating this function requires expert knowledge!
Activation changes the welding characteristics with sustained effect.
This function should only be activated by SKS personnel.
Wire cleaning:
Soiled components and the use of welding gases with a high CO2 content can lead to
an increase in the build up of silicate on the end of the wire, this in turn leads to ignition
spatter. The silicate deposits on the end of the wire can be removed during the start
using the wire cleaning function. This is achieved before welding starts by means of the
wire being fed in until it collides with the component, this collision blasts off the silicate
deposit.
This facilitates a reduction of the ignition spatter but the cycle time is increased.
Lift to Start:
Aluminium wires in particular ignite unreliably when they are in firm contact with the
material before ignition. "Lift to Start" automatically lifts the wire off the component
before ignition.
66
4. Page:
Window width:
The percentage range for the current window is entered here (cf. "Current window"
Page 61). The welding current monitoring limits are calculated as follows:
Minimum current = Current window – (Current window*Window width)
Maximum current = Current window + (Current window*Window width)
The welding current monitoring is deactivated by setting "0%".
*COM protocol:
The transmission protocol for communication between the Q4 and a PC can be
switched between "PRO2" (Protocol 2) and "STD". Protocol 2 should be used as
standard. The older STD protocol (standard) is only appropriate in exceptional cases.
WK5 status:
Display for the instantaneous current consumption of the water pump motor and the
level in the WK5. The level is divided into three different status values:
F0 (Minimum amount not reached) F1 (Amount of water OK) F2 (Maximum level)
Synchroweld:
www.synchroweld.de or www.synchroweld.com
We would be glad to send you more information about the benefits of Synchroweld or to
inform you personally.
.
This function MUST be deactivated in systems that are not equipped for
Synchroweld!
Activating Synchroweld without the appropriate system requirements will
lead to welds with substantially lower capacity!
6.4.4 Key switch
ON
125
OFF
Keylock
6.4-16 Key switch
67
The key switch locks the + and – keys. All display functions are retained without
limitation.
6.5 The Q8-Tool4 system software

The Q8 Tool4 software is suitable and designed exclusively for the Q4, Q6p, Q8p(t/w)
and Q8i welding controllers. Q8Tool4 provides online working with controllers as well as
offline management with a PC.
Individual welding jobs and complete control jobs can be created and managed using
the software.
The integral measurement and storage facility enables welding jobs to be documented,
with the option of continuous recording of complete series of measurements.
Alarm message recording and evaluation speeds up fault-finding and ensures smooth
production.
The Q8Tool4 software accesses the Q4 control via the USB interface.
Q8Tool4 manages the following jobs:

• Creating, editing and storing of Q8/Q6/Q4 controllers.
• Creating, editing and storing of welding jobs in individual part numbers (files).
• Creating alias names for the gases used
• Managing Q8/Q6/Q4 controllers and file numbers in a database on the hard disk
of a PC and on networks.
• Import/Export of data
The user interface of Q8Tool4 is designed in a similar way to Windows Explorer, and
appears as follows:
Main menu
Symbol bar
Tree view
Workingspace
Status bar
6.5-1 Q8Tool4-Program Interface
The program area is divided into several sub-areas, which are designated as main
menu, symbol bar, tree view, workspace, and status bar.
68
To be able to work effectively with Q8Tool4, you should be familiar with the
basic functions of Windows-based programs and how to use them.
Details of software, operation and settings are given in the individual manual
"Q8Tool4" which is part of the delivery of the Q4 robot welding system.
69
7 Shutting down the Q4 robot welding system
7 Shutting down the Q4 robot welding system

When you have finished welding, you can switch off the system. Make sure that you
also switch off the power source and the gas supply.
70
8 Maintenance and care of the Q4 robot welding system
8.1 Power source

Under normal working conditions the individual components are almost maintenance-
free and require just a minimum of care. However, some points should be observed in
order to ensure trouble-free operation of the equipment. This includes regular cleaning
and checking as described below, depending on the degree of ambient pollution and the
operating time of the equipment components.
8.1 Power source

The cleaning, checking, and repairing of welding units must
only be carried out by trained personnel. If one of the tests
below is not passed, the unit must not be operated until the
defect is repaired. Cleaning
Electrical voltage!
Attend to the individual assemblies as follows:

• Power source: REMOVE MAINS PLUG FROM SOCKET OUTLET! Blow-out
the power source with compressed air (oil and water free), depending on amount
of dust.
• Do not blow out electronics, printed circuit boards or electronic components with
compressed air. Use a vacuum cleaner.
8.1.1 Retesting in accordance with VDE 0702 and BGV D1 (formerly VBG
15)
The following description of the retest is only an excerpt from the detailed
test instruction. This can be obtained from SKS on request.
We recommend that you carry out a quarterly and a yearly check. The yearly check
must also be carried out after each repair. Checking sequence:
Quarterly check:
• Visual inspection to ascertain that the equipment is in good condition
• Measurement of earth cable resistance
71
8.1 Power source
Yearly check:
• Visual inspection to ascertain that the equipment is in good condition
• Measurement of earth cable resistance
• Measurement of insulation resistance after internal cleaning of the welding power
source
• Measurement of open circuit voltage
• Functional check of the welding machine
Visual inspection to ascertain that the equipment is in good condition

The unit is inspected for externally visible defects (without opening the unit). In doing so,
attention must be paid to the following:
External damage to mains plug and mains cable, e.g. insulation faults, scorching or
pressure marks.
Defective bending protection and strain relief of the mains cable and mains switch.
Faults in welding cables, cable assembly, plug connectors, torch.
Signs of overload and improper use.
Damage to the lifting points and housing.
Unauthorised interference and modifications.
Nameplate and warning symbol are present and legible.
Measurement of earth cable resistance

Measure between earth contact of mains plug and touchable metal parts, e.g. housing
screws.
During measurement, move the mains cable of the unit along its entire length,
especially in the vicinity of the connecting points.
The resistance must be < 0.1Ω. Carry out the measurement with at least 200 mA.
Measurement of insulation resistance

The unit must not be connected to the mains supply!
Open welding unit and clean carefully (as described above).
Turn mains switch to 'ON'.
• Insulation resistance, mains circuit - housing: Measure between one contact
of the mains plug and the housing. The resistance must be > 2.5MΩ.
• Insulation resistance, welding circuit - housing: Measure between a welding
socket and the earth lead. The resistance must be > 2.5MΩ.
• Insulation resistance, mains circuit - welding circuit: Measure between one
contact of the mains plug and a welding socket. The resistance must be >
5.0MΩ.
72
8.2 Wire feeder
Measurement of open circuit voltage (to EN 60974-1 / VDE 0544 Part 1)

Diode similar to 1N4007
Connect the measuring circuit shown in
Figure 1 to the welding current sockets.
The voltmeter must show the mean value.
Input During measurement, adjust the
potentiometer from 0kΩ to 5kΩ.
The measured voltage must not deviate
from the figure shown on the rating plate
(U0) by more than 10%.
8.1-1 Circuit for measuring peak values
Functional check of the welding machine

Carry out a functional check appropriate to the type of machine.
Repair work
Repair and maintenance work must only be carried out by trained specialists. As a basic
principle, contact your dealer for all matters relating to service. Components can only be
returned under guarantee via your local supplier.
When replacing parts, use only genuine spare parts.
When ordering spare parts, you must indicate the type of unit, serial number and item
number of the unit, and the type description and item number of the spare part.
If repair or maintenance work is carried out on this unit by persons who are not trained
and not authorized for such work, the guarantee will become void.
8.2 Wire feeder

8.2.1 Centre guide
Ensure that the centre guide is properly installed. The funnel-shaped opening should
point towards to the wire-inlet, and the tip towards the central connector.
8.2.2 Capillary tube

• The capillary tube is specially designed to suit the wire feeder and the central
connector.
• Use only SKS genuine spare parts. Otherwise considerable disruption may occur
to the wire feed.
• Please indicate with your order the torch type for which the capillary tube is
intended (TOUGH GUN / DINSE / BINZEL).
Caution! The capillary tube must not touch the drive rollers!
73
8.2 Wire feeder
8.2.3 Adjusting the water monitor

The water monitor is set in the factory to 0.3 l/min.
If the Q4 message "Lack of Water" appears, one of the following may be the cause:
¾ Water tank in the cooling unit is empty

¾ Water pump defective
¾ Water hose kinked
¾ Welding torch does not admit sufficient water.
In this case, the welding torch must be replaced.
! Do not carry out adjustments to or bypass the water monitor!
74
8.2 Wire feeder
8.2.4 Checking the water flow

Depending on the length of the intermediate hose package, the water pump delivers
1 – 1.5 l/min of cooling water to the wire feeder (water flow, blue).
After the water has passed through the welding torch (water return, red), the flow must
not drop below 0.7 l/min, as otherwise the water pump will be overloaded.
!!! In this case, the guarantee for the water pump will become void!!!
To calculate the flow, you will need a tank of a known volume and a clock with seconds
indicator (see sketch below).
1. Switch off the power source.

2. Pull off the water pre-flow hose (blue) from the wire feeder and hold it above the
tank.
3. Switch on the power source.
4. Stop the timer when the tank is full.
5. Then switch off the power source once more.
6. Calculate the water flow using the following formula.
Q = 60 V / t
Q = Water flow in l/min

V = Volume of tank in l
t = Time taken to fill tank in s
7. Insert the hose into the quick-release coupling and repeat the procedure with the
water return (red).
1l 1l
SKS
2. Check water postflow (red), 1. Check water preflow (blue),

min. 0.7 l/min min. 1-1.5 l
8.2-1 Water flow test
75
8.2 Wire feeder
8.2.5 Cleaning
The welding units are extensively maintenance free. However, depending on the
accumulation of dirt but at least every three months, clean the unit as described below
and carry out a visual inspection.
Electrical voltage!
Remove both side walls.

Check the tightness of all screwed and clamped connections and carry out a visual
inspection.
Have a specialist investigate and remove scorched parts.
Be sure to remove any remains of wire in the case; risk of short-circuit!
Have defective cables changed.
Check drive and pressure rollers for wear, especially the V-groove of drive rollers.
Have defective drive rollers and bearings replaced.
Replace wire feed hoses and liners regularly.
Cable assembly:
Check wire guide regularly (e.g.: when replacing spools).
Watch for a gradual increase in motor current consumption or a reduction of free
movement (Q4 display). Replace liners, blow out wire feed hose.
Avoid loops and sharp bends etc.
Wire feeder
Depending on degree of contamination, blow out housing and four-roller drive with
oil- and water-free compressed air.
Electronics, printed circuit boards

Do not blow out electronic components with a compressed air jet. Use a vacuum
cleaner.
Water cooler
Use only tap water without addition of cooling agents (in temperature controlled
rooms).
Check level (1x per day).
Replace depending on degree of contamination.
76
8.2 Wire feeder
8.2.6 Repair work

¾ Repair and maintenance work must only be carried out by trained specialists.
o Contact your dealer.
o When replacing parts, use only genuine spare parts.
o When ordering spare parts, you must indicate the type of unit, serial number and
item number, and the type description and item number of the spare part.
o If repair or maintenance work is carried out on this unit by persons who are
not trained and not authorised for such work, the guarantee will become void.
¾ Any interference with or alteration to the unit will result in the guarantee
becoming void.
8.2.7 Displays of the firmware versions

After the welding system has been switched on the system status is determined. All
connected components are readout and tested and your firmware version is readout.
This takes place while the display of the Q4 is built up from the middle of the screen
outwards (the process can be compared to the opening of a curtain).
The firmware versions can be displayed by pressing the START key immediately after
the build-up of the display is completed on the screen.
Now the firmware statuses for all connected components are displayed (VX.XX).
SYSTEM-INFORMATION:
---------------------------------------- Q4: 7701001 V6.45
MULTIPROCESS_Q4 WELDER: 1222263 V1.35
Version: 6.25 FEEDER1: 231255 V1.09
Leipold + CO GmbH 2002 FEEDER2:--------------
Im Vertrieb von SKS INTERF: 841263 V1.15
---------------------------------------- TIME 029F3DA0
AKTIVTIME 003BD02A
8.2-2 Build-up of the display after switching on (curtain)
8.2-3 Display of the firmware statuses of the SKS components
77
9 Transport and storage of the Q4 robot welding system
9 Transport and storage of the Q4 robot welding system

Keep the packaging safely. Ship the units in their original packaging only.
If the system is not put into operation immediately after delivery, the following points
must be observed:
¾ The Q4 system must be stored in a safe place.
¾ Protect the units against humidity, dirt, and metallic pollution.
If you should resell the power unit, please provide us with the name and postal address
of the new owner so that we can replace any chapters of the operating manual that may
have changed.
78
10 Data records stored in the Q4 on delivery
10 Data records stored in the Q4 on delivery

Group 0:
File Process Material Wire Inert gas
01 GMAW-M Steel 2-S 0.8mm Ar>9%CO2

02 I-pulse Steel 2-S 0.8mm Ar>9%CO2
07 GMAW-M Steel 1-L 1.2mm Ar>9%CO2
08 I-pulse Steel 1-L 1.2mm Ar>9%CO2
09 GMAW-M CrNi 2-S 0.8mm Ar<9%CO2
10 I-pulse CrNi 2-S 0.8mm Ar<9%CO2
15 GMAW-M CrNi 1-L 1.2mm Ar<9%CO2
16 I-pulse CrNi 1-L 1.2mm Ar<9%CO2
17 MIG Al 2-S 0.8mm Ar99.999%
18 I-pulse Al 2-S 0.8mm Ar99.999%
19 MIG Al 2-S 1.0mm Ar99.999%
20 I-pulse Al 2-S 1.0mm Ar99.999%
21 MIG Al 1-L 1.2mm Ar99.999%
22 I-pulse Al 1-L 1.2mm Ar99.999%
23 MIG Al 1-L 1.6mm Ar99.999%
24 I-pulse Al 1-L 1.6mm Ar99.999%
25 I-pulse CuSi 2-S 0.8mm Ar99.999%
26 I-pulse CuSi 2-S 1.0mm Ar99.999%
27 I-pulse CuSi 1-L 1.2mm Ar99.999%
28 ELECTRODE
29 ELECTRODE
30 TIG-DC Ar99.999%
31 TIG-DC Ar99.999%
79
11 ALARM CODE LIST
11 ALARM CODE LIST

The alarm codes are divided into groups according to their association:
ALARM 00... System configuration

ALARM 10... Gas, water, wire, cable
ALARM 20... Power source
ALARM 30... Welding process
ALARM 40... Messages for documentation
ALARM 50... Synchronisation PC <=> Q4
ALARM 60...
ALARM 70... Control system
ALARM 80... Wire feeders
ALARM 90... Interface
80
11 ALARM CODE LIST
Alarm Description Possible cause Remedy

No.
1 POWER SOURCE NOT SPW cable between power Check, rectify or replace
CONNECTED source and controller if necessary
Q350/351/500/501/1000 power
The control system is unit:
unable to find a power Board LTRDCx in power source
source. missing
Ribbon cable TRDC3/LTRDCx
Q420/421 power unit:
Cable BuBuCON/Q420H
2 WIRE FEEDER NOT SPW cable between power Check, rectify or replace
CONNECTED source and controller if necessary
Connection in wire feeder
The control system is Motor card not fitted in wire
unable to find a wire feeder
feeder. Wire feeder coding (master/slave)
incorrectly selected
Cable connection (Master/Slave)
incorrectly selected
3 CABLE or CABLING not SPW cable mechanically Check, rectify or replace
OK damaged if necessary
Connector mechanically
The control system has damaged
detected a defective SPW cable incorrectly connected
cable. to interface
7 THE CONTROLLER IS The controller has been changed Check, rectify or replace
NOT SUITABLE Data sets not stored properly if necessary
The controller and other

modules are not
compatible.
8 INTERFACE MISSING No interface connected Check, rectify or replace
Cable in cabinet not connected if necessary
The control system is correctly
unable to find an SPW cable to electrical cabinet
interface. missing
Especially with MASTER/SLAVE

systems:
MASTER not switched on
MASTER/SLAVE interchanged
Second cabinet cable missing
Synchronising cable missing
Direction of synchronising cable
wrong
81
11 ALARM CODE LIST

No.
9 CHANGE IN THE A module has been changed Check, rectify or replace
ENVIRONMENT without switching off if necessary
The cabling has been changed
The control system has without switching off
detected a new or SPW cable damaged
modified module.
Especially with MASTER/SLAVE
systems:
MASTER no longer switched on
MASTER/SLAVE cabling
changed
10 GAS SHORTAGE Gas bottle empty Check, rectify or replace
Gas feed interrupted if necessary
The GAS sensor Gas valve defective
indicates a lack of shield
gas. Especially with double-wire
systems:
Gas connected to wrong wire
feeder
11 LACK OF WATER Lack of cooling water Check, rectify or replace
Water circuit blocked if necessary
The WATER sensor Water circuit interrupted
indicates a cooling water Water pump defective
problem. The system has an air-cooled
torch
Especially with double-wire

systems:
Water connected to wrong wire
feeder
12 WIRE DIAMETER Output of power source is too low Check, rectify or replace
UNSUITABLE Configuration parameters for this if necessary
wire diameter missing
The selected wire
diameter cannot be
processed.
20 POWER SOURCE NOT Mains voltage incorrect Check, rectify or replace
READY One phase of supply missing if necessary
The mains voltage has been
The power source briefly interrupted
indicates a problem. Power unit defective

systems:
Doubler cable missing
Doubler cable mechanically
damaged
82
11 ALARM CODE LIST

No.
21 TEMPERATURE OF Air circulation obstructed Check, rectify or replace
POWER SOURCE - OR An unsuitable location has been if necessary
WIRE FEEDER - TOO chosen
HIGH Power source needs cleaning
Too high a load has been
The temperature probe in selected
the power source or wire Permissible duty cycle exceeded
feeder unit indicates that The temperature probe in the
the temperature is too power source or wire feeder unit
high. is defective.
Fans tripped or obstructed
22 POWER SOURCE Power source is not suitable Change power source
UPDATE REQUIRED Wrong welding process selected Upgrade power source
Do not use this welding
The selected welding process
process cannot be
carried out with this
power source.
23 SPECIAL EQUIPMENT Wrong welding process selected
"KF-PULSE" MISSING Power source is not suitable
Update the LTRDC 4
If you want to use the board in the power
"KF-PULSE" welding source
process you will need a
power source with a
special fitting.
24 GMAW SYSTEM Wrong welding process selected Check, rectify or replace
MISSING A GTAW power source is not if necessary
suitable
The controller needs a
GMAW power source to
carry out the selected
welding process.
25 GTAW or AC SYSTEM Wrong welding process selected Check, rectify or replace
MISSING A GMAW power source is not if necessary
suitable
The controller needs a
GTAW power source to
carry out the selected
welding process.
26 CURRENT SETPOINT Too high a setpoint has been Check, rectify or replace
TOO HIGH selected if necessary
The GTAW power source is not
The preset value of the suitable
welding current in the
welding data set is too
high for a GTAW system.
83
11 ALARM CODE LIST

No.
27 SLAVE CONTROLLER Controller missing Switch system off and on
NOT READY Synchronising cable missing again.
Data transmission from the slave
The welding data set controller has been deactivated
requires a slave with "P3"
controller. This is
missing.
28 CURRENT WINDOW Torch distance wrong Find and rectify
EXCEEDED Air gap on component mechanical fault
Shunt path on torch / cable
The welding current has assembly / wire feed
been outside the set
current window for longer
than the time set in "Arc
filter".
29 CURRENT WINDOW see ALARM 31
EXCEEDED DUE TO
WIRE FEED FAULT
The welding current has

been outside the set
current window for longer
than the time set in "Arc
filter" because the
welding wire could not be
transported correctly.
30 IGNITION TIME Earth cable not connected Check, rectify or replace
EXCEEDED Earth cable defective if necessary
Torch cable not connected
The arc could not be Torch cable defective
ignited within the time No welding wire
defined under "Start filter" Roller drive not closed
Washing residues on component
Attempt to ignite on the vitreous
coating of the previous seam
Especially in systems with large

spools:
Earth connection on large spool
Auxiliary drive of large spool
defective
84
11 ALARM CODE LIST

No.
31 WIRE FEED PROBLEM Wire liner blocked Check, rectify or replace
Brake on wire reel set too close if necessary
The welding wire cannot Wire reel sticking (jumping)
be fed in normally. The Wire has jumped out of guide
motor current upper limit
selected in "Motor limit" Especially in systems with large
has been exceeded for spools:
longer than the time Auxiliary drive of large spool
specified in "Motor filter".
defective
Large spool takes too long to
accelerate
Hose to wire feeder blocked
Hose to wire feeder not laid
correctly
Distance from wire feeder too
large
32 ARC FAILURE Wire spool empty Check, rectify or replace
The robot has strayed from its if necessary
The arc has extinguished path
for no apparent reason. No component has been inserted
The welding current has A hole has formed in the
been less than 10 A for component
longer than the time
specified in "Arc_filter". Especially with double-wire
systems:
One of the two wire spools is
empty
One wire cannot be transported
properly
One wire stuck in torch
33 ARC FAILURE DUE TO Wire spool empty Check, rectify or replace
WIRE FAULT Wire jamming or caught in reel. if necessary
The earlier ALARM 32 has been
The arc has extinguished ignored
due to a wire fault. The
welding current has been Especially with double-wire
less than 10 A for longer systems:
than the time specified in One of the two wire spools is
"Arc_filter". It had empty
previously been One wire cannot be transported
established that there properly
was a wire fault (see One wire stuck in torch
ALARM 31).
85
11 ALARM CODE LIST

No.
34 AUTOCOMP LIMIT Torch distance too great Check, rectify or replace
EXCEEDED Torch touching component if necessary
Shunt path on wire in transport
The automatic welding system
voltage correction The robot has strayed from its
(Autocomp) has path
exceeded the value No component has been inserted
specified in "Autocomp- A hole has formed in the
limit" for longer than the component
time specified in
"Autocomp-filter". Especially with double-wire
systems:
One of the two wire spools is
empty NOTE: The test voltage
One wire cannot be transported indicated on the
properly controller must always
One wire stuck in torch be greater than 15V.

spools:
Shunt path on large spool
Wire feed insulation defective
35 AUTOCOMP LIMIT ALARM 31 has been ignored Check, rectify or replace
EXCEEDED DUE TO Torch too close to component if necessary
WIRE FEED FAULT The robot has jammed the cable
assembly
The automatic welding Wrong contact nozzle in torch
voltage correction
(Autocomp) has Especially with double-wire
exceeded the value systems:
specified in "Autocomp- One of the two wire spools is
limit" for longer than the empty
time specified in One wire cannot be transported
"Autocomp-filter". properly
A wire feed problem was One wire stuck in torch
previously detected.
spools:
Large spool sticking
Insulation defective
86
11 ALARM CODE LIST

No.
36 AUTOCOMP LIMIT see ALARM 32 Check, rectify or replace
EXCEEDED DURING and see ALARM 34 if necessary
ARC FAILURE
As both events can occur
The automatic welding simultaneously, an unambiguous
voltage correction assessment is not possible.
(Autocomp) has
exceeded the value
specified in "Autocomp-
limit" for longer than the
time specified in
"Autocomp-filter". At the
same time, an arc-break
was detected.
37 AUTOCOMP LIMIT see ALARM 33 Check, rectify or replace
EXCEEDED and see ALARM 34 if necessary
- DURING ARC
FAILURE The event was initiated by the
- AFTER WIRE FEED wire feed problem.
PROBLEM Further unambiguous
assessment is not possible.
The automatic welding
voltage correction
(Autocomp) has
exceeded the value
specified in "Autocomp-
limit" for longer than the
time specified in
"Autocomp-filter".
Previously, a wire feed
fault had been detected,
which followed an arc
failure.
87
11 ALARM CODE LIST

No.
38 WIRE STUCK AT THE Shunt path on wire in transport Check, rectify or replace
END OF WELDING system if necessary
Torch touching part of clamp unit
The controller measures Wire in contact with component
too small a test voltage at Steel wool protruding from a
the end of welding. catalyser

systems:
One wire cannot be transported NOTE: The test voltage
properly indicated on the
Torch insulation defective controller must always
be greater than 15V.
spools:
Shunt path on large spool
Wire feed insulation defective
39 WIRE FEED PROBLEM (see also ALARM 31) Check, rectify or replace
(DOUBLE WIRE) if necessary
Single-sided wire feed fault
The welding wires cannot One wire stuck in contact nozzle
be fed in normally.
There is a difference of
more than 1 A between
the two motor currents,
which has been
exceeded for longer than
the time specified in
"Motor-filter".
40 START OF WELD ON A "Component counter" input is
NEW COMPONENT provided on the interface.
If this input is set by the robot
before the start of a weld, the Q4
controller indicates "ALARM 40"
for later evaluation on the PC.
If the robot only sets the signal on
the first seam of a component,
then later evaluations can be
carried out more easily.
41 SETPOINTS HAVE The Q4 controller can be pre-
BEEN CHANGED programmed so that manual
MANUALLY changes to welding parameter
setpoints are recorded as
"ALARM 41".
In this way, the PC can be used
later to evaluate when and how
which data were modified.
88
11 ALARM CODE LIST

No.
42 ROBOT SELECTS If the robot selects a program that Check, rectify or replace
WRONG PROGRAM does not exist in the Q4 if necessary
controller, "ALARM 42" is
displayed. Note:
The controller rejects the If the robot selects a
selection and continues welding wrong program before
with the previously selected starting welding,
program. "ALARM 93" is output
and welding is not
started.
43 ROBOT SELECTS If the robot selects a file or group Check, rectify or replace
WRONG FILE/GROUP that does not exist in the Q4 if necessary
controller, "ALARM 43" is
displayed. Note:
The controller rejects the The Q4 controller
selection and does not start. additionally discriminates
between the faulty
selection of a FILE
(ALARM 94) or GROUP
(ALARM 95).
44 USER HAS The Q4 controller has a memory
PERFORMED A for data backup
"BACKUP" (BACKUP/RESTORE).
If a backup is performed,
"ALARM 44" is recorded for later
evaluation on the PC.
45 USER HAS The Q4 controller has a memory
PERFORMED A for data backup
"RESTORE" (BACKUP/RESTORE).
If the setpoints are restored from
a data backup, "ALARM 45" is
recorded for later evaluation on
the PC.
46 UNKNOWN ERROR An update is required.
An alarm message is
generated, which is not
yet included in this list.
50 BASE DATA NOT YET Data missing from a new Load data from PC
LOADED controller Measure battery voltage:
Damaged data (e.g.: lightning Switch off controller
The control system has strike) - wait at least 1 min
established that data sets Backup battery failed - measure Ubatt > 2.65V
are missing or defective.
89
11 ALARM CODE LIST

No.
51 DATA CREATED WITH Data created using out of date Request a software
OUT OF DATE software update
SOFTWARE Damaged data (e.g.: lightning Reload the data
strike)
The control system has
established that data sets
are incomplete.
59 TRAP-ERROR GTAW high voltage ignition in the Switch off the system
vicinity Wait 5s
THE CONTROLLER Damaged data (e.g.: lightning Switch system on again
HAS ESTABLISHED strike)
THAT THE Replace the controller if
OPERATIONAL the message appears
SEQUENCE IS again immediately.
INCORRECT.
70 HEIGHT SENSING Use the correct controller
CONTROL MISSING
THE CONTROL
SYSTEM DOES NOT
SUPPORT HEIGHT
SENSING.
71 GMAW PROCESS Use the correct controller
CONTROL MISSING
THE CONTROL
SYSTEM DOES NOT
SUPPORT THE GMAW
PROCESS.
72 GTAW PROCESS Use the correct controller

CONTROL MISSING
THE CONTROL
SYSTEM DOES NOT
SUPPORT THE GTAW
PROCESS.
73 GTAW-AC PROCESS Use the correct controller
CONTROL MISSING
THE CONTROL
SYSTEM DOES NOT
SUPPORT THE GTAW-
AC WELDING
PROCESS.
90
11 ALARM CODE LIST

No.
80 UNSUITABLE WIRE Use the correct wire
FEEDER feeder
THE WIRE FEEDER IS

NOT SUITABLE FOR
THIS WELDING
SYSTEM.
81 WIRE FEEDER Use the correct wire
WITHOUT TACHO feeder
THE WIRE FEEDER IS

NOT SUITABLE FOR
THIS WELDING
SYSTEM.
82 OBSOLETE WIRE Load new software
FEEDER (Motor4/5)
Replace motor card (all
THE WIRE FEEDER others)
DOES NOT HAVE ALL
THE REQUIRED
CHARACTERISTICS.
83 GMAW WIRE FEEDER Set coding switch
MISSING correctly (Motor4/5)
Use the correct wire
THE WIRE FEEDER IS feeder
NOT SUITABLE FOR Replace motor card
GMAW WELDING
SYSTEMS.
84 GTAW WIRE FEEDER Set coding switch
MISSING correctly (Motor5)
THE WIRE FEEDER IS feeder
NOT SUITABLE FOR Replace motor card
GTAW WELDING
SYSTEMS.
85 SECOND WIRE The "MASTER" wire feeder is not See: ALARM 02.
FEEDER MISSING suitable for double-wire welding
processes.
THE CONTROL
SYSTEM IS UNABLE TO
FIND THE NECESSARY
SECOND WIRE
FEEDER.
91
11 ALARM CODE LIST

No.
86 DOUBLE-WIRE WIRE Set coding switch
FEEDER 1 MISSING correctly (Motor4/5)
feeder
Replace motor card
87 UNSUITABLE WIRE Use the correct wire
FEEDER 2 feeder
THE "SLAVE" WIRE

FEEDER IS NOT
SUITABLE FOR THIS
WELDING SYSTEM.
88 DOUBLE-WIRE WIRE Set coding switch
FEEDER 2 MISSING correctly (Motor4/5)
THE "SLAVE" WIRE feeder
FEEDER IS NOT Replace motor card
SUITABLE FOR
DOUBLE-WIRE
WELDING SYSTEMS.
90 LSP INTERFACE Set up interface correctly
REQUIRED (UNI5)
Use correct interface
THE DATA SET
REQUIRES AN LSP
INTERFACE. A PGM
INTERFACE HAS BEEN
CONNECTED INSTEAD.
91 PGM INTERFACE Set up interface correctly
REQUIRED (UNI5)
THE DATA SET
REQUIRES A PGM
INTERFACE. AN LSP
INTERFACE HAS BEEN
CONNECTED INSTEAD.
92 ANGLE TRANSMITTER Set up interface correctly
INTERFACE REQUIRED (UNI5)
THE DATA SET
REQUIRES AN ANGLE
TRANSMITTER
INTERFACE. A
PGM/LSP INTERFACE
HAS BEEN
CONNECTED INSTEAD.
92
11 ALARM CODE LIST

No.
93 INVALID PROGRAM Load missing program
SELECTED from PC or add to Q4
Prevent selection
THE ROBOT/PLC HAS
SELECTED A WELDING
PROGRAM THAT DOES
NOT EXIST.
94 INVALID FILE NUMBER Load missing file number
SELECTED from PC or add to Q4
Prevent selection
THE ROBOT/PLC HAS
SELECTED A FILE
NUMBER THAT DOES
NOT EXIST.
95 INVALID GROUP Load missing group from
SELECTED the PC
Prevent selection
THE ROBOT/PLC HAS
SELECTED A GROUP
THAT DOES NOT
EXIST.
99 START SIGNAL Cancel start signal
PRESENT
THE ROBOT/PLC IS
STILL SENDING THE
START SIGNAL EVEN
THOUGH WELDING
HAS BEEN
AUTOMATICALLY
COMPLETED.
93
12 Index and table of figures

12.1 Index
Installating the interface ........................................... 37
B
Installing the welding torch ...................................... 35
bus connection ........................................................ 29 Intended use ........................................................ 8, 13
Interface................................................................... 28
C
I-pulse ...................................................................... 23
Cable length, maximum ........................................... 33
K
Cleaning ............................................................ 71, 76
Company-specific operating instruction manual ........ 6 KF-pulse .................................................................. 25
Confined rooms ....................................................... 31
L
Confirmation ............................................................ 97
Connecting the components .................................... 33 Liability....................................................................... 6
Copyright ................................................................... 8 Location ................................................................... 31
Current window........................................................ 61 LSQ 3 technical data ............................................... 22
Current window (welding current monitoring) .......... 61 LSQ 5 ...................................................................... 21
Cursor ...................................................................... 47
M
Customer service..................................................... 30
Magnetic fields ......................................................... 38
D
Mains connection ..................................................... 35
Data records on delivery .......................................... 79 Maintenance ............................................................ 71
DISPLAY key ........................................................... 48
N
Displays of the firmware versions ............................ 77
Navigation and status line........................................ 47
E
O
Electric shock .......................................................... 15
Electromagnetic compatibility .................................... 8 Operating conditions ................................................ 31
End program ............................................................ 63 Operating manual .................................................. 4, 7
Error code table ....................................................... 40 Operating modes ..................................................... 50
Error messages ....................................................... 40 EXTERNAL .......................................................... 50
TIMER .................................................................. 50
F
Operator guidance ................................................... 17
File number.............................................................. 44
P
G
Packaging ................................................................ 30
GMAW ..................................................................... 23 Personal protective equipment .................................. 6
Guarantee ................................................................. 6 Personnel .................................................................. 5
Program keys .......................................................... 54
H
Protective clothing ............................................. 14, 38
Handling instructions ................................................. 8
Q
Hazards ................................................................... 10
Heart pacemaker ..................................................... 12 Q4 control keys ........................................................ 47
Q4 controller ...................................................... 17, 45
I
Q4 displays .............................................................. 47
Ignition process ....................................................... 41 Q4 installation location............................................. 32
Import and export data ............................................ 68
94
12.1 Index
Q4 Operation ........................................................... 41 T
Q4 Process control .................................................. 20
Transport damage ................................................... 30
Q8 Tool4 Software ................................................... 68
Quarterly check ....................................................... 71 U
R Unauthorised conversion ......................................... 16

Universal interface ................................................... 28
Repair work ............................................................. 73
U-pulse .................................................................... 24
Retesting in accordance with VDE 0702 ................. 71
USB slave cable ...................................................... 34
S
W
Safety instructions ................................................... 38
Water flow................................................................ 75
Safety shutdown ...................................................... 34
Water monitor .......................................................... 74
Safety symbols ........................................................ 11
Welding data............................................................ 45
SELECT key ............................................................ 49
Welding power source ............................................. 21
Self test ................................................................... 39
Welding process monitoring .................................... 17
Selling the system ................................................... 30
Welding program ..................................................... 44
Shutting down .......................................................... 70
Welding programs ....................................... 17, 41, 58
SKS Welding Systems GmbH ........................... 4, 8, 9
Welding torch ........................................................... 35
SKS Welding Systems subsidiaries ......................... 30
Window width .......................................................... 67
SPW bus cable ........................................................ 29
Wire feed hose ........................................................ 35
SPW field bus .......................................................... 29
Wire feeder .............................................................. 34
SPW93 standard ..................................................... 18
wire feeders ............................................................. 27
SPW99 standard ..................................................... 18
Start program..................................................... 41, 55 Y
Storage .................................................................... 78
Yearly check ............................................................ 72
Switching on and testing .......................................... 39
system cable L-703 ................................................. 28
System components ................................................ 19
95
12.2 Table of figure
12.2 Table of figure
3.2-1 Overview of system components ...................................................................................................... 19

3.3-1 Q4 process controller, front view....................................................................................................... 20
3.3-2 LSQ 5 power source.......................................................................................................................... 21
3.3-3 I-pulse process schematic ................................................................................................................. 23
3.3-4 U-pulse process schematic ............................................................................................................... 24
3.3-5 KF-pulse process schematic ............................................................................................................. 25
3.3-6 Universal robot interface ................................................................................................................... 28
3.3-7 SPW bus connection ......................................................................................................................... 29
3.3-8 SPW bus cable L700 ......................................................................................................................... 29
5.2-1 SPW connection of components ....................................................................................................... 33
5.2-2 Set-up GMAW/Pulse ......................................................................................................................... 34
6.2-1 System properly installed .................................................................................................................. 39
6.2-2 System faulty ..................................................................................................................................... 39
6.3-1 Welding program - example .............................................................................................................. 41
6.3-2 Key selection ..................................................................................................................................... 41
6.3-3 START program ................................................................................................................................ 42
6.3-4 Welding program ............................................................................................................................... 42
6.3-5 END-Programm ................................................................................................................................. 43
6.3-6 FILL program ..................................................................................................................................... 43
6.3-7 Process sequence ............................................................................................................................. 44
6.3-8 Q4 display: File number .................................................................................................................... 44
6.3-9 File number - welding programs........................................................................................................ 44
6.3-10 31 file numbers ................................................................................................................................ 45
6.4-1 Front of Q4 ........................................................................................................................................ 46
6.4-2 Q4 display ......................................................................................................................................... 47
6.4-3 Cursor keys ....................................................................................................................................... 47
6.4-4 Program keys .................................................................................................................................... 48
6.4-5 Display key ........................................................................................................................................ 48
6.4-6PAR select key ................................................................................................................................... 49
6.4-7 Gas parameter groups ...................................................................................................................... 52
6.4-8 Special materials ............................................................................................................................... 53
6.4-9 Example of use of program keys....................................................................................................... 54
6.4-10 START program key........................................................................................................................ 55
6.4-11 Program keys P2-P4 ....................................................................................................................... 58
6.4-12 Example of measurement recording ............................................................................................... 61
6.4-13 Mean value and window width ........................................................................................................ 61
6.4-14 END program key ............................................................................................................................ 63
6.4-15 Endfilling .......................................................................................................................................... 63
6.4-16 Key switch ....................................................................................................................................... 67
6.5-1 Q8Tool4-Program Interface .............................................................................................................. 68
8.1-1 Circuit for measuring peak values ..................................................................................................... 73
8.2-1 Water flow test................................................................................................................................... 75
8.2-2 Build-up of the display after switching on (curtain) ........................................................................... 77
8.2-3 Display of the firmware statuses of the SKS components ................................................................ 77
96
13 Confirmation
13 Confirmation
I confirm that I have read and fully understood this operating manual:
Date Name
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97
Contents Appendix 1
A1. Power source LSQ5 2

A1.1. Technical data 2
A1.2. Mains voltage 3
A1.3. Programming/Setting up 3
A1.4. Displaying the current settings 3
A1.5. Changing the settings 4
A1.6. LED functions in welding mode 5
A1.7. LSQ5 alarms 6
A1.8. CSA Certificate 7
A1.9. EU Declaration of Conformity 8
A1 Power source LSQ5
A1.1 Technical data
A1. Power source LSQ5
Description Item number

DCT Power source Type LSQ5 77-1185-00
Housing revision1 Housing revision2
A1.1. Technical data

TECHNICAL DATA LSQ 5
Adjustment range:
Welding current / Welding voltage
GTAW 10 A / 10.4 V – 510 A / 30.4 V
GMAW 15 A / 14.8 V – 480 A / 38 V
Duty cycle at 40°C
Ambient temperature: 40% duty cycle 480 A
Duty cycle at 20°C
Ambient temperature: 40% duty cycle 500 A
Duty cycle 10 min (60%: 6min ON, 4min OFF)
No load voltage 70V
Mains voltage (tolerances) 3x400 V (-10%, +10%)
3x480 V (-10%, +10%)
Frequency 50/60 Hz
Mains fuse (slow-acting fuse) 35 A
Mains cable 4x4 mm²
Max. connected power 25.8 kVA
Recommended generator power 32 kVA
cosϕ / Efficiency >0.95 / 91%
Insulation class / Protection class H / IP23
Ambient temperature <45°C
Cooling Air
Workpiece cable 70 mm²
Dimensions L / W / H [mm] 450x400x540
Weight 49 kg
Manufacturing standards EN 60974 / IEC 60974 / VDE 0544
EN 50199 / VDE 0544 Part 206 /
SPW99
CE mark EN 60974 / IEC 60974 / VDE 0544
[S] mark EN 50199 / VDE 0544 Part 206
V1.3 A1-2
A1.2 Mains voltage
A1.2. Mains voltage

The permissible mains voltages are given by the respective nominal voltages ± 10%,
i.e. 360V – 440V for the 400V setting, and 432V – 528V for the 480V setting.
The mains voltage selector switch is safeguarded against accidental operation.
Never operate the mains selector switch when the unit is switched
on.
Before changing over the mains voltage, switch off the power source
and wait for 2 minutes.
Check that the voltage selector switch is set correctly and

appropriately before using the equipment.
If the power source is used on supplies with nominal voltages greater than 528V, a
series transformer must be used to reduce the input voltage to the power source.
Nominal voltage Series transformer Voltage selector switch setting

575V 3x575V Æ 3x 400V 400V
360V-435V --- 400V
436V-528V --- 480V
A1.3. Programming/Setting up
The LSQ5 service panel has 2 buttons (ENTER [ENT],
SELECT [SEL]), and 4 LEDs. The LEDs provide status
indication in welding mode, extended alarm indication,
and an indication of the current settings.
LED
A1.4. Displaying the current settings
• Switch off the power source
• Press and hold the [ENT] or [SEL] buttons and
switch on the power source
• The LEDs will now show the set value of each of the
Markers A to D for 1s.
Value of Marker = 1
Value of Marker = 2
Value of Marker = 3
Value of Marker = 4
Example: Programming 1.2.1.1 (single GTAW system with Q8p)
V1.3 A1-3
A1.5 Changing the settings
flashes (single system), then flashes (GTAW), then

(Q8p/LSP4) and finally (special OFF)
A1.5. Changing the settings

Op. panel
• Switch off the power source
• Press and hold the [ENT] and [SEL]
buttons
• Switch on the power source
• Press [SEL], [SEL], [ENT]
• The contents of Marker A are
displayed and can be changed by
pressing [SEL]. The value is stored by pressing [ENT].
Marker A=1 Single power source
Marker A=2 Master in a share power or double-wire system
Marker A=3 Slave in a share power or double-wire system
Master and slave must be identical power sources (LSQ4-LSQ4 or LSQ5-

LSQ5).
Share power and double-wire systems cannot be operated with LSQ4 and
LSQ5 together.
• The contents of Marker B are displayed and can be changed by pressing [SEL]. The
value is stored by pressing [ENT].
Marker B=1 GMAW or pulse process
Marker B=2 All GTAW processes
• The contents of Marker C are displayed and can be changed by pressing [SEL]. The
Marker C=1 The controller connected is Q8p or LSP4
Marker C=2 The controller connected is Q8i
Marker C=3 The controller connected is Q8
Marker C=4 The controller connected is LSP
• The contents of Marker D are displayed and can be changed by pressing [SEL]. The
Marker D is currently not used, and therefore only the setting Marker D = 1
(OFF) is possible.
• After setting Marker D, all LEDs go off and the selected programming is displayed
once more. The LSQ5 then switches to welding mode.
V1.3 A1-4
A1.6 LED functions in welding mode
A1.6. LED functions in welding mode
The LEDs fulfil two functions in welding mode.

• Status indication
If the LSQ5 is operating correctly in welding mode,
the instantaneous status of the LSQ5 can be seen
from the LEDs.
• Alarm indication
If a power-source-specific alarm should occur in
welding mode, then the alarm code is indicated by
means of the LEDs.
V1.3 A1-5
A1.7 LSQ5 alarms
A1.7. LSQ5 alarms
ALARM 101 Sensor fault or sensor defective

A defective sensor was detected when the power source was switched on.
The fault will bring up "ALARM 20".
Remedy: Switch controller off and on again. If the fault is then indicated
again, please contact customer service.
ALARM 102 Not currently used
ALARM 103 Marker C "SYSTEM" incorrectly set

The wrong transmission protocol between controller and power source has
been selected.
Remedy: Select Marker C appropriate to the controller used.
ALARM 104 STOP due to message in alarm buffer

The power source has detected a critical entry in the alarm buffer and will
therefore not start. The fault will bring up "ALARM 20".
ALARM 105 Marker A "STRUCTURE" not compatible

A "slave" controller is being used without a "master".
Remedy: Select Marker A accordingly.
V1.3 A1-6
A1.8 CSA Certificate
A1.8. CSA Certificate
V1.3 A1-7
A1.9 EU Declaration of Conformity
A1.9. EU Declaration of Conformity
EU – Konformitätserklärung
EU – conformity declaration
Déclaration de Conformité de U.E.
Name des Herstellers: Leipold+Co. GmbH
Name of manufacturer:
Nom du fabricant:
Anschrift des Herstellers: Kreuzwiese 12, D-67806 Rockenhausen

Address of manufacturer:
Adresse du fabricant
Hiermit erklären wir, dass das nächste- We herewith declare that the Par la présenté nous déclarons que
hend bezeichnete Gerät in seiner Kon- machine described below meets the la conception et la construction
zeption und Bauart sowie in der von standard safety regulations of the ainsi que le modèle, mis sur le
uns in Verkehr gebrachten Ausführung EU- guidelines mentioned below in marché par nous, de l'appareil
den grundlegenden Sicherheitsan- its conception and construction, as décrit ci - dessous correspondent
forderungen der unten genannten EG - well as in the design put into aux directives fondamentales de
Richtlinien entspricht. Im Falle von circulation by us. In case of sécurité de la U.E. mentionnees ci-
unbefugten Veränderungen, unsachge- unauthorized changes, improper dessous. En cas de changements
mäßen Reparaturen und / oder uner- repairs and / or unauthorized non autorisés, de réparations
laubten Umbauten, die nicht ausdrück- modifications, which have not been inadéquates et / pu de
lich von Leipold autorisiert sind, verliert expressly allowed by Leipold, this modifications prohibees, qui n´ont
diese Erklärung ihre Gültigkeit. declaration will lose its validity. pas été autorisés expressement
par Leipold, cette déclaration
devient caduque.
Gerätebezeichnung: Schweißstromquelle
Description of the machine: Welding power source
Déscription de la machine:
Gerätetyp: LSQ 5
Type of machine:
Type de machine:
Artikelnummer Leipold+Co.GmbH: 77.11.100

Article number:
Numéro d'article:
Seriennummer:
Serial number:
Numéro de série:
Optionen: keine
Options: none
Options:
Zutreffende EG – Richtlinien: EG – Niederspannungsrichtlinie (73/23/EWG)

Applicable EU – guidelines: EU – low voltage guideline
Directives de la U.E. applicables: Directive de la U.E. pour basses tensions
EG – EMV – Richtlinie (89/336/EWG)
EU – EMC guideline
U.E. – EMC directive
Angewandte harmonisierte Normen: EN 60974 / IEC 60974 / VDE 0544

Used co – ordinated norms: EN 50199 / VDE 0544 Teil 206
Normes harmonisées appliquées:
Hersteller – Unterschrift:
Signature of manufacturer:
Signature du fabricant:
V1.3 A1-8
Contents Appendix 2
A2. Universal interface UNI5A 2

A2.1. Key to configuration 2
A2.2. Signal-time diagrams 3
A2.3. Parameter selection 4
A2.3.1. Group selection 4
A2.3.2. File selection, binary (4111, 4211, 4411) 5
A2.3.3. File selection, analogue with binary tens digit (4441) 6
A2.3.4. File selection, analogue 0-12.4V (4451) 7
A2.3.5. File selection, analogue 0-9.3V (4461) 8
A2.3.6. Program selection, binary (4111) 9
A2.3.7. Program selection, digital (4211) 9
A2.3.8. Program selection, analogue (4411) (4441) 10
A2.4. Interrogating the system configuration 10
A2.5. Programming the UNI5 interface. 11
A2.6. "Delayed alarm" function 13
A2.6.1. Description: 13
A2.6.2. Operation 13
A2.6.3. Signal characteristics when Terminal 1 not used 14
A2.6.4. Signal characteristics when Terminal 1 used 15
A2.7. Circuit diagrams 16
A2.7.1. Schematic representation 16
A2.7.2. UNI 5A.4111 PLC, ABB, FANUC, KUKA binary 17
A2.7.3. UNI 5A.4111 Yaskawa XRC/NX100 binary (XIO02) 18
A2.7.4. UNI 5A.4111 XRC binary (MIO02) 19
A2.7.5. UNI 5A.4111 FANUC RJ3IC binary (negative logic) 20
A2.7.6. UNI 5A.4211 PLC digital program selection 21
A2.7.7. UNI 5A.4411 ABB analogue (S3) 22
A2.7.8. UNI 5A.4441 Yaskawa RX 23
A2.7.9. UNI 5A.4441 Yaskawa RG 24
A2.7.10. UNI 5A.4441 Yaskawa ERC 25
A2.7.11. UNI 5A.4451 Yaskawa MRC 26
A2.7.12. UNI 5A.4451 Yaskawa XRC analogue (XEW01-1) 27
A2.7.13. UNI 5A.4461 PLC analogue 28
A2.7.14. UNI 5A.4461 Fanuc (analogue) 29
A2 Universal interface UNI5A
A2.1 Key to configuration
A2. Universal interface UNI5A
Interface For robot controller Item number

UNI 5A.4111 PLC, ABB, FANUC, KUKA binary 77-8011-08
UNI 5A.4111 Yaskawa XRC/NX100 binary (XIO02) 77-8011-13
UNI 5A.4111 Yaskawa XRC (MIO02) 77-8011-06
UNI 5A.4111 FANUC RJ3IC binary (negative logic) 77-8001-84
UNI 5A.4211 PLC digital program selection 77-8011-14
UNI 5A.4411 ABB analogue (S3) 77-8011-08-01
UNI 5A.4441 Yaskawa RG 77-8011-08-02
UNI 5A.4441 Yaskawa RX 77-8011-08-03
UNI 5A.4441 Yaskawa ERC 77-8011-09
UNI 5A.4451 Yaskawa MRC + XRC (USA) analogue with wire 77-8011-02
retraction (MEW02-1)
UNI 5A.4451 Yaskawa XRC analogue (XEW01-1) 77-8011-03
UNI 5A.4461 FANUC (negative logic) 77-8001-82
UNI 5A.4461 PLC analogue 0...10 V with wire retraction 77-8011-08-04
Printed circuit board UNI4/5 SB ABB (Item No. 77-8001-81) should also be
used for ABB robots.
A2.1. Key to configuration

The configuration of the UNI5A interface consists of up to 4 digits.
e.g. 4 1 1 1
The two middle digits are definitive for use with a Q8p, i.e. as an interface with program
selection.
The individual figures have the following meaning:
Program selection File selection
1: Binary coded (p.A2-9) 1: Binary coded (p.A2-5)
2: Digitally coded (1 from 7) (p.A2-9) 4: Analogue 0-9V with binary tens digit (p.A2-6)
4: Analogue 7V=PGM7 (p.A2-10) 5: Analogue 0-12.4V (0.4V per file) (p.A2-7)
6: Analogue 0-9.3V (0.3V per file) (p.A2-8)
Example: UNI5A.4111 interface with
(binary program selection) and (binary file selection)
A2-2
A2.2 Signal-time diagrams
A2.2. Signal-time diagrams
Start
Release
Ready
Alarm
Cycle without alarm Cycle with alarm
Position Description
1 • PLC/robot sets welding "Start" signal.
• Arc is ignited.
2 Ignition process: Gas pre-flow → Wire feed → Ignition
3 • Arc established, "Release" relay is set.
• Welding process runs.
4 • PLC/robot resets welding "Start" signal.
• Arc is extinguished.
• "Release" relay is reset.
• Gas post-flow.
• Alarm-free welding cycle is complete.
5 • PLC/robot sets welding "Start" signal.
• Arc is ignited.
6 Ignition process: Gas pre-flow → Wire feed → Ignition
7 • Arc established, "Release" relay is set.
• Welding process runs.
8 The welding machine controller detects an alarm during welding.
• Arc is extinguished.
• "Alarm" relay is set.
• "Release" relay is reset.
• "Ready" relay is reset.
9 Only when the alarm has been rectified and the PLC/robot has reset the
"Start" signal, then
• the "Alarm" relay is reset, and
• the "Ready" relay is set.
• Welding cycle with alarm is complete.
A2-3
A2.3 Parameter selection
A2.3. Parameter selection

When selecting binary parameters, it is essential to ensure that the change of signal
when switching the PLC/robot outputs occurs simultaneously and block by block for
program, file number and group.
There must be no time shift on the cables, as otherwise the Q8p may select and
process the wrong programmes.
A2.3.1. Group selection
G2 G1
Group 0 0 0
Group 1 0 1
Group 2 1 0
Group 3 1 1
The group can only be changed during breaks in welding. When the bit combination for
the new group is applied to inputs G1 and G2, it is essential to maintain a waiting time
of 50ms before restarting. The controller needs this time to load the new parameter set.
1
Start
0 t
On Off On
1
Group 0 Group 1
G1-G2
0 t
min.
50ms
A2-4
A2.3.2. File selection, binary (4111, 4211, 4411)
T16 T8 T4 T2 T1
File No. 1 0 0 0 0 1
File No. 2 0 0 0 1 0
File No. 3 0 0 0 1 1
File No. 4 0 0 1 0 0
File No. 5 0 0 1 0 1
File No. 6 0 0 1 1 0
File No. 7 0 0 1 1 1
File No. 8 0 1 0 0 0
File No. 9 0 1 0 0 1
File No. 10 0 1 0 1 0
File No. 11 0 1 0 1 1
File No. 12 0 1 1 0 0
File No. 13 0 1 1 0 1
File No. 14 0 1 1 1 0
File No. 15 0 1 1 1 1
File No. 16 1 0 0 0 0
File No. 17 1 0 0 0 1
File No. 18 1 0 0 1 0
File No. 19 1 0 0 1 1
File No. 20 1 0 1 0 0
File No. 21 1 0 1 0 1
File No. 22 1 0 1 1 0
File No. 23 1 0 1 1 1
File No. 24 1 1 0 0 0
File No. 25 1 1 0 0 1
File No. 26 1 1 0 1 0
File No. 27 1 1 0 1 1
File No. 28 1 1 1 0 0
File No. 29 1 1 1 0 1
File No. 30 1 1 1 1 0
File No. 31 1 1 1 1 1
The file number can only be changed during breaks in welding. When the bit
combination for the new file number is applied to inputs T1 – T16, it is essential to
maintain a waiting time of 50ms before restarting. The controller needs this time to load
the new parameter set.
1
Start
0 t
On Off On
1
File No. 7 File No. 8
F1-F16
0 t
min.
50ms
A2-5
A2.3.3. File selection, analogue with binary tens digit (4441)
A-WELD File No. +10 File No. +20

File No. 1 1V 0 0
File No. 2 2V 0 0
File No. 3 3V 0 0
File No. 4 4V 0 0
File No. 5 5V 0 0
File No. 6 6V 0 0
File No. 7 7V 0 0
File No. 8 8V 0 0
File No. 9 9V 0 0
File No. 10 0V 1 0
File No. 11 1V 1 0
File No. 12 2V 1 0
File No. 13 3V 1 0
File No. 14 4V 1 0
File No. 15 5V 1 0
File No. 16 6V 1 0
File No. 17 7V 1 0
File No. 18 8V 1 0
File No. 19 9V 1 0
File No. 20 0V 0 1
File No. 21 1V 0 1
File No. 22 2V 0 1
File No. 23 3V 0 1
File No. 24 4V 0 1
File No. 25 5V 0 1
File No. 26 6V 0 1
File No. 27 7V 0 1
File No. 28 8V 0 1
File No. 29 9V 0 1
File No. 30 0V 1 1
File No. 31 1V 1 1
Start
1
0 t
On Off On
A-WELD
5V
4V
3V
2V
1V
0 t
min. min.
50ms 50ms
The file number is selected by means of the reference voltage AWELD Terminal 18.
A2-6
The file number can only be changed during breaks in welding. When the new reference
voltage for the new file number is applied, it is essential to maintain a waiting time of
50ms before restarting. The controller needs this time to load the new parameter set.
A2.3.4. File selection, analogue 0-12.4V (4451)
A-WELD A-WELD
File No. 1 0.4V File No. 17 6.8V
File No. 16 6.4V
Start
1
0 t
On Off On
A-WELD
2,0V
1,6V
1,2V
0,8V
0,4V
0 t
min. min.
50ms 50ms
The file number is selected by means of the reference voltage AWELD Terminal 18.
A2-7
A2.3.5. File selection, analogue 0-9.3V (4461)
DACH 1 DACH 1
File No. 16 4.8V
Start
1
0 t
On Off On
A-WELD
1,5V
1,2V
0,9V
0,6V
0,3V
0 t
min. min.
50ms 50ms
The file number is selected by means of the reference voltage DACH 1 Terminal 18.
A2-8
A2.3.6. Program selection, binary (4111)
P4 P2 P1
Program 2 0 1 0
Program 3 0 1 1
Program 4 1 0 0
Program 5 1 0 1
Program 6 1 1 0
Program 7 1 1 1
Welding programs can be changed at will during welding.

1
Start
0 t
On Off
1
Program 2 Program 3
P1-P4
0 t
If no program is selected by the PLC/robot, then the Q8p automatically works

with Program 2.
A2.3.7. Program selection, digital (4211)
P3 P4 P5 P6 P7
Program 2 0 0 0 0 0
Program 3 1 0 0 0 0
Program 4 0 1 0 0 0
Program 5 0 0 1 0 0
Program 6 0 0 0 1 0
Program 7 0 0 0 0 1
Start
0 t
On Off
1
Program 2 Program 3
P1-P4
0 t
If no program is selected by the PLC, then the Q8p automatically works with
Program 2. For this reason, the P2 input is not included in the "digital" program
selection.
A2-9
A2.4 Interrogating the system configuration
A2.3.8. Program selection, analogue (4411) (4441)
The program is selected by means of the reference voltage VWELD (Terminal 19).
V-WELD
Program 2 0V (2V)
Program 3 3V
Program 4 4V
Program 5 5V
Program 6 6V
Program 7 7V
Start
1
0 t
On Off
V-WELD
7V
6V
5V
4V
3V
Prog. 4 Prog. 7 Prog. 3
0 t
If no program is selected by the robot, then the Q8p automatically works with
Program 2. For this reason, it is not absolutely essential to apply a voltage for
welding program 2.
A2.4. Interrogating the system configuration

The current interface program status can be indicated by means of the output relay
LEDs. It is contained within the item designation, e.g. UNI5.4111.
The interface must be connected with a functioning environment, i.e. a complete system
must be ready for operation.
The output relays also switch in conjunction with the LEDs. Before
interrogating the program status, it must be ensured that the overall
system will not malfunction due to the relays switching.
A2-10
A2.5 Programming the UNI5 interface.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Test
SOFTWARE VERSION
UNI 5
0123456789
B C
1 2 3 4 5 6 7
A
Enter LED`s
1 2 3 4 5 6 7
Select
1
123456
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
The LEDs can be found underneath the relays.
Interrogation:
• Press and hold the ENTER button on the interface when switching on the power
source.
• The TEST LED illuminates, and the LEDs will come on one after the other
depending on the configuration.
• After the fourth LED has come on (the program status has four digits) the
indication function is complete and the Test LED will begin to flash rapidly.
The power source must then be switched off and on again.
A2.5. Programming the UNI5 interface.

As a general rule, it is not necessary to program the interface during installation, as it
has already been appropriately configured in the factory.
These programming instructions can be used to re-program any UNI5 interface
regardless of its programming status (UNI4.xxxx).
Functions are displayed and programmed via the LEDs of the six relays (1- 6 from left to
right) on the printed circuit board.
The relays also switch at the same time!

Make sure that the system does not malfunction as a result!
The interface must be programmed in a functioning environment. A Q8i tester or a

complete system must be available.
A2-11
A2.5 Programming the UNI5 interface.
Programming mode
Reprogramming a UNI5 interface to configuration 4XY1

The example of UNI5.4411 where X=4 and Y=1 is shown in brackets:
• Press and hold the SELECT and ENTER buttons until the TEST LED comes on.
• Enter the codeword (SELECT SELECT ENTER)

One of the LEDs 1...6 and TEST will come on. The interface is ready for
programming.
• Selection: Press the SELECT button repeatedly until the 4 LED comes on.
Confirm the selection with ENTER.
• Selection: Press the SELECT button repeatedly until the X LED comes on. (4 LED)
• Selection: Press the SELECT button repeatedly until the Y LED comes on. (1 LED)
• Selection: Press the SELECT button repeatedly until the 1 LED comes on.
• Selection (Calibrate/End): Press the SELECT button repeatedly until the 1 LED
(Interface ready) comes on. Confirm the selection with ENTER.
After the fifth selection, the TEST LED will flash rapidly. At this point, the reference
voltages can be calibrated although this is not normally necessary. Separate
calibration instructions are available for this.
• When the programming of the interface is complete, TEST flashes slowly and the
system must be switched off and on again.
A2-12
A2.6 "Delayed alarm" function
A2.6. "Delayed alarm" function

A2.6.1. Description:
In transfer systems, it is sensible not to forward Q8p alarm messages until after the end
of a welding seam, as if the system stops before the end of the seam, the whole system
is shut down. In this case, the system should complete the weld, but not shut down the
robot.
A2.6.2. Operation
With the appropriate circuit, the alarm message output to the robot is delayed until the
end of the welding seam. The welding system safely stops welding when an alarm
occurs, but the robot continues to move and the transfer system is not shut down. The
part can be separated out at the end of the transfer system.
Connect Terminal 1 (delayed alarm/acknowledge) on the UNI5 interface to an output of

the robot controller/PLC.
If a high signal is present on Terminal 1 and an alarm occurs, the welding system is
switched off and the alarm message stored, but not output (robot continues to work,
welding system is shut down).
Terminal 39 (Alarm 1):

As long as there is a high signal present on Terminal 1, all alarms (Terminal 39) are
delayed until the robot removes the "Welding ON" signal.
If the robot switches the "Welding ON" signal to low (end of welding seam), Terminal 39
is set high and all alarms are now output as usual. In addition, the welding system
ignores the "Welding ON" signal each time it is reset by the robot.
In order to restart the welding system, Terminal 1 must be briefly (≥ 50ms) set low. This
confirms the reading of the alarm message, and Alarm 1 (Terminal 39) is set low once
more.
As an option, Terminal 41 (Alarm 2) of the UNI5 interface can be connected to an input

of the robot controller/PLC. The alarm is output without a delay on this terminal as
before. This can be used to indicate to the robot controller/PLC the fact that an alarm
has occurred without shutting down the robot as a result. With appropriate
programming, the robot can now respond to the alarm.
Delayed alarms are only possible in those operating modes, which do not use Terminal
1. However, this only affects "Thumbwheel selection of file number" and "analogue
selection of file number with ERC robots".
A2-13
A2.6.3. Signal characteristics when Terminal 1 not used

Start of welding seam Alarm End of welding seam
high
ArcOn signal of the robot/PLC low
high
Robot/PLC output to terminal 1 low
an
LSQ (welding process) aus
high
Release arc low
high
Alarm 1 (terminal 39) low
high
A2-14
A2.6.4. Signal characteristics when Terminal 1 used

without alarm
high
high
an
high
Release arc low
high
high
with alarm
Start of welding seam Alarm End of welding seam Start of welding seam
high
Alarm
high acknowledged
an
high
Release arc low
high
high
Restart (ArcOn)
ignored
A2-15
A2.7 Circuit diagrams
A2.7. Circuit diagrams

A2.7.1. Schematic representation
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Test
SOFTWARE VERSION
UNI 5
B C 0123456789
1 2 3 4 5 6 7
A
Enter LED`s
1 2 3 4 5 6 7
Select
1
123456
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
5
3,
31
22
Fitting dimensions L-703 cable to cabinet with fitted plug

Item.No.: 5 410 311 00
Pin assignment L-703
gray Terminal strip
5 - RS +12V 1 WAGO 234-506
yellow
4 - RS GND 2
green
3 - RxD 3
brown
2 - TxD 4
white
1 - 42VAC 5
pink
6 - 42VAC 6
7 - Shielding
A2-16
A2.7.2. UNI 5A.4111 PLC, ABB, FANUC, KUKA binary
1
1
40
Blatt
9
von
36 Ready
*: with software motorboard > 1.05

Release
Group-,file number- and program selection binary

38
Digital input
39 Alarm
8
32
Part
33 contact
37Gas valve ext*
7
2 F1 GND
3 F2 pink
123456
white
6
4 F4 brown
green
yellow
5 F8 gray
UNI5.4111
6 F16
5
7 G1
UNI5A w. Q8i / Q8P - SPS
Digital output
8 G2
9 BTZ
4
22 P1
23 P2
UNI5.4111
3
24 P4
Art. Nr.: 77-8011-00
27 Start
28 Wire feed
04.11.04 Masch. Nr.:
2
42 Wire retract
29 Gas test
W.Brück
+12VDC
10, 14, 21, 31
1
Bearb.
Datum
Gepr.
Norm
11, 16, 20 GND

Datum
0V
PLC
+24V
0
+24V
Änderung
PE
0V
A2-17
A2.7.3. UNI 5A.4111 Yaskawa XRC/NX100 binary (XIO02)

CN10
Wire length 1m
+24V B18
1
1
A14 Wire black
OUT 31
Blatt
9
gray
von
B14 7 G1
A15

OUT 32 green
B15 8 G2
Group-, file number-aund program selection binary

A13
OUT 30 yellow
B13 9 BTZ
A11
8
A12
Wire without colour
A8
OUT 25 blue
B8 27 Start
A9
OUT 26 black
B9 28 Wire feed
7
A10
OUT 27 red
B10 29 Gas test
A11
OUT 28 pink
B11 42 Wire retract
white 32 Part contact

IN29 B3
6
33
green 34 Wire stuck

IN27 B2
35
5
A2 brown 36 Ready
IN28
IN25 B1 gray 38 Release

UNI5 an Q8p/i - XRC-2 (binary)
IN26 A1 yellow 39 Alarm

4
37 Gas valve ext.*
Wire yellow
CN12
+24V B18 green
40
3
OUT 49 B12 gray

UNI5.4111
22 P1
Art. Nr.: 77-8011-01
OUT 50 A12 yellow GND

23 P2
OUT 51 B13 brown

24 P4
26.10.04 Masch. Nr.:
pink
123456
2
white
Wire red brown
pink green
GND B16 11 GND yellow
gray
W.Brück
OUT 41 B8 white
XRC/NX100 (XIO02)
2 F1
OUT 42 A8 yellow
3 F2
1
Bearb.
Datum
Gepr.
Norm
OUT 43 B9 brown
UNI5.4111
4 F4
Datum
OUT 44 A9 gray
5 F8
blue
blau
0
OUT 45 B10
Änderung
6 F16
A2-18
A2.7.4. UNI 5A.4111 XRC binary (MIO02)
1
1
Blatt
9
von
Cable length: 1m
HONDA-socket

Group-, file number and program selection binary
MR-50L
8
CN2
violett
GND 50 11 GND
7
green 40
+24V 25
33 Part
6
contact
white 32
Digital input
IN27 35
gray 38 Release
IN26 33
yellow 39 Alarm
5
IN25 34
37Gas valve ext*
white/yellow
UNI5A w. Q8p/i - XRC (binary)
OUT 25 1 2 F1
yellow/brown
OUT 26 2 3 F2
4
brown/green
OUT 27 3 4 F4 GND
gray/brown
OUT 28 4 5 F8
pink
UNI5.4111
123456
red/blue white
3
OUT 29 5 6 F16 brown

green
Art. Nr.: 77-8011-06
gray/pink yellow
OUT 33 9 7 G1 gray
Digital output
white/green
OUT 34 10 8 G2
26.10.04 Masch. Nr.:
pink
2
OUT 30 6 22 P1
red
OUT 31 7 23 P2
W.Brück
brown
OUT 32 8 24 P4
XRC (MIO02)
1
blue
Bearb.
Datum
Gepr.
Norm
OUT 35 11 27 Start
UNI5.4111
black
OUT 36 12 28 Wire feed
Datum
white/gray
OUT 37 13 29 Gas test
0
Änderung
A2-19
A2.7.5. UNI 5A.4111 FANUC RJ3IC binary (negative logic)
1
1
HONDA-plug 40
50pin
Blatt
9
von
SDI/3 yellow 36 ready
1
release
Group-, file number and program selection binary

SDI/4 gray 38
Digital Inputs
2
39 alarm
8
32
part contact
SDI/6 white 33
5 37 gas valve ext
7
34
white/red 35 wire stick

SDI/5
4
purple
+24V DC
6
50
white/yellow
SDO/10 1 2 F1
44
yellow/brown
SDO/11 1 3 F2
45
brown/green
5
SDO/12 1 4 F4
46
gray/brown
SDO/13 1 5 F8
19
Digital Outputs
red/blue
UNI5A Q8i / Q8P - RJ3IC
SDO/14 1 6 F16
20
UNI5.4111
gray/pink
4
SDO/15 1 7 G1
21
white/green
SDO/16 1 8 G2
22
green
SDO/06 9 last seam
39 1
3
UNI5.4111
10 12V
Art. Nr.: 77-8001-84
pink
SDO/07 1 22 P1 GND
40
red
FANUC binary RJ3IC
SDO/08 23 P2
17.01.07 Masch. Nr.:
41 1
2
pink
brown
123456
white
SDO/09 1 24 P4 brown
43 green
blue yellow
W.Brück
SDO/01 1 27 start
T.Klein
gray
33
black
SDO/03 1 28 wire feed
35
1
Bearb.
Datum
white/gray
Gepr.
Norm
SDO/02 1 29 gastest
34
21 12V
Datum
SDO/04 white/black
1 42 wire retract
36
0
12V
Änderung
white/blue
GND/48 20 GND
47
A2-20
A2.7.6. UNI 5A.4211 PLC digital program selection
1
1
40
Blatt
9
von
36 Ready
38 Release
Digital input
*: with software motor board > 1.05

39 Alarm
8
37 Gas valve ext*
34
Program selection digital

35 Alarm 2
7
2 F1
3 F2
4 F4
6
5 F8
UNI 5.4211
6 F16
7 G1
5
8 G2
Digital output
9 BTZ
UNI 5 / Q8p/i - SPS (digital)
22 P3 GND
4
23 P4
pink
123456
24 P5 white
brown
green
25 P6 yellow
UNI 4.4211
gray
3
26 P7
27 Start
28 Wire feed
23.11.05 Masch. Nr.:
2
29 Gas test
42 Wire retract
W.Brück
T.Klein
+12VDC
10, 14, 21, 31
1
Bearb.
Datum
11, 16, 20 GND

Gepr.
Norm
Input
PLC
0V
Datum
+24V
+24V
0
Änderung
PE
0V
A2-21
0 1 2 3 4 5 6 7 8 9
ABB
Analogue output Digital output Digital input
U1
GND
0 - 7V
0V
+24V
8
7
6
5
4
3
2
9
32
33
18
20
29
28
27
39
38
36
40
37
A2.7.7. UNI 5A.4411 ABB analogue (S3)
GND
11, 16, 20
A2-22
F8
F4
F2
F1
G2
G1
F16
+12VDC
BTZ
10, 14, 21, 31

Start
GND
0 - 7V
Alarm
Ready
Gas test
Release
Wire feed
Part contact
Program 2 - 7
123456
Gas valve. ext*
UNI 5.4411
+24V
gray
pink
GND
green
white
brown
0V yellow
PE
Änderung Datum Datum 10.10.05 Masch. Nr.: UNI 5 w. Q8i/p - ABB analogue *: with software motor board > 1.05
Bearb. W.Brück UNI 5.4411
Program selection analogue 2 - 7V
Gepr. T.Klein Blatt 1
File number selection binary
Norm Group selection binary von 1
A2.7.8. UNI 5A.4441 Yaskawa RX
MR20LW
1
1
HONDA
socket
Blatt
9
von
CE
17 yellow 40
+24V
ARC- 1 pink 38 Release
*: w. software motor board > 1.05

Detector
Alarm
8
2 blue 39
Arc break
18 white
21 +12V
Wire 19 brown
28 Wire feed
7
37Gas valve ext*

MR20LW
HONDA
socket
CD
6
19 yellow
31 +12V
Start 12 blue
27 Start
F3+ 15 green
19 Corr. + -5V
5
GND 17 brown
F2+ 3 black DV 0-18
18 m/min
GND 5 red
20 GND
4
1 pink 34
Stick-
UNI 5 / Q8p - RX
Detector 2 magenta 35 Wire stuck

Yascawa RX / JANCD-RY02
GND
UNI 5.4441
3
pink
123456
white
1TB
brown
22 green
yellow
gray
OT 3 23
10.10.05 Masch. Nr.:
6 File +10
UNI 5
2
24
W.Brück
OT 4 25
T.Klein
1 File +20
2
EXH
1
Bearb.
Datum
Gepr.
Norm
7
COM21
Safety disconnection
Datum
0
Änderung
A2-23
A2.7.9. UNI 5A.4441 Yaskawa RG
1
1
Blatt
9
von
GND
pink
123456
white
brown
green
8
yellow
gray
17 pol. Amphenol
socket
7
V-WELD A gray/pink 19 P2 - P7
Analogue output
GND B
A-WELD C white/yellow
6
18 F1 - F10
GND D yellow/brown
20 GND
5
Digital input
N brown
4
34
Stick-
Detector M white 35 Wire stuck
UNI 5 / Q8p - RG
Yascawa WELCO cable ROB 1
UNI 5.4441
UNI 5
3
L pink
21 +12V
Start K blue
27 Start
10.10.05 Masch. Nr.:
2
Digital output
W.Brück
T.Klein
1
Bearb.
Datum
Gepr.
Norm
Datum
0
Änderung
A2-24
A2.7.10. UNI 5A.4441 Yaskawa ERC
1
1
Blatt
9
von
*: with software motor board > 1.05
HONDA-plug
8
MR20LW
11 GND
20 magenta 16 GND
GND
7
V-WELD 3 yellow/brown 19 P2 - P7
Analogeu output
GND 5
6
A-WELD 15 white/yellow
18 F1 - F31
GND 17 brown/green 20 GND
5
18 green 40
+24V
ARC- 8 gray 38 Release
Detector
39 Alarm
UNI5A Q8i/Q8p w. ERC
Digital input
9 yellow
Arc break
4
37Gas valve ext*

1 brown
34
Stick-
Detector 2 white 35 Wire stuck
UNI5.4441
3
UNI5.4441
Art. Nr.: 77-8011-09
12 pink
31 +12V
Start 19 blue
27 Start
05.11.04 Masch. Nr.:
13 red
2
21 +12V
Wire 14 black
Digital output
28 Wire feed
W.Brück
Yascawa ERC
OT 03 6 graa/pink
6 File +10
1
OT 04 7 white/green
Bearb.
Datum
Gepr.
Norm
1 Feil +20
OT
7 G1
Datum
OT
8 G2
0
Änderung
A2-25
A2.7.11. UNI 5A.4451 Yaskawa MRC
1
1
Blatt
9
von
HONDA-plug
MRL34
GND 7
8
GND 14 16 GND
GND 30 magenta 11 GND
7

Analogue output
GND 32
6
18 F1 - F31
5
29 green 40
+24V
Detector
UNI5A w. Q8i/Q8p - MRC
39 Alarm
Digital input
13 yellow
Arc break
4
37Gas valve ext*

26 brown 34
Stick-
UNI5.4451
3
UNI5.4451
Art. Nr.: 77-8011-02

Yascawa MRC (MEW02-1)
15 pink
31 +12V
Start 16 blue
27 Start
05.11.04 Masch. Nr.:
17 red
2
21 +12V
Wire 18 black
Digital output
28 Wire feed
W.Brück
19
1
OT 46 20 white/green
Bearb.
Datum
Gepr.
Norm
8 G2
21
Datum
OT 45 22 gray/pink
7 G1
0
Änderung
A2-26
A2.7.12. UNI 5A.4451 Yaskawa XRC analogue (XEW01-1)
1
1
Blatt
9
von
HONDA-plug
MRL34
File number selection analogue 0 - 12,4V (0,4V steps)

GND 7
8
GND 14 11 GND
GND 30 magenta 16 GND

7
Group selection binary

Analogue output
GND 32
6
18 F1 - F31
5
29 green 40
+24V
UNI5A w. Q8i/p - XRC analogue
Detector
39 Alarm
Digital input
13 yellow
Arc break
4
37Gas valve ext*

26 brown 34
Stick-
3
UNI5.4451
Art. Nr.: 77-8011-03
15 pink
31 +12V
Start 16 blue
27 Start
27.10.04 Masch. Nr.:
17 red
2
21 +12V
Yascawa XRC (XEW01-1)
Wire 18 black
Digital output
28 Wire feed
W.Brück
19
1
OT 46 20 white/green
Bearb.
Datum
Gepr.
Norm
8 G2
UNI5.4451
21
Datum
OT 45 22 gray/pink
7 G1
0
Änderung
A2-27
0 1 2 3 4 5 6 7 8 9
PLC analogue
Analogue output Digital output Digital input
U1
U2
0 - 9,3V
GND
GND
0 - 7V
0V
+24V
A2.7.13. UNI 5A.4461 PLC analogue
9
8
7
18
20
19
29
28
27
33
32
39
38
36
40
GND
+12VDC
11, 16, 20
A2-28
G2
G1
BTZ
10, 14, 21, 31

Start
GND
Alarm
0 - 7V
Ready
0 - 9,3V
Gas test
Release
Wire feed
Part contact
Program 2 - 7
File n°.: 0 - 31
123456
Gas valve ext*
UNI 5.4461
+24V
gray
pink
GND
green
white
brown
yellow
0V
PE
Änderung Datum Datum 10.10.05 Masch. Nr.: UNI 5 an Q8i/p - SPS analogue 0..10V *: w. software motorboard > 1.05
Bearb. W.Brück UNI 5.4461
Gepr. T.Klein Blatt 1
File number selection analogue 0 - 9,3V (0,3V steps)
Norm Group selection binary von 1
A2.7.14. UNI 5A.4461 Fanuc (analogue)
1
1
Blatt
9
von
11 GND
HONDA-plug

16 GND
8
MRL34
1 yellow
DACH 1 18 F1 - F31
Analogue output
7
2
GND
3 pink
DACH 2 19 P2 - P7
4 magenta 20 GND
GND
6
19 green 40
GND
6 gray 38 Release
WDI 2
Alarm
5
39
37Gas valve ext*
Digital input
31 brown 34
WDI +
4
UNI 5 / Q8p - FANUC
WDI - 32 white 35 Wire stuck

FANUC I/O CRW1 (standard)
UNI-NEPOS
UNI 5.4461
UNI 5
3
23 blue
WDO 1 1 27 Start
26 black
WDO 4 1 28 Wire feed
24 red
WDO 2 1 29 Gas
10.10.05 Masch. Nr.:
2
GND
Digital output
21 +12V
W.Brück
pink
UNI-NEPOS
T.Klein
123456
white
brown
1 7 G1 green
yellow
1
gray
Bearb.
Datum
Gepr.
Norm
1 8 G2
10 +12V
Datum
0
Änderung
A2-29
Contents Appendix 3
A3. Power Feeder PF5........................................................................................... 2
A3.1. Technical data ...............................................................................................2
A3.2. Wire feed .......................................................................................................2
A3.3. Important information.....................................................................................2
A3.4. View and spare parts .....................................................................................3
A3.4.1. Side views PF5 ..........................................................................................3
A3.4.2. Front of PF5 ...............................................................................................4
A3.4.3. Four-roller drive PF5-E...............................................................................5
A3.4.4. Consumables four-roller drive PF5-E .........................................................6
A3.4.5. Wire feed body ...........................................................................................7
A3.4.6. Gas pressure monitor option ......................................................................7
A3.4.7. Small parts .................................................................................................8
A3.5. Maintenance ..................................................................................................9
A3.5.1. Centre guide...............................................................................................9
A3.5.2. Cleaning .....................................................................................................9
A3.6. Fitting instructions PF5 ................................................................................11
A3.7. Circuit diagrams...........................................................................................15
A3.7.1. Connection diagram, motor board MOTOR 51.........................................15
A3 Power Feeder PF5
A3.1 Technical data
A3. Power Feeder PF5

A3.1. Technical data
PF 5
Dimensions L * W * H 220x170x136 mm
Fixing holes: 200x150 mm, M6
Weight: 3.8 kg
Wire feed: 0 – 25 m/min
Motor: 70 W, 42 V
Solenoid valve: 42 V AC
Maximum pressure: 5 bar
Drive rollers: 28 mm
A3.2. Wire feed

The welding wire must be fed manually from the wire spool through the wire feed hose
to the four-roller drive. Make sure that the welding wire is properly located in the groove
of the two drive rollers.
Close the drive cover.
The welding wire can now be threaded into the torch cable assembly by pressing the
Wire feed button .
A3.3. Important information

Any interference with or alteration to the unit will result in the loss of entitlement to
warranty.
The unit must only be opened by an authorised specialist.
Use only SKS original spare parts, as otherwise trouble-free operation of the unit cannot
be guaranteed.
Products sold by SKS are subject to continuous development.
We must therefore reserve the right to make changes to the scope of supply with regard
to form, technology and equipment.
Please understand that no claims can be accepted resulting from the information and
diagrams in this operating manual.
We reserve the right to make technical changes.
A3-2
A3 Power Feeder PF5
A3.4 View and spare parts
A3.4. View and spare parts

A3.4.1. Side views PF5
Item Description Item No.

Left-handed Left-handed Right-handed
version version EA version (PF5-
(PF5-L) (PF5-LEA) R)
1 Keypad for PF5 77-2010-05 77-2010-09 77-2010-06
2 Quick-release coupling 23M32 91-3-0-22-1 91-3-0-22-1 91-3-0-22-1
3 Rear wall for wire feed 10-2-0-17 10-2-0-17 10-2-0-17
4 7-pin plug/socket combination 77-2010-03 77-2010-03 77-2010-04
5 Wire feed body
5a Wire feed body with M10 internal 10-2-0-50 10-2-0-50 10-2-0-50
thread for ESAB
5b Wire feed body with UNF 3/8x24" 10-2-0-51 10-2-0-51 10-2-0-51
external thread
5c Wire feed body with ∅9.6mm hole 10-2-0-52 10-2-0-52 10-2-0-52
5d Wire feed body with ∅13mm hole 10-2-0-53 10-2-0-53 10-2-0-53
6 Front plate for wire feeder 10-2-0-14 10-2-0-14 10-2-0-14
housing 85x32mm with holes
7 Sealing plug 581010150 581010150 581010150
(not Cover plate for wire feeder 10-2-0-28 10-2-0-28 10-2-0-28
shown) housing 85x55mm with holes
(not Knurled screw for Item 5c and 5d 575005800 575005800 575005800
shown)
The bulge on the rear wall of the wire feeder is for protecting the motor
beneath it and cannot be used for fixing.
A3-3
A3 Power Feeder PF5
A3.4.2. Front of PF5

1 Blanking plug QSC-6H 153268 153268 153268
FESTO
2 L-shaped plug QSML-M5-6 153335 153335 153335
FESTO
3 Power pin connector 10-2-0-20-2 10-2-0-20-2 10-2-0-18-2
4 2/2-way proportional valve 10-2-0-40 10-2-0-40 10-2-0-40
NC, NW 2mm 24V 5bar
1+2+3+ Power pin connector unit 10-2-0-20 10-2-0-20 10-2-0-18
4
5 Clamp for wire feed body 10-2-0-16 10-2-0-16 10-2-0-15
6 Precision four-roller drive 12-4-1 12-4-1 12-2-1
(not Door for PF5 housing 10-2-0-7 10-2-0-7 10-2-0-7
shown)
(not Motor board MOTOR 51 77-2010-00 77-2010-00 77-2010-00
shown)
A3-4
A3 Power Feeder PF5
A3.4.3. Four-roller drive PF5-E

Left- Left-handed Right-handed
handed version EA version
version (PF5-LEA) (PF5-R)
(PF5-L)
1 Precision four-roller drive 12-4-1 12-4-1 12-2-1
2 Maxon motor with encoder and 2- 12-2-2 12-2-2 12-2-2
stage planetary gearbox
3 Drive unit, Maxon motor + four-roller 12-4 12-4 12-2
drive (comprising 1 and 2)
A3-5
A3 Power Feeder PF5
A3.4.4. Consumables four-roller drive PF5-E
Pos. Bezeichnung Artikelnummer

4 Drive roller for wire diameter 0.8 mm 12-2-3-08
Drive roller for wire diameter 0.9 mm 12-2-3-09
Drive roller for wire diameter 0.03" 12-2-3-30
Drive roll for Aluminium wire ∅1,0mm 12-2-3-110
5 Centre guide for four-roller drive, ∅2mm, brass 12-2-1-15
Centre guide for four-roller drive, ∅2mm, Delrin for Aluminium 12-2-1-17
6 Pressure roller for four-roller drive PF5 12-2-3-0
A3-6
A3 Power Feeder PF5
A3.4.5. Wire feed body
Item Description Item number

1 Wire feed body including Item 2 and 3 ---
Wire feed body with M10 internal thread for ESAB 10-2-0-50
Wire feed body with UNF 3/8x24" external thread 10-2-0-51
Wire feed body with ∅9.6mm hole 10-2-0-52
Wire feed body with ∅13mm hole 10-2-0-53
2 Insert 62mm for 10-2-0-50/-52/-53 10-2-0-50-3
Insert 83.5mm for 10-2-0-51 10-2-0-51-3
3 Universal sealing cap MS58 for wire feed body PF5 10-2-0-50-4
A3.4.6. Gas pressure monitor option

The gas pressure monitor is an option for monitoring the gas
pressure (dynamic pressure) and thus for monitoring the gas
flow.
Upper switching point (on): ca. 10 l/min

Lower switching point (off): ca. 5 l/min
Burst pressure: 20 bar
Item number: 10-2-0-70
A3-7
A3 Power Feeder PF5
A3.4.7. Small parts

Description Item No.
Set of screws 581063000 581063000 581063000
The set of screws includes screws and serrated washers for assembling the following
components:
Front plate for wire feeder PF5 Fillister head screw with cross head 3.5x8
AMTEC
Cover plate for wire feeder PF5 Fillister head screw with cross head 3.5x8
AMTEC
Keypad for PF5 Fillister head screw with cross head 3.5x8
AMTEC
Rear wall for wire feed Countersunk screw DIN7991 M4x10
7-pin plug/socket combination Fillister head screw with cross head 3.5x8
AMTEC
Power pin connector Serrated washer DIN6797 A 5.3 and cheese-
head screw DIN912 M5x16 steel 8.8
Power pin connector unit Serrated washer DIN6797 A 5.3 and cheese-
Motor card Motor51 Cheese-head screw DIN912 M4x8 steel 8.8
Clamping bush for wire feed body Serrated washer DIN6797 A 5.3 and cheese-
Four-roller drive Serrated washer DIN6797 A 5.3 and cheese-
Drive unit for four-roller drive Serrated washer DIN6797 A 5.3 and cheese-
Maxon motor Serrated washer DIN6797 A 4.3 and cheese-
head screw DIN912 M4x16 steel 8,8
A3-8
A3 Power Feeder PF5
A3.5 Maintenance
A3.5. Maintenance
Centre guide
A3.5.1. Centre guide

Ensure that the centre guide is properly installed. The funnel-shaped opening should
point towards to the wire inlet, and the tip towards the central connector.
A3.5.2. Cleaning
The welding units are extensively maintenance free. Depending on the accumulation of
dirt, but at least every 4-6 months, clean the unit as described below and carry out a
visual inspection.
Electrical voltage!
Power Pin connector may be energised.
Electric shock possible on contact.
Disconnect power source from power supply by unplugging power plug.
Assure against reconnection. Switching off power source or removal of
fuse is not a sufficient isolation measure.
Remove both side walls.

Check the tightness of all screwed and clamped connections and carry out a visual
inspection.
Have a specialist investigate and remove scorched parts.
Have defective cables changed.
Have defective drive rollers and bearings replaced.
A3-9
A3 Power Feeder PF5
A3.5 Maintenance
Replace wire feed hoses and liners regularly.

The wire feed (from the wire spool to the torch) must be checked for freedom of
movement. Watch for a gradual increase in motor current consumption (Q8i/p
display).
Attend to the individual assemblies as follows:
PF5
Depending on degree of contamination, blow out housing and four-roller drive with oil-
and water-free compressed air.
Blow out power pin connector. To do this, press in the blue ring on the blowout duct and
remove the stopper. Then blow out with compressed air.
Electronics, printed circuit boards

Do not blow out electronic components with a compressed air jet. Use a vacuum
cleaner.
Repair work
Repair and maintenance work must only be carried out by trained specialists.
Contact your dealer.
When replacing parts, use only genuine spare parts.
When ordering spare parts, you must indicate the type of unit, serial number and item
number, and the type description and item number of the spare part.
If repair or maintenance work is carried out on this unit by persons who are not
trained and not authorized for such work, the guarantee will become void.
Any interference with or alteration to the unit will result in the guarantee
becoming void.
A3-10
A3 Power Feeder PF5
A3.6 Fitting instructions PF5
A3.6. Fitting instructions PF5
Move the U-axis roughly into a

horizontal position. Move the robot
arm into the assembly position with
the B-axis sloping downwards at
approximately 15°.
Attach the fixing bracket to the robot.

To do this, use the M8 spring
washers, M8 washers and M8x25
cheese-headed screws supplied (3
of each).
Check that the fixing clips of the

quick-release coupling are pressed
outwards. If this is not the case,
press these out carefully. Now feed
the corrugated hose into the quick-
release coupling as far as the stop.
Clamp the corrugated hose by
pressing in the retaining clips until
they engage.
Fix the supply cable mounting

bracket to the wire feed bracket with
the M8 washers and the M8 self-
locking nuts. The hinge of the supply
cable mounting bracket should be
pointing downwards. The washers
and nuts are included in the
connector pack for the PF5 power
source.
A3-11
A3 Power Feeder PF5
Screw the wire feeder PF5 to the

wire feeder bracket using the M6
spring washers, the M6 washers and
the M6x12 hexagon head screws.
Position the wire feeder bracket

together with the fitted wire feeder on
the fixing angle by feeding the
corrugated hose through the opening
in the robot arm, and inserting the
studs on the wire feeder bracket into
the slots in the fixing angle. Place
the M6 washers on the studs. Then
screw the M6 self-locking nuts onto
the studs, but do NOT tighten them!
Carefully grease the power pin

sealing rings on the power cable with
the grease supplied. Ensure that the
gas outlets between the two sealing
rings remain open.
Feed the power pin and the power

cable through the corrugated tube.
Plug the power pin into the top
opening of the power pin connector
of the PF5 wire feeder as far as the
stop. If necessary, move the PF5
and the bracket in the slots to ensure
that the cable is not pulled tight and
is not compressed. Then tighten the
top clamping screw on the power pin
connector.
A3-12
A3 Power Feeder PF5
Fix the wire feed bracket in place by

tightening the two diagonally
opposed nuts.
Carefully grease the power pin

sealing rings on the supply cable
assembly with the grease supplied.
Ensure that the gas outlets between
the two sealing rings remain open.
Feed the power pin of the supply

cable assembly through the opening
in the PF5 below the wire feed body.
Plug the power pin into the bottom
opening of the power pin connector
of the PF5 as far as the stop. Then
tighten the bottom clamping screw
on the power pin connector.
Plug the socket of the L700 cable

onto the SPW plug of the PF5 and
tighten.
A3-13
A3 Power Feeder PF5
Place the clamping sleeve of the

cable assembly into the supply cable
mounting bracket on the bracket and
close the clamp.
Carry out a trial run by moving the B-

axis of the robot while observing the
tensioning of the power cable. If the
cable should become too tight or if it
is compressed, loosen the nuts on
the fixing angle. Then move the PF5
and the bracket on the fixing angle
until tightness or compression no
longer occurs. Then tighten all nuts.
Feed the wire liner coming from the

wire spool into the wire feed body,
and fix this in place with the locking
screw.
A3-14
A3 Power Feeder PF5
A3.7. Circuit diagrams

A3.7.1. Connection diagram, motor board MOTOR 51
Item Connection
1 Tacho cable
2 Power supply ±42V,
screen
3 Motor +, Motor -
4 Water monitor
5 Gas monitor
6 Gas valve
7 SPW connection
8 Setup switches
9 Keypad on PF5
Switch Function
1 WASok ON OFF Water monitor fitted
ON Water monitor bypassed
2 GASok ON OFF Gas monitor fitted
ON Gas monitor bypassed
3 AUTO ON OFF Manual mode
ON Automatic mode
4 Mode 2 OFF OFF GMAW
ON GTAW cold wire
5 Mode 1 OFF Thread speed
OFF: 5m/min, after 1s
10m/min
ON: 5m/min
6 Mode 0 OFF OFF Normal mode
ON Double wire
7 SLAVE OFF OFF Motor 1
ON Motor2
8 TRxD OFF Always OFF
A3-15

SKS System - B - Q4 LSQ5 UNI5 PF5 - V1.0 - EN

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SKS System - B - Q4 LSQ5 UNI5 PF5 - V1.0 - EN

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Version 1.

SKS Welding Systems GmbH Austraße 2a D-66849 Landstuhl

0 Important notes for owners and operators!

Please observe the following points:

SKS Welding Systems GmbH

Phone: +49 (0) 6371 92670

As the operator or owner, you are obliged

Unauthorized interference with the robot welding system as well as unauthorized

1 Guide to this operating manual

There is an immediate threat to life and health of personnel. Danger

There is a possible threat to life and health of personnel.

There is a risk of an undesirable situation arising, which could lead to

The equipment may be damaged if the warning is not observed.

Disregarding this information will interfere with product handling,

General information and notes on the optimum use of the product

1.1 Intended use

1.2 Electromagnetic compatibility

1.3 Name of the buyer when reselling

SKS Welding Systems GmbH

Phone: +49 (0) 6371 92670

As we work continuously on improvements, we reserve the right to make changes

2.1 General information

We ask you to observe the following points:

2.2 Safety symbols

There is an immediate threat to life and health of personnel. Danger

There is a possible threat to life and health of personnel.

There is a risk of an undesirable situation arising, which could lead to

There is a risk of minor or moderate material damage.

Disregarding this information will interfere with product handling,

General information and notes on the optimum use of the product

The following symbols point to special hazards:

Warning of dangerous electrical voltage

Warning of electromagnetic fields

Prohibition signs mean:

Persons fitted with a heart pacemaker are prohibited

Symbols relating to personal protective equipment mean:

Wear protective clothing

Wear safety goggles

Wear ear defenders

Wear head protection

2.3 Personnel qualifications

2.4 Intended use

2.5 Safety instructions

Disregarding the following safety instructions can be life-

Hot sparks and molten drops!

Strong electric and electromagnetic fields!

Electric shock may be life-threatening!

Vapours from chlorinated hydrocarbons can be converted into poisonous phosgene by

Fumes and gases!

Warning against unauthorised conversion or modification.

3 Operation of the Q4 robot welding system

Welding process monitoring:

Supported field bus modules:

3.2 Components of the Q4 robot welding system

The overall Q4 system comprises the following individual components:

3.2-1 Overview of system components

3.3 Q4 Process control

3.3-1 Q4 process controller, front view

3.3.1 Power source

3.3-2 LSQ 5 power source

TECHNICAL DATA LSQ 3

Duty cycle at 40°C

Duty cycle 10 min (60%: 6min ON, 4min OFF)