The

Orig
ina l.

W eld P ackage P ower J oint

For robot types with inner cable dress

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

Power Joint Weld Package: DCT power source • Weld process controller •
Robot interface • Wire feeder• Wire guidance • Cable bundle • Control cable •
Torch system • Torch necks • Consumables
Document no.: DOC-0110EN | Revision: SKSde.06DEZ19.ms.bp.v2.0.0
SKS Weld Package: System design

5
4

1 DCT power source

2 Weld process controller +

Software

3 Robot interface
9
4 Wire feeder

5 Wire guidance 12

6 Cable bundle

7 Ground cable 6

8 Control cable

9 Torch system Power Joint

10 Torch necks/
Consumables

11 Gas nozzles/
Reamer blades

12 TCP dimensions/Checking fixtures/

eReam

For all industrial robots with

inner cable dress.
This brochure contains information about the SKS Weld Package, the torch system
Power Joint, as well as consumables and spare parts. There are various features of the
welding machine components and torch systems available depending on the robot sys-
tem and the welding task.
The Power Joint Weld Package can be used with common industrial robots, such as
ABB, FANUC, KUKA and YASKAWA/MOTOMAN.
 8

The complete SKS Power Joint Weld Package is designed

for the following welding processes, materials and power range:

Processes: MIG/MAG (GMAW), Pulse, MIG Brazing

Wire materials: High-alloy steels, low-alloy steels, aluminum and copper alloys,
nickel-based materials
Wire diameter: 0.8-1.6 mm
Max. power: 420 A - 60 % duty cycle/40 °C, air-cooled
 Power source

LSQ5 power source with Direct Control Technology DCT

The LSQ5 ensures the optimum arc energy. It uniquely adjusts to different weld processes.
Unlike conventional power sources with inverter technology, the LSQ5 with Direct Control
Technology controls its switching transistors without any fixed clock frequency according
to the needs of the weld process. Without any delay, the energy needed for the process
is provided instantly. The flexible fine tuning is done by a central processor. The CPU
continuously analyzes the weld process and current/voltage values on the basis of data
obtained and optimally drives the switching transistors of the power section. This results
in an extremely high efficiency and a low temperature development.
The power source can be configured with only two buttons and four LED indicators. For
world-wide usage, voltages can be configured without opening the power source.

LSQ3 power source with Direct Control Technology (DCT)

The LSQ3 offers enough power reserves for special weld tasks like chassis and exhaust
parts and other thin sheet metal applications.
Power source LSQ5 LSQ3: 340 A at 60 % duty cycle, 3 x 400 V
LSQ3A: 340 A at 60 % duty cycle, 3 x 480 V

ALTERNATIVE
Overview of power sources
DESCRIPTION PART-NO.
LSQ5 77-1185-00
LSQ3 77-1184-00
LSQ3A 77-1184-10
LSQ5-CCC 77-1185-60
LSQ3-CCC 77-1184-40

The main benefits are:

• DCT provides a speed regulation up to ten times higher compared to conventional
inverter technology. This leads to excellent control behavior and shorter response times.
• The weld properties are substantially improved. Software replaces hardware:
Fewer components also increase the reliability in continuous operation.

Specifications:
DESCRIPTION LSQ5(-CCC) LSQ3(-CCC) LSQ3A
420 A - 60% 340 A - 60% 340 A - 60%
Power source LSQ3 Performance
duty cycle/40 °C (400 A) duty cycle/40 °C duty cycle/40 °C
Processes MIG/MAG (GMWA), Pulse, MIG Brazing
Weight 49 kg 37 kg 37 kg
OPTION
Primary voltage 3 x 400 (480)V 3 x 400V 3 x 480V
Wall mounting Yes (optional) Yes (integrated) Yes (integrated)
Conformities CE, CSA, UL (CCC) CE (CCC) CE
Dimensions 450 x 400 x 540mm 450 x 330 x 540mm 450 x 330 x 540mm

Wall mount

DESCRIPTION PART-NO.
Wall mount for LSQ5 77-1180-01
Wall mount for LSQ3 integrated
Wall mount for LSQ3 A integrated

Accessories: Wall mount for LSQ5

Space-saving design that makes for easy cleaning/
maintenance.
 2 Weld process controller

Innovative Control Concepts with Touch Screen.

With the new Q84r and the compact Q84s up to four weld machines can be
controlled centrally.

The new Q84r and Q84s are equipped with a touch screen, an innovative usability concept and an
advanced visualization technology for much easier operating. The user interfaces have the look and
feel of the Q8Tool4 software. Individual weld process controllers are in card slots in the Q84r/s. This
new weld process controller concept can host up to four weld process controller cards. Each card
independently controls a weld machine. As an alternative to the Q84r/s weld process controllers,
the Q80 has been developed to control a single weld machine.

2 4

4 3 2 1

Controlling up to four weld

machines at the same time
 2 Weld process controller

Weld process controller Q84r/s

The universal weld process controllers Q84r and Q84s calculate the optimal parameters for
each welding process. Only basic data such as material, wire type, wire feed speed and type
of gas must be entered. The Q84r is equipped with a 10" touch screen, the space-saving Q84s
with a 7" touch screen. For wall mounting the display of the Q84s can be rotated by an angle of
180°.
• Processes/features: MIG/MAG (GMAW), I-Pulse, U-Pulse, KF-Pulse, Synchroweld,
RWDE, NWDE
Weld process controller Q84r • Programs: 992 (x4)
• General functions: Display and saving of readings, alarms
• Monitoring functions: Weld current monitoring, auto compensation, arc and ignition
monitoring, motor current, gas and water monitoring
• Easy to network via Ethernet: Traceability
• Ports: RJ45-Ethernet, SPW-Bus, SD card slot
• Remote Control/Administration: Q8Tool, VNC client

Overview weld process controller

DESCRIPTION PART-NO. (Q84s) PART-NO. (Q84r)
Q84r/s with one weld card 77-7410-00 77-7310-00
Q84r/s with two weld cards 77-7420-00 77-7320-00
Q84r/s with three weld cards 77-7430-00 77-7330-00
Q84r/s with four weld cards 77-7440-00 77-7340-00

Overview Q84r/s mounting kits

DESCRIPTION PART-NO.
Bracket for Q84r for mounting onto power source LSQ5 77-7240-01
Bracket for Q84s for mounting onto power source LSQ5 77-7240-06
Bracket for Q84r for wall mounting 77-7240-02
Bracket for Q84r mounting in the robot cabinet 77-7240-05

Overview Q84r/s replacement parts and accessories

DESCRIPTION PART-NO.
Touchpen for Q80 / Q84r/s weld process controller (replacement part) 77-7240-03
Weld process controller Q84s Connection cable for Q84r/s 5m with open end for external power supply (option) 77-3305-00
Plug for external power supply of Q84r/s (replacement part) 77-7240-96
Please note:
SD card for Q80 / Q84r/s weld process controller (replacement part) 91-8-6
The Q84r/s can be equipped with up to four weld
USB adapter for SD cards for Q80 / Q84r/s weld process controller 91-8-1
process controller cards.

ALTERNATIVE
Weld process controller Q80
The Q80 is the alternative to the Q84r/s. It has the same functionality/features as a single
weld card of the Q84r/s - optimized for a single weld machine. With the universal Q80 all
parameters and values needed for the weld task can be optimally calculated.
• Processes/features/general functions see Q84r/s
• Easy to network via Ethernet: up to traceability
• Ports: RJ45-Ethernet, SPW-Bus, SD card slot
• Wall mounting capability
Weld process controller Q80 front view
• Remote Control / Administration: Q8Tool
Overview weld process controller
DESCRIPTION PART-NO.
Q80 77-7260-00

Overview Q80 mounting kits

DESCRIPTION PART-NO.
Bracket for mounting onto power source LSQ5 77-7240-06

Overview Q80 replacement parts and accessories

DESCRIPTION PART-NO.
Weld process controller Q80 back view
Touchpen for Q80 / Q84r/s weld process controller (replacement part) 77-7240-03
SD card for Q80 / Q84r/s weld process controller (replacement part) 91-8-6
USB adapter for SD cards for Q80 / Q84r/s weld process controller 91-8-1
 2 Weld process controller

ALTERNATIVE
Weld process controller Q6pw and Q4

The perfect solution for local administration – the weld process controllers Q6pw and Q4
provide all basic functions of the Q80. The controllers can be administrated over the USB
port with the Q8TOOL4 software. As a small and compact solution for the cost-optimized
application, the Q4 is integrated into the power sources LSQ3 or LSQ5.
• Processes/features: MIG/MAG (GMAW), I-Pulse, U-Pulse, KF-Pulse
• Programs: 186
• General functions: Display and saving of readings, alarms
Weld process controller Q6pw
• Monitoring functions: Weld current monitoring, auto compensation, arc and ignition
monitoring,motor current, gas and water monitoring
• Ports: RS232 (Q6pw only), SPW-Bus (Q6pw only), USB

Overview weld process controller

DESCRIPTION PART-NO. Please note:
Q6pw 77-7230-00 The Q4 weld process
controller is integrated
Q4/LSQ5 77-1185-20 into the front of the
Q4/LSQ3 77-1184-20 power source and is
Q4/LSQ3A 77-1184-30 delivered with the power
Weld process controller Q4 source.
Q4/LSQ5-CCC 77-1185-21
Weld process controller Q4 as integrated
Q4/LSQ3-CCC 77-1184-21
solution into the power source

2a Software/IT

Q8Tool software

The Q8Tool software provides accurate and comprehensive process monitoring. The user
can store weld parameters for documentation on a PC and/or administrate them. It offers
basic functions such as reading, modifying and documenting of weld parameters.
Additionally, new weld parameters can be created and transferred to the universal weld
process controllers. The weld data is portable and the installation of further control
units on new equipment is easy. Also, the software allows reading and exporting of
measurements and alarms. Graphical and numerical recording of measures helps defining
and optimizing parameters for new parts. Users have a powerful tool for analyzing and
documenting their weld results.

Network

The weld process controller units can easily be networked via Ethernet ports: Time savings
through centralized administration of all controllers within the corporate network. There is
a central backup of all welding parameters, management of user rights and access, process
monitoring up to traceability. The Q8Tool software is provided free of charge with the weld
process controller. No additional hardware or software is required.
 3 Robot interface

Perfect integration.
Interfacing all industrial robot types.

A B

With the universal interface solution, weld process controllers can be connected with all industrial
robot types. Users basically have two options for connecting robots with weld process controllers:
The connection can be realized with the interface UNI 5 or by integrating into a given field bus
environment with a field bus solution.

Standard application Field bus application

Robot controllers or overall system controllers (e.g. PLC) use digital Field bus systems exchange signals via serial communication.
or analog signals to communicate with the weld process controller. The field bus master, usually the robot controller or overall system
The interface UNI 5 translates these signals for the welding controller, bundles and processes the signals of the connected
machine. With just one interface, a variety of digital encodings and field bus, including the welding machine. Standard field bus
analog levels can be processed. The interface UNI 5 comes with a systems are e.g., Interbus-S, Profibus DP or DeviceNet. The field
preconfigured connection kit for easy installation. bus interface FB5 translates the field bus signals for the welding
machine using a standardized protocol. It makes no difference
which type of field bus system is used. The signals are always at
the same place on the field bus. This makes the preparation of the
robot or system controller much easier.
3 Robot interface

A Robot interface UNI 5

The interface connects the welding equipment with all industrial robot types. With its
high degree of standardization, the UNI 5 is the perfect choice for connecting the weld
process controller (e.g. Q80) with an industrial robot. The UNI 5 comes preprogrammed
and configured for different robot types. Configuration to a particular robot type is handled
easily by programming the interface with two buttons for the given robot type.

Overview of robot interfaces

DESCRIPTION PART-NO.
For robot type-ABB
UNI 5A for IRC5 77-8011-08

For robot type-FANUC

UNI 5A for RJ3iC 77-8001-84

For robot type-KUKA

UNI 5A for KR C2 77-8011-08

For robot type-YASKAWA/MOTOMAN

UNI 5C (Synchroweld over RS232)
77-8013-00
for NX 100 / DX 100 / DX 200

ALTERNATIVE
Field bus application
B

Various field bus types are supported (e.g. Profibus DP, DeviceNet). The field bus interface
has drilled bore holes for flexible mounting within the weld cell. Two additional mounting
kits provide easy installation at the power source or into the cabinet. Additionally, external
power can be connected to the interface. More details on solutions for the specific field
bus types are available on request.

Overview FB5 interfaces

DESCRIPTION PART-NO.
OPTION Interbus-S (copper line) 77-3-1
Profibus DP 77-3-2
DeviceNet 77-3-3
EtherCAT 77-3-4
Profinet IRT (copper line) 77-3-5
Synchroweld unites the weld system Profinet IRT (LWL 2 ports) 77-3-6
and robot by a communication protocol Interbus-S (LWL FSMA) 77-3-7
(RWDE). This technology allows the weld Ethernet/IP 77-3-8

system to get the actual robot speed and

Cabinet mounting
automatically adjusts the weld parame- DESCRIPTION PART-NO.
ters accordingly. The result is a constant Mounting kit for cabinet 77-1182-02
energy per unit length. At the same time, Control cable with bracket 77-3102-02
the programming effort can be signifi-
Power source mounting
cantly reduced. DESCRIPTION PART-NO.
Mounting kit for power source 77-1182-03

Optional power supply (24V)

Please note: DESCRIPTION PART-NO.

Further information on Synchroweld with ABB, Connection cable 2.0 m (with open end) 77-1182-04
Fanuc, KUKA, Yaskawa/Motoman can be found in our
Synchroweld brochure.
 4 Wire feeder

Strong, lightweight and precise.

The PF5 wire feeder.

Smaller and with less weight accompanied by improved efficiency over conventional wire feeders
the PF5 goes along with the steady development of arc welding robots.

Power Feeder PF5

Modern motor, gear and control technology provide a strong performance and highest
possible precision. The robust plastic housing is electrically insulated. As a "lightweight"
the PF5 is the perfect choice for the new generation of robots with inner cable dress.
The industrial proven Power Feeder PF5 is available with an additional monitoring
functionality: an integrated gas-flow sensor. The weld process controller displays the gas
flow values, and can also be triggered to an alarm, in case of a non-defined gas flow rate.

Overview PF5
ALTERNATIVE DESCRIPTION PART-NO.
PF5 LEA 10-2-9
PF5 LEA with integrated gas flow sensor 10-2-109

Technical data
Weight 3.8 kg
Motor 70W
Wire feeding speed 2.5 - 25 m/min
Roll diameter 0.8 - 1.6 mm

PF5 with integrated gas flow sensor

Shielding Gas Saver

The benefit of the shielding gas saver is its pre-regulated working pressure of 1.2 bar /
17 psi (common 4.5 bar / 65 psi). Therefore the ram pressure is reduced, i.e. there are key
benefits of the shielding gas saver at ignition of the welding torch and an improved gas
saving. The shielding gas saver ensures a constant gas flow during the welding task.

Shielding Gas Saver

DESCRIPTION PART-NO.
Shielding Gas Saver 93-62-5
4 Wire feeder

Center guides

Available in two versions: For steel or aluminum wires

Overview of center guides

DESCRIPTION PART-NO.
Wire-ø mm for steel wire 12-2-1-15
Wire-ø mm for aluminum 12-2-1-19

Drive roll for wire feeder

For wire diameters 0.8-1.6 mm (V-groove for steel and U-groove for aluminum)

Overview of four roller drive rolls

DESCRIPTION PART-NO. Wire-ø 1.4 mm, V-groove 12-2-3-14
Wire-ø 0.8 mm, V-groove 12-2-3-08 Wire-ø 1.6 mm, V-groove 12-2-3-16
Wire-ø 0.9 mm, V-groove 12-2-3-09 Wire-ø 1.2 mm, U-groove 12-2-3-112
Please note: Wire-ø 1.0 mm, V-groove 12-2-3-10 Wire-ø 1.6 mm, U-groove 12-2-3-116
Two drive rolls per system are needed. Wire-ø 1.2 mm, V-groove 12-2-3-12

Pressure roll

Pressure roll for wire feeder.

Pressure roll
DESCRIPTION PART-NO.
Pressure roll 12-2-3-0
Locating bolt for pressure roll 12-13-5
Pressure roll for aluminum wire, U-groove 1.2 mm 12-2-5-112
Pressure roll for aluminum wire, U-groove 1.6 mm 12-2-5-116
Please note:
Locating bolt for pressure roll U-groove 12-2-1-23
Two pressure rolls and two locating bolts are needed Knurled screw for pressure roll U-groove 12-2-1-24
per system.

Wire feeder brackets

Wire feeder bracket for PF5 with holes and screws for installation

Overview of wire feeder brackets

DESCRIPTION PART-NO.
For robot type-ABB
IRB 1600iD / IRB 1660iD 14-2-5
IRB 2600iD 15/1.85 14-2-10
IRB 2600iD 8/2.00 14-2-10

Please note:
For robot type-FANUC
Wire feeder brackets for further robot types are
M-10iA/6L 14-4-4
available on request.
M-10iA/8L 14-4-4
M-10iA/12 on request
M-10iA/12s on request

For robot type-KUKA

KR6 R1820 arc HW / KR8 R1420 arc HW / KR8 R1620 arc HW 14-3-8
KR8 R2100 arc HW 14-3-9

For robot type-YASKAWA/MOTOMAN

MA 1440 / MA 2010 / GP 12 / GP 25 14-1-25
5 Wire guidance polymer for aluminum wires

3
1 Wire inlet body with quick
2
coupling
4
2 Connection nipple for polymer conduit

3 Polymer conduit

4 Drum connector with ceramic inlay

Please note:
With the new SKS polymer guidance, the high efficiency of the whole system extends up to
Further information can be found in our brochure
the drum.
"Wire guidance" (DOC-0193EN).
Advantages of polymer wire guidance
• Extraordinary good glide properties reduces motor load
• Minimized abrasive wear and reduced dirt in wire feeder and torch system
• Lightweight design and a high inherent stability for easy installation
• Length can be freely chosen by the customer
• Cost optimized exchange: only the polymer conduit must be changed,
connectors are reuseable.
• Optimized materials for longer life and reduced downtimes

Wire inlet body, Connection nipple, Polymer conduit and Connection for wire drum
Wire inlet body with quick coupling
DESCRIPTION PART-NO.
Wire Inlet body with quick lock and polymeric inlet 10-2-0-63
Polymeric inlet (spare part) 10-2-0-63-2
Inset for aluminum wire 10-2-0-57-3

Connection nipple for polymer conduit

DESCRIPTION PART-NO.
Connection nipple 44-40-3

Polymer wire conduit

DESCRIPTION PART-NO.
Polymer wire conduit, blue, per meter 44-9-1

Connection for wire drum

DESCRIPTION PART-NO.
Drum connector with ceramic inlay 44-40-1

OPTION
DESCRIPTION PART-NO.
Strain-Relief for wire guidance 14-10-7
 5 Wire guidance ERC for steel and stainless steel wire materials

1 2

2
1 Wire inlet body with quick coupling

2 Connection nipple for ERC conduit

4
3 Polymer wire conduit ERC

4 Connection for wire drum with inner ceramic inlay

With the ERC wire guidance for steel/stainless steel, the high efficiency of the whole system extends up to the drum.

Advantages
• Very good inherent stability due to thick polyethylene insulating jacket
• Good sliding properties
• Reduced wear by using flat wire for monocoil core
• Suitable for steel and stainless steel wires

Wire guidance ERC

DESCRIPTION PART-NO. OPTION
Wire inlet body with quick coupling 10-2-0-61 DESCRIPTION PART-NO.
Connection nipple for ERC conduit 44-70-2 Strain Relief for wire guidance 14-10-7
Polymer wire conduit ERC / per meter 44-70-1 Strain Relief spring for wire guidance 44-70-3
Drum connector with ceramic inlay 44-40-1
Please note:
Two connection nipples are necessary.

ALTERNATIVE
Wire inlet bodies for additional systems
Beside the wire inlet body for the SKS wire guidance, inlet bodies
for additional systems are available.

Overview of wire inlet bodies for additional systems

ALTERNATIVE

DESCRIPTION PART-NO.
M10 with internal thread for ESAB 10-2-0-50
with 9.6 mm bore hole 10-2-0-52
with 13 mm bore hole 10-2-0-53
with PG9 thread 10-2-0-56
with 1/4” internal thread 10-2-0-60

Aluminum inlets for wire inlet bodies

DESCRIPTION PART-NO.
for types 50/52/53/54/59/60/61 10-2-0-57-3
for types 51/55/56 10-2-0-58-3
6 Cable bundles

Cable bundles: Power source to wire feeder PF5

Coaxial power cable 72 mm2 with internal gas flow, control cable L700,
disconnect cable, corrugated tube and cable holder. Air-cooled version.

Overview of cable bundles

Length PART-NO.
5m 20-4-5
7m 20-4-7
10 m 20-4-10

Please note:
Further lengths available on request

6a Cable bundles: Clamping set

Mounting cable bundle: Clamping set

Provides perfect installation of the cable bundle for all different robot types.
Undesired cable movements are prevented. This results in higher lifetime.

Overview of cable bundle clamping sets

DESCRIPTION PART-NO. DESCRIPTION PART-NO.
For robot type-ABB For robot type-FANUC
IRB 1600iD / IRB 1660iD 91-3-0-41-10 M-10iA/6L 91-3-0-41-6
IRB 2600iD 15/1.85 M-10iA/8L 91-3-0-41-15
91-3-0-41-11
IRB 2600iD 8/2.00 M-10iA/12 / M-10iA/12S on request

DESCRIPTION PART-NO. DESCRIPTION PART-NO.

For robot type-KUKA For robot type-YASKAWA/MOTOMAN
MA 1440 91-3-0-41-14
KR6 R1820 arc HW
KR8 R1420 arc HW 91-3-0-41-17 MA 2010 91-3-0-41-14
KR8 R1620 arc HW GP 12 91-3-0-41-22
KR8 R2100 arc HW 91-3-0-41-12 GP 25 91-3-0-41-22

Please note: ALTERNATIVE

DESCRIPTION PART-NO.
Clamping sets for further robot types are available
Mounting for WF-bracket for external guided cable bundle 14-10-10
on request.
Dividable cable bundles

ALTERNATIVE

1 2 3

PARTS OF THE DIVIDABLE CABLE BUNDLE

1 2 3

Connection from power source Connection bracket Connection from connection

to connection bracket bracket to wire feeder PF5

LENGTH PART-NO. DESCRIPTION PART-NO. LENGTH PART-NO.

5m 20-7-5 Connection bracket 20-6-0-3 3m 20-6-3
7m 20-7-7 5m 20-6-5
10 m 20-7-10 7m 20-6-7

Please note: Cable bundle with separation between power source and wire feeder PF5
Further lengths available on request
The moving parts of the cable bundle (next to the robot) are separated from the
non-moving parts (power source). In case of maintenance work, only the moving parts
have to be changed. The quick and easy replacement concept results in time and cost
savings.

TO POWER SOURCE TO WIRE FEEDER

7 Ground cable

Ground cable with 70 mm2 connector and cable plug

Cables with larger diameters are available on request

Overview of ground cables

LENGTH PART-NO.
6m 228078106
10 m 228078100

Please note:
Further lengths available on request

8 Control cable

Control cable: L700/SPW-bus

Standard control cable to connect the components:

Weld process controller, power source, robot interface, wire feeder.

Overview of control cables

LENGTH PART-NO.
0.5 m 541031050
1m 541031001
2m 541031002
Please note: 3m 541031003
For the Power Joint system three control cables are 5m 541031005
needed. One control cable is already included in the 7m 541031007
cable bundle. 10 m 541031000
12 m 541031012
15 m 541031015

Please note:
Further lengths available on request

PLUG & PLAY: CONTROL CABLE L700

The advantages of a system concept are revealed by its details: One standard control cable (L700) connects all system components
(power source, robot interface, weld process controller and wire feeder) within the welding system.
The system is expandable: Other components can be integrated at any time into an existing system. New devices are automatically
detected.

POWER SOURCE ROBOT INTERFACE WELD PROCESS CONTROLLER WIRE FEEDER

 9 Torch system Power Joint

The new freedom of motion.

Power Joint for hollow wrist robots with inner torch cable.

The
Orig
inal.

The Power Joint torch system perfects the interaction of welding machines and robots with inner
cable dress. A single rotary joint, endlessly rotatable, transmits electrical energy and all media
such as gas, air and wire. This reduces torch cable movement (no twisting/no torsional strain) and
therefore increases the lifetime of the torch cable. The lack of reorientations also saves airtime
because the torch reaches every position in the shortest possible path.

The complete SKS Power Joint Weld Package is designed

for the following welding processes, materials and power range:

Processes: MIG/MAG (GMAW), Pulse, MIG Brazing

Wire materials: High-alloy steels, low-alloy steels, aluminum and copper alloys,
nickel-based materials
Wire diameter: 0.8-1.6 mm
Max. power: 420 A - 60 % duty cycle/40 °C, air-cooled
9 Torch system Power Joint: Parts overview

Power Joint
torch system
parts overview

10

10a

11

The Power Joint torch system can be

configurated with different gas
nozzles for standard applications or
heavy duty applications.
9 Torch system Power Joint: Parts overview

9b

9a

9b

9 Power Joint 9a Mounting kit for Power Joint

9b Torch cable with Power Pin connector 10 Torch neck
10a Consumables 11 Gas nozzle
9 Torch system

Power Joint for all industrial robots with inner cable dress

A single rotary joint, endlessly rotatable, transmits electrical energy and all media such as
gas, air and wire. This reduces torch cable movement (no twisting/no torsional strain) and
therefore increases the lifetime of the cable. The lack of reorientations also saves airtime
because the torch reaches every position in the shortest possible path.

Power Joint
DESCRIPTION PART-NO.
Power Joint 71-9-0

Technical data
Welding current 420 A - 60 % ED
Switch-Off automatic system Deflection 10°
Reset accuracy ± 0.2 mm with TCP 400 mm
Weight 1,8 kg

9a Torch system: Installation

Mounting kit for Power Joint

Kit includes: Fixing cover, connecting flange, clamping bush, sealing grommet and
mounting material for the specific robot type

Overview of mounting kits

DESCRIPTION PART-NO.
For robot type-ABB
IRB 1600iD 71-9-0-3
IRB 1660iD 71-9-0-9
IRB 2600iD 15/1.85 71-9-0-9
IRB 2600iD 8/2.00 71-9-0-9

For robot type-FANUC

M-10iA/6L 71-9-0-14
M-10iA/8L 71-9-0-14
M-10iA/12 on request
M-10iA/12S on request

For robot type-KUKA

KR6 R1820 arc HW 71-9-0-17
KR8 R1420 arc HW 71-9-0-17
KR8 R1620 arc HW 71-9-0-17
KR8 R2100 arc HW 71-9-0-17

For robot type-YASKAWA/MOTOMAN

MA 1440 71-9-0-16
MA 2010 71-9-0-16
GP 12 71-9-0-16
GP 25 71-9-0-16
9b Torch system: Torch cable/Accessories

Torch cable
High flexible coaxial cable 72 mm2 with Power Pin connector.

Overview of torch cable

DESCRIPTION PART-NO.
For robot type-ABB
IRB 1600iD 61-9-1800
IRB 1660iD 61-9-100-6
IRB 2600iD 15/1.85 61-9-2600-15
IRB 2600iD 8/2.00 61-9-2600-8

For robot type-FANUC

M-10iA/6L 61-9-100-6
M-10iA/8L 61-9-100-8
M-10iA/12 on request
M-10iA/12S on request

For robot type-KUKA

KR6 R1820 arc HW 61-9-MH24
KR8 R1420 arc HW 61-9-1420
KR8 R1620 arc HW 61-9-1420
Please note: KR8 R2100 arc HW 61-9-120

Torch cables for further robot types are available on For robot type-YASKAWA/MOTOMAN
request. MA 1440 61-9-1440
MA 2010 61-9-2010
GP 12 61-9-1440
GP 25 61-9-MH24

Liner for torch cable

For the following diameters and filler materials:

Quick load liner:

Steel, bronze (wire-ø 0.8 - 1.0 mm)
LENGTH PART-NO.
1.8 m 415-35-6Q
3.0 m 415-35-10Q

Quick load liner:

Steel, bronze (wire-ø 1.2 - 1.6 mm)
1.8 m 415-116-6Q
3,0 m 415-116-10Q

Aluminum (wire-ø 1.2 - 1.6 mm)

per meter 91-68-47025-25E
Sleeve 44-30-7
Power Pin cap 61-2-0-2-7

Sleeve for quick load liner

Fixates the liner in the torch cable

Sleeve for quick load liner

DESCRIPTION PART-NO.
Sleeve for quick load liner 415-26
10 standard Torches: Torch necks/Accessories

Torch necks for Power Joint

With the innovative bayonet lock system, the SKS torch neck can be replaced quickly. This
unique tool-free quick change system is also highly precise with TCP accuracy of ± 0.2 mm.

Overview torch necks Application recommendations

Type PART-NO. TCP length [mm] angle [°] Steel/CrNi Al*
58-1-00-400-1 400.0 0 √ √
58-1-22-350-1 350.0 22 √ √

standard dressing air-cooled

58-1-22-400-1 400.0 22 √ √
58-4-330-500-1 438.5 30 O O
58-1-130-450-1 450.0 30 O O
58-1-35-400-1 400.0 35 √ X
58-1-45-350-1 350.0 45 √ X
58-1-45-400-1 400.0 45 √√ X
58-1-45-450-1 450.0 45 √ X
58-4-345-450-1 388.5 45 √ √
58-4-345-567-1 505.5 45 √ √

Type PART-NO. TCP length [mm] angle [°] Steel/CrNi Al

ZK 58-1-245-400-1 400.0 45 √ X

* Please note:
√√ Recommended standard torch neck
√ Recommended For aluminum applications
SKS recommends a Frontpull
O Special design: application specific
torch system
X Not recommended

INFO: TORCH NECK

SKS offers a special torch neck (up to

250 A, ZK-HeavyDuty up to max. 300 A)
for welding components with tight
accessibility.
The special torch neck needs a smaller
insulator (ZK) and a more compact gas
nozzle (ZK). Standard Power Lock contact
tips can be used.

TCP drawings can be found on the next to

last page (torch necks).

Clamping cap for SKS single wire

torch necks
Tool-free assembly with bayonet quick-change
system
Clamping cap
DESCRIPTION PART-NO. ZK TYPE
Clamping cap 71-3-25

Insulator for SKS torch necks

Overview insulator
DESCRIPTION PART-NO.
Standard 58-1-5
ZK type 43-6-4-2
ZK heavy duty type 43-6-4-3
10 HQX Torches: Torch necks/Accessories

Torch necks for Power Joint

Overview torch necks Application recommendations

Type PART-NO. TCP length [mm] angle [°] Steel/CrNi Al*
58-1-622-350-1 350.0 22 √ √
58-1-622-400-1 400.0 22 √ √

HQX-dressing
58-1-635-400-1 400.0 35 √ X

air-cooled
58-1-645-350-1 350.0 45 √ X
58-1-645-400-1 400.0 45 √√ X
58-4-6345-450-1 388.5 45 √ √
58-4-6345-567-1 505.5 45 √ √

√√ Recommended standard torch neck * Please note:

√ Recommended For aluminum applications

O Special design: application specific SKS recommends a Frontpull
torch system
X Not recommended

Insulator for SKS torch necks

Insulator
DESCRIPTION PART-NO.
HQX Insulator for single wire torch necks 58-1-14

10a Torches: Consumables

Lock: Retaining head

Retaining heads for heavy duty applications with thread for threaded gas nozzles for
simple and safe installation
Overview of retaining heads
DESCRIPTION PART-NO.
High performance retaining head Power Lock standard 43-9-2
High performance retaining head Power Lock with 6 holes (AL-application) 43-9-4
High performance retaining head HQX Power Lock Plus with 6 holes (Fe-/Al-application) 43-20-3
High performance retaining head Power Lock (ZK-Version) 43-8-6
High performance retaining head Power Lock Plus 43-16-2
High performance retaining head Power Lock Plus (ZK-Version) 43-24-1

Power Lock: Contact tips

• Tapered design for high TCP reproducibility
• Improved heat transfer extends lifetime
• Improved power transition: constant arc quality
Overview of contact tips (also for ZK type)
Wire-ø Steel applications Stainless steel applications Aluminum applications
Power Lock Power Lock Plus Power Lock Power Lock Plus Power Lock Power Lock Plus
0.8 mm 40-4-5-0.8E 40-6-5-0.8E 40-4-7-0.8S 40-6-7-0.8S –––––––––– ––––––––––
0.9 mm 40-4-5-0.9E 40-6-5-0.9E 40-4-7-0.9S 40-6-7-0.9S –––––––––– ––––––––––
1.0 mm 40-4-5-1.0E 40-6-5-1.0E 40-4-7-1.0S 40-6-7-1.0S –––––––––– ––––––––––
1.2 mm 40-4-5-1.2E 40-6-5-1.2E 40-4-7-1.2S 40-6-7-1.2S 40-4-7-1.2AL 40-6-7-1.2AL
1.4 mm –––––––––– –––––––––– 40-4-7-1.4S 40-6-7-1.4S –––––––––– ––––––––––
Please note:
1.6 mm –––––––––– –––––––––– 40-4-7-1.6S 40-6-7-1.6S 40-4-7-1.6AL 40-6-7-1.6AL
An overview of gas nozzles with dimensions can
be found on the next pages.
10a Torches: Consumables

Gas nozzles with thread

Standard gas nozzles Heavy Duty gas nozzles
13 mm bottle shaped PART-NO. 13 mm PART-NO.
short 41-19-13-BS flush, bottle shaped 41-20-13-BF
flush 41-19-13-BF long, tapered 41-20-13-TR
long 41-19-13-BR 16 mm tapered PART-NO.
13 mm tapered PART-NO. short 41-20-16-TS
short 41-19-13-TS flush 41-20-16-TF
flush 41-19-13-TF long 41-20-16-TR
long 41-19-13-TR
ZK type
15 mm bottle shaped PART-NO.
13 mm bottle shaped PART-NO.
short 41-19-15-BS
short 41-21-13-BS
flush 41-19-15-BF
flush 41-21-13-BF
long 41-19-15-BR
15 mm bottle shaped PART-NO.
Please note: 16 mm tapered PART-NO.
short 41-21-15-BS
An overview of gas nozzles with dimensions can short 41-19-16-TS
flush 41-21-15-BF
be found on the next page. flush 41-19-16-TF
13+15 mm Heavy Duty/tapered PART-NO.
long 41-19-16-TR
Please note: 13 mm, flush 41-22-13-TF

Further information can be found in our brochure 15 mm, flush 41-22-15-TF

"Consumables" (DOC-0135EN).

Gas nozzles with thread (HQX)

HQX gas nozzles
16 mm bottle shaped PART-NO.
short 41-16-16-BS
16 mm tapered PART-NO.
short 41-16-16-TS
flush 41-16-16-TF
long 41-16-16-TR

Tool for contact tips

For replacement of contact tips: Fast exchange of contact tip without removing
the gas nozzle
contact tips
DESCRIPTION PART-NO.
Mounting tool SW6 for contact tips (Power Lock) 51-9001-00
Mounting tool SW7 for contact tips (Power Lock Plus) 51-9002-00

Programming tips
Power Lock programming tips for precise seam programming

Overview of programming tips

Stickout PART-NO.
12 mm (Power Lock) 65-6
15 mm (Power Lock) 65-7
20 mm (Power Lock) 65-8
12 mm (Power Lock Plus) 65-11
15 mm (Power Lock Plus) 65-12
11 Gas nozzles: Overview dimensions

13 mm bottle-shaped 13 mm tapered 13 mm Heavy Duty

41-19-13-BS 41-19-13-BF 41-19-13-BR 41-19-13-TS 41-19-13-TF 41-19-13-TR 41-20-13-BF 41-20-13-TR

Gas nozzle PART-NO. 41-19-13-BS 41-19-13-BF 41-19-13-BR 41-19-13-TS 41-19-13-TF 41-19-13-TR 41-20-13-BF 41-20-13-TR
Reamer Blade:
Power Lock
(UNF 3/8“ x 24) PART-NO. 66-13-S 66-13-F 66-13-R 66-13-S 66-13-F 66-13-R 66-13-F 66-13-R
(M10 x 1) eReam PART-NO. 67-13-S 67-13-F 67-13-R 67-13-S 67-13-F 67-13-R 67-13-F 67-13-R
Power Lock Plus
(UNF 3/8“ x 24) PART-NO. 68-13-S 68-13-F 68-13-R 68-13-S 68-13-F 68-13-R 68-13-F 68-13-R
(M10 x 1) eReam PART-NO. 69-13-S 69-13-F 69-13-R 69-13-S 69-13-F 69-13-R 69-13-F 69-13-R

15 mm bottle-shaped 16 mm tapered 16 mm Heavy Duty

41-19-15-BS 41-19-15-BF 41-19-15-BR 41-19-16-TS 41-19-16-TF 41-19-16-TR 41-20-16-TS 41-20-16-TF 41-20-16-TR

Gas nozzle PART-NO. 41-19-15-BS 41-19-15-BF 41-19-15-BR 41-19-16-TS 41-19-16-TF 41-19-16-TR 41-20-16-TS 41-20-16-TF 41-20-16-TR
Reamer Blade:
Power Lock
(UNF 3/8“ x 24) PART-NO. 66-15-S 66-15-F 66-15-R 66-16-S 66-16-F 66-16-R 66-16-S 66-16-F 66-16-R
(M10 x 1) eReam PART-NO.. 67-15-S 67-15-F 67-15-R 67-16-S 67-16-F 67-16-R 67-16-S 67-16-F 67-16-R
Power Lock Plus
(UNF 3/8“ x 24) PART-NO. 68-15-S 68-15-F 68-15-R 68-16-S 68-16-F 68-16-R 68-16-S 68-16-F 68-16-R
(M10 x 1) eReam PART-NO. 69-15-S 69-15-F 69-15-R 69-16-S 69-16-F 69-16-R 69-16-S 69-16-F 69-16-R

ZK type:
13 mm bottle-shaped 15 mm bottle-shaped 13+15 mm Heavy Duty/tapered

41-21-13-BS 41-21-13-BF 41-21-15-BS 41-21-15-BF 41-22-13-TF 41-22-15-TF

Gas nozzle PART-NO. 41-21-13-BS 41-21-13-BF 41-21-15-BS 41-21-15-BF 41-22-13-TF 41-22-15-TF

Reamer Blade:
Power Lock
(UNF 3/8“ x 24) PART-NO. 66-13-ZK-S 66-13-ZK-F 66-15-ZK-S 66-15-ZK-F 66-13-ZK-F 66-15-ZK-F
(M10 x 1) eReam PART-NO. 67-13-S 67-13-F 67-15-ZK-S 67-15-ZK-F 67-13-F 67-15-ZK-F
Power Lock Plus
(UNF 3/8“ x 24) PART-NO. 68-13-ZK-S 68-13-ZK-F 68-15-ZK-S 68-15-ZK-F 68-15-ZK-F 68-15-ZK-F
(M10 x 1) eReam PART-NO. 69-13-S 69-13-F 69-15-ZK-S 69-15-ZK-F 69-15-F 69-15-ZK-F

Dimensions in mm.
Further gas nozzles, reamer blades and torch necks can be found in our consumables brochure.
11 Gas nozzles: Overview dimensions

HQX Version
16 mm bottle-shaped 16 mm tapered

41-16-16-BS 41-16-16-TS 41-16-16-TF 41-16-16-TR

Gas nozzle PART-NO. 41-16-16-BS 41-16-16-TS 41-16-16-TF 41-16-16-TR

Reamer Blade:
Power Lock Plus
(UNF 3/8“ x 24) PART-NO. 68-16-HD-S 68-16-HD-S 68-16-HD-F 68-16-HD-R
(M10 x 1) eReam PART-NO. 69-16-HD-S 69-16-HD-S 69-16-HD-F 68-16-HD-R

Dimensions in mm.
Further gas nozzles, reamer blades and torch necks can be found in our consumables brochure.
11a Gas nozzles: Reamer blades

Standard torch neck – Power Lock

Reamer blade (internal thread UNF 3/8“ x 24)

Reamer blade short flush long
Inner diameter of the gas nozzle PART-NO. PART-NO. PART-NO.
13 mm 66-13-S 66-13-F 66-13-R
15 mm 66-15-S 66-15-F 66-15-R
16 mm 66-16-S 66-16-F 66-16-R

Dimensions
A B C D E F PART-NO.
44 - 67 12.5 9 - 66-13-S
44 - 70 12.5 9 - 66-13-F
44 - 73 12.5 9 - 66-13-R

45 68 85 14.5 11.8 9 66-15-S

45 71 88 14.5 11.8 9 66-15-F
45 74 91 14.5 11.8 9 66-15-R

45 68 85 15.5 11.8 9 66-16-S

45 71 88 15.5 11.8 9 66-16-F
45 74 91 15.5 11.8 9 66-16-R

Reamer blade (internal thread M10 x 1 – eReam)

Reamer blade short flush long
Inner diameter of the gas nozzle PART-NO. PART-NO. PART-NO.
13 mm 67-13-S 67-13-F 67-13-R
15 mm 67-15-S 67-15-F 67-15-R
16 mm 67-16-S 67-16-F 67-16-R

Dimensions
A B C D E F PART-NO.
55 - 78 12.5 9 - 67-13-S
55 - 81 12.5 9 - 67-13-F
55 - 84 12.5 9 - 67-13-R

38 61 78 14.5 11.8 9 67-15-S

38 64 81 14.5 11.8 9 67-15-F
38 67 84 14.5 11.8 9 67-15-R

38 61 78 15.5 11.8 9 67-16-S

38 64 81 15.5 11.8 9 67-16-F
38 67 84 15.5 11.8 9 67-16-R

Standard torch neck – Power Lock Plus

Reamer blade (internal thread UNF 3/8“ x 24)

Reamer blade short flush long
Inner diameter of the gas nozzle PART-NO. PART-NO. PART-NO.
13 mm 68-13-S 68-13-F 68-13-R
15 mm 68-15-S 68-15-F 68-15-R
16 mm 68-16-S 68-16-F 68-16-R

Dimensions
A B C D E F PART-NO.
55.5 - 67 12.5 9 - 68-13-S
52.5 - 67 12.5 9 - 68-13-F
49.5 - 67 12.5 9 - 68-13-R

51 63 91 14.5 11.8 9 68-15-S

48 63 91 14.5 11.8 9 68-15-F
45 63 91 14.5 11.8 9 68-15-R

51 63 91 15.5 11.8 9 68-16-S

Please note: 48 63 91 15.5 11.8 9 68-16-F

Dimensions in mm. 45 63 91 15.5 11.8 9 68-16-R

11a Gas nozzles: Reamer blades

Standard torch neck – Power Lock Plus

Reamer blade (internal thread M10 x 1 – eReam)

Reamer blade short flush long
Inner diameter of the gas nozzle PART-NO. PART-NO. PART-NO.
13 mm 69-13-S 69-13-F 69-13-R
15 mm 69-15-S 69-15-F 69-15-R
16 mm 69-16-S 68-16-F 68-16-R

Dimensions
A B C D E F PART-NO.
66.5 - 78 12.5 9 - 69-13-S
66.5 - 81 12.5 9 - 69-13-F
66.5 - 84 12.5 9 - 69-13-R

38 50 78 14.5 11.8 9 69-15-S

38 53 81 14.5 11.8 9 69-15-F
38 56 84 14.5 11.8 9 69-15-R

38 50 78 15.5 11.8 9 69-16-S

38 53 81 15.5 11.8 9 69-16-F
38 56 84 15.5 11.8 9 69-16-R

ZK-Series – Power Lock

Reamer blade (internal thread UNF 3/8“ x 24)

Reamer blade short flush long

Inner diameter of the gas nozzle PART-NO. PART-NO. PART-NO.
13 mm 66-13-ZK-S 66-13-ZK-F -
15 mm 66-15-ZK-S 66-15-ZK-F -

Dimensions
A B C D E F PART-NO.
54 - 77 12.5 9 - 66-13-ZK-S
51 - 77 12.5 9 - 66-13-ZK-F

45 68 77 14.5 11.8 9 66-15-ZK-S

42 68 77 14.5 11.8 9 66-15-ZK-F

Reamer blade (internal thread M10 x 1 – eReam)

Reamer blade short flush long

Inner diameter of the gas nozzle PART-NO. PART-NO. PART-NO.
13 mm 67-13- S 67-13-F -
15 mm 67-15-ZK-S 67-15-ZK-F -

Dimensions
A B C D E F PART-NO.
55 - 78 12.5 9 - 67-13-S
55 - 81 12.5 9 - 67-13-F

46 69 78 14.5 11.8 9 67-15-ZK-S

46 72 81 14.5 11.8 9 67-15-ZK-F

Please note:
Dimensions in mm.
11a Gas nozzles: Reamer blades

ZK-Series – Power Lock Plus

Reamer blade (internal thread UNF 3/8“ x 24)

Reamer blade short flush long
Inner diameter of the gas nozzle PART-NO. PART-NO. PART-NO.
13 mm 68-13-ZK-S 68-13-ZK-F -
15 mm 68-15-ZK-S 68-15-ZK-F -

Dimensions
A B C D E F PART-NO.
65.5 - 77 12.5 9 - 68-13-ZK-S
62.5 - 77 12.5 9 - 68-13-ZK-F

45 58 77 14.5 11.8 9 68-15-ZK-S

42 58 77 14.5 11.8 9 68-15-ZK-F

Reamer blade (internal thread M10 x 1 – eReam)

Reamer blade short flush long

Inner diameter of the gas nozzle PART-NO. PART-NO. PART-NO.
13 mm 69-13- S 69-13-F -
15 mm 69-15-ZK-S 69-15-ZK-F -

Dimensions
A B C D E F PART-NO.
66.5 - 78 12.5 9 - 69-13-S
66.5 - 81 12.5 9 - 69-13-F

46 59 78 14.5 11.8 9 69-15-ZK-S

46 62 81 14.5 11.8 9 69-15-ZK-F

HQX-Series – Power Lock Plus

Reamer blade (internal thread UNF 3/8“ x 24)

Reamer blade short flush long
Inner diameter of the gas nozzle PART-NO. PART-NO. PART-NO.
16 mm 68-16-HD-S 68-16-HD-F 68-16-HD-R

Dimensions
A B C D E F PART-NO.
49.5 62 85 15.5 12.8 9 68-16-HD-S
46.5 62 85 15.5 12.8 9 68-16-HD-F
43.5 62 85 15.5 12.8 9 68-16-HD-R

Please note:
Dimensions in mm.
11a Gas nozzles: Reamer blades

HQX-Series – Power Lock Plus

Reamer blade (internal thread M10 x 1 – eReam)

Reamer blade short flush long

Inner diameter of the gas nozzle PART-NO. PART-NO. PART-NO.
16 mm 69-16-HD-S 69-16-HD-F 69-16-HD-R

Dimensions
A B C D E F PART-NO.
38 50.5 73.5 15.5 12.8 9 69-16-HD-S
38 53.5 76.5 15.5 12.8 9 69-16-HD-F
38 56.5 79.5 15.5 12.8 9 69-16-HD-R

Please note:
Dimensions in mm.

12 Torches: TCP dimensions

A
15
m
m

Overview of air cooled torch necks

Standard dressing HQX A B C

PART-NO. PART-NO. (distance in mm) (TCP length in mm) (angle in °)
58-1-00-400-1 on request 0 400.0 0
58-1-22-350-1 58-1-622-350-1 45 350.0 22
58-1-22-400-1 58-1-622-400-1 45 400.0 22
58-4-330-500-1 on request 120 438.5 30
58-1-130-450-1 on request 0 450.0 30
58-1-35-400-1 58-1-635-400-1 70 400.0 35
58-1-45-350-1 58-1-645-350-1 90 350.0 45
58-1-45-400-1 58-1-645-400-1 90 400.0 45
58-1-45-450-1 on request 90 450.0 45
58-4-345-450-1 58-4-6345-450-1 120 388.5 45
58-4-345-567-1 58-4-6345-567-1 120 505.5 45

Overview torch necks ZK type

Standard dressing A B C
PART-NO. (distance in mm) (TCP length in mm) (angle in °)
58-1-245-400-1 62 400,0 45

Please note:
Dimensions in mm.
12a Torches: Checking fixtures

To check TCP of torch necks and complete torch.

Checking fixtures are provided for all listed torch necks

with Power Joint torch system. Please contact us for
detailed information.

Top view checking fixture

Please note:
Further information can be found in our brochure
"Checking fixtures" (DOC-0137EN).

P u re
Elect
ric .
for a precise cleaning For further information

of the torch frontend please visit

www.eReam.de

Please note:
Further information can be found in our eReam
brochure (DOC-0184EN).
SKS Welding Systems GmbH | Marie-Curie-Strasse 14 | 67661 Kaiserslautern | Germany
info@de.sks-welding.com | www.sks-welding.com

Subject to change.