SKS PI Weld Process Controllers Overview of Functions en

Weld Process Controllers
Overview of functions
Document no.: DOC-0118EN | Revision: sks1109.en.2.i.ms

Content
Introduction
Weld Process Controllers – System design Page
Weld Process Controller
Q84r Weld Process Controller Page
Q84s Weld Process Controller Page
Q80 Weld Process Controller Page
Q6pw Weld Process Controller Page
Software
Q1Tool Software Page
Q8Tool4 Software Page
Q8Tool Software Page
Networking Page
Weld data documentation (DCOM) Page
Weld Process Controllers: Overview of functions Page
2 Weld Process Controllers – Overview of functions | Issued: 15. June 2015

Weld Process Controllers – system design
The weld process control concept ranges from weld process controllers with touchscreen and weld data visualization up to the cost-
effective entry-level solution Q4 (integrated into the power source)
The universal weld process controllers (Q1, Q4, Q6pw, Q80, Q84r, 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. These determine the proper welding voltage for short - or spray - arc or the parameters for
the pulse process. Furthermore, a digital control unit calculates the ideal current source characteristics for each
welding process. The controllers have an auto compensation to stabilize the arc. Here, the voltage is adjusted in
case of distance changes to the component to keep the penetration stability.
In addition to the cost-optimized variant Q4 for installation in the power source, SKS welding process controls
are flexible in placing within the welding cell: for optimal operation and high flexibility.
With the Q1Tool, Q8Tool or Q8Tool4 software, our controls are well prepared for future applications. The
software supplied with the controls is free of charge.
The Software solution provides the basis for a precise and comprehensive process control. Included in the
scope of delivery of our welding process controls is a professional software package. The Q8Tool software is
designed for administration, i.e. all service and data recording functions are available to users with an
easy-to-use software.
Weld Process Controllers – Overview of functions | Issued: 15. June 2015 3

Q84r Weld Process Controller
Absolute modularity: With the Q84r weld controller you can operate up to 4 weld machines from a central point.
With a maximum of four pluggable Q81 weld cards, plugged into its internal slots, the Q84r can be configured
for best profitable efficiency. The graphical design of the large touchscreen is following the proven software
design of the Q8Tool4. Thus it provides a really intuitive interface. With VNC, the weld controller can be remote
controlled from other computers, and provides full access on the welding equipment. The offered modularity
particularly brings advantages in pricing an ease of use; especially in welding cells with several welding
machines. The Q81 weld cards have the same functionality as a Q80 weld controller.
Technical specifications
 Processes/features: GMAW(MIG/MAG), I-Pulse, U-Pulse, KF-Pulse, PlasmaTIG, Dual Wire, microMIG,
microMIG-cc, Synchroweld, RWDE, NWDE
 Digital parameter selection: 992 programs (per weld process card), max. 4 weld process cards
 Materials: Steel, CrNi, Al, CuSi
 Q8TOOL Software (Weld Data Administration/Network), VNC remote control
 Innovative graphical usability concept with touch screen
 General functions: Visualization and saving of measurements, alarm messages
 Monitoring functions: Weld current monitoring, auto compensation, arc and ignition monitoring, motor
current, gas and water monitoring
 Ports: RJ45 Ethernet (NWDE), SPW-Bus, SD card slot
 Wall mounting
Available versions of Q84r Weld Process Controller

Description Part number
Q84r Weld Process Controller with one (1) weld card 77-7310-00
Q84r Weld Process Controller with two (2) weld cards 77-7320-00
Q84r Weld Process Controller with three (3) weld cards 77-7330-00
Q84r Weld Process Controller with four (4) weld cards 77-7340-00
Mounting parts for Q84r Weld Process Controller

Bracket for Q84r for mounting onto power source LSQ5 77-7240-01
Bracket for Q84r for wall mounting 77-7240-02
Bracket for Q84r for mounting into the robot cabinet 77-7240-05
Overview Q84r replacement parts and accessories

Connection cable Q84r/s 5m with open end for ext. power supply (option) 77-3305-00
USB adapter for SD/microSD Card (option) 91-8-1
Touch pen for Q80/Q84r/Q84s (replacement part) 77-7240-03
SD Card for Q80/Q84r/Q84s (replacement part) 91-8-6
Plug for external power supply Q84r/Q84s (replacement part) 77-7240-96

Q84r Weld Process Controller
Administration of parameters
With the Q8Tool software the Q84r can be programmed over The measured values can easily be displayed within the
the integrated network interface with a PC. The welding software Q8Tool.
parameters are clearly displayed. In addition, the software
supports Q8Tool network functionalities in the Q84r.
Example configuration
Rob 2
Rob 3
Rob 4
Example configuration with a Q84r in a Power Clutch Weld Package
Views of the Q84r Weld Process Controller
Front view of the Q84r Weld Process Controller Back view of the Q84r Weld Process Controller

Q84s Weld Process Controller
Modular control concept: the Q84s weld process controller offers the possibility to control of up to four welding
machines from a central point. It has four card slots that are built into the system. With process controller cards
(Q81 weld card) it can be equipped for controlling up to four weld systems. The user interface is a large full-
color graphical touch screen with an intuitive interface, which is modeled after the industrial proven software
Q8Tool4. The surface can easily be operated from other computers via a VNC client and offers full access to
the weld equipment. Especially in welding cells, with several welding machines, this modularity benefits in price
and ease of use. The Q81 weld process cards are full-value weld process controllers. The Q84s has a compact
design.
 Processes/features: GMAW(MIG/MAG), I-Pulse, U-Pulse, KF-Pulse, PlasmaTIG, Dual Wire, microMIG,
 Digital parameter selection: 992 programs (x4), max. 4 weld process cards
 Q8TOOL Software (Weld Data Administration / Network), VNC remote control
 Touch Screen
 Wall mounting
 Screen rotatable 180° by software for flexible mounting
Q84s Weld Process Controllers

Q84s Weld Process Controller with one (1) weld card 77-7410-00
Q84s Weld Process Controller with two (2) weld cards 77-7420-00
Q84s Weld Process Controller with three (3) weld cards 77-7430-00
Q84s Weld Process Controller with four (4) weld cards 77-7440-00

Bracket for Q80/Q84s for mounting onto power source LSQ5 77-7240-06
Overview Q84s replacement parts and accessories

Bezeichnung Artikelnummer
Connection cable Q84r/s 5m with open end for ext. power supply (option) 77-3305-00
Plug for external power supply Q84r/Q84s (replacement part) 77-7240-96

Q84s Weld Process Controller
With the Q8Tool software the Q84s can be programmed over The measured values can easily be displayed easily with the
the integrated network interface with a PC. The welding software Q8Tool.
parameters are clearly displayed. In addition, the software
supports Q8Tool network functionalities in the Q84s.
Rob 2
Rob 3
Rob 4
Example configuration with a Q84s in a Power Clutch Weld Package
Views of the Q84s Weld Process Controller
Front view of the Q84s Weld Process Controller Back view of the Q84s Weld Process Controller

Q80 Weld Process Controller
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: GMAW(MIG/MAG), I-Pulse, U-Pulse, KF-Pulse, PlasmaTIG, microMIG,
 Digital program selection: 992 programs
 Q8TOOL Software (Weld Data Administration/Network)
 Monitoring functions: Weld current monitoring, auto compensation, arc and ignition, monitoring, motor
 Wall mounting
 Screen rotatable 180° by software for flexible mounting
Q80 Weld Process Controllers

Q80 Weld Process Controller 77-7260-00

Bracket for Q80/Q84s for mounting onto power source LSQ5 77-7240-06
Overview Q80 replacement parts and accessories


With the Q8Tool software the Q80 can be programmed over the The measured values can easily be displayed within the
integrated network interface with a PC. The welding parameters software Q8Tool.
are clearly displayed. In addition, the software supports Q8Tool
network functionalities in the Q80.
Example configuration with a Q80 in a Power Clutch Weld Package
Views of the Q80 Weld Process Controller
Front view of the Q80 weld process controller Back view of the Q80 weld process controller

Q6pw Weld Process Controller
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 with the Q8TOOL4 software over the USB port. As a
compact solution for cost optimized usage the Q4 controller is integrated into the power source LSQ3 or LSQ5.
 Processes/Features: GAMW(MIG/MAG), I-Pulse, U-Pulse, KF-Pulse, Synchroweld, RWDE
 Q8TOOL4 Software (Local Weld Data Administration)
 Ports: USB, RS232 (local), SPW-Bus

Q6pw Weld Process Controller (Wall mounting) 77-7230-00
Overview Q6pw replacement parts and accessories

Cable USB Slave for connection PC to Weld Process Controller (option) 91-8-2-01
Key for key switch (replacement part) 541072200

With the Q8Tool software the Q6pw can be programmed over

USB port with a standard PC. The measured values can easily
be displayed with the software Q8Tool.
Example configuration with a Q6pw in a Power Clutch Weld Package
Views of the Q6pw Weld Process Controller
Front view of the Q6pw weld process controller Bottom view of the Q6pw weld process controller

According to customer needs, a cost optimized solution was created.

The integration of the Q4 Weld Process Controller into the Power Source provides a cost-advantage.
 Processes/Features: GMAW(MIG/MAG), I-Pulse, U-Pulse, KF-Pulse, Synchroweld, RWDE
 Q8TOOL4 Software (Local Weld Data Administration)
 The Q4 Weld Process Controller is integrated into the front cover of the power source
 General functions: Display of measurements (LCD), alarm messages
 Connection: USB

DCT Power Source LSQ5 with integrated Q4 Weld Process Controller 77-1185-20
DCT Power Source LSQ5-CCC with integrated Q4 Weld Process Controller 77-1185-60
DCT Power Source LSQ3 with integrated Q4 Weld Process Controller 77-1184-20
DCT Power Source LSQ3-CCC with integrated Q4 Weld Process Controller 77-1185-40
DCT Power Source LSQ3A with integrated Q4 Weld Process Controller 77-1184-30

Bezeichnung Artikelnummer
Cable USB Slave for connection PC to Weld Process Controller (option) 91-8-2-01
Key for key switch (replacement part) 541072200
LSQ3 / LSQ5 Power Source for Q4 Weld Process Controller

The LSQ series 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.
Overview LSQ5 and LSQ3 Power Sources

Power Source LSQ5(-CCC) LSQ3(-CCC) LSQ3A
Power 60% duty cycle 420 A (400 A) 340 A 340 A
Processes MSG MSG MSG
Weight 49 kg 37 kg 37 kg
Power supply 3x400/480 V (switchable) 3x400 V 3x480 V
Wall mounting Yes (optional) Yes (integrated) Yes (integrated)
Conformities CE, CSA, UL, (CCC) CE, (CCC) CE

With the Q8Tool software the Q4 can be programmed over USB

port with a standard PC. The measured values can easily be
displayed easily with the software Q8Tool.
Example configuration with a Q4 in a Power Clutch Weld Package
Views of the Q4 Weld Process Controller
Q4 Weld Process Controller integrated Q4 Weld Process Controller integrated

into the front cover of the LSQ5 Power Source into the front cover of the LSQ3 Power Source

Q1 Weld Process Controller for manual welding
Modern GMAW(MIG/MAG) robotic arc welding technology meets the highest quality requirements, which hand
welding technology must face. The constant desire for complete automation, are facing technical feasibility and
cost of complex component geometries. In many applications it is therefore technically and economically
feasible, in the sense of the pareto principle (80-20 rule) to weld the remaining percentages manually. However,
here the same high quality is required, such as in robotic arc welding.
 Processes/Features: GMAW(MIG/MAG), I-Pulse
 Manual job selection: 14 Jobs
 Q1Tool Software (local Weld Data Administration)
 General functions: Display of measurements (LCD), alarms
 Monitoring functions: Motor current monitoring
 Connections: D-Sub 9 pol. (SKS specific)

Q1 Weld Process Controller 77-7250-00

Q1 USB cable (option) 77-7250-10
Operation of the Q1 Weld Process Controller
Display
Multiline display for good readability
Control buttons
Control buttons for direct function access
Rotary switch
Rotary switch for comfortable menu and parameter selection
Job buttons
Job buttons for direct selection of individual welding programs
SPW/USB port
SPW/USB port for connection with the welding system (Power Source) or with a
PC. With a USB adapter cable, the Q1 can easily be configured
Display of Q1
Navigation line
Cursor
Status line

Q1 Weld Process Controller for manual welding
Semi Automatic Machine (SAM)
The Semi Automatic Machine Weld Package consists of a trolley with Power Feeder PF5, the LSQ power
source as well as a holder for the control Q1. The Q1Tool software is included. The trolley is prepared for wire
feeding directly from the drum, but can also be equipped with a wire spool holder. So this is highly configurable.
The free Q1Tool software allows easy administration of the hand control from a standard PC or notebook
(reading, writing and saving the welding parameters, up to documentation capabilities). The hand control can be
configured independently of the welding machine with pre-definable parameters. With the simple duplication of
the welding parameters, hand welding stations can be configured fast and easy.
Example Configuration
For making available the robot welding quality for hand welding applications, SKS has developed a Weld Package (Semi Automatic
Machine) for hand welding. This was realized with the proven components of the robot application.
Q1 Weld Process Controllers for hand welding

Semi Automatic Machine with Q1 / LSQ5(-CCC) / Power Pin-Connector On request
Semi Automatic Machine with Q1 / LSQ5(-CCC) / Euro-Connector On request
Semi Automatic Machine with Q1 / LSQ3(-CCC) / Power Pin-Connector (Optional with LSQ3A) On request
Semi Automatic Machine with Q1 / LSQ3(-CCC) / Euro-Connector (Optional with LSQ3A) On request
Views of Q1 Weld Process Controller for Hand Welding
Q1 Weld Process Controller connected to a SAM Weld Package

Q1Tool Software
SKS software solutions lay the cornerstone for precise and comprehensive process control. Our Weld Process
Controllers (including Q1, Q4, Q80, Q84r and Q84s) come with a professional software package.
The associated free software tool allows the read Q1 and Q1 playing of the controls. With the USB adapter
cable that is connected directly to the computer, the power supply via USB. All parameters are clearly displayed
in an intuitive form. Both, individual jobs as well as the complete content of the weld process controller can be
saved on a computer and restored on a weld process controller.
Screenshot of the Q1Tool software

Q8Tool4 Software
Advanced functionality offers our Q8Tool software. In conjunction with the software Q8Tool, our Weld Process
Controllers (Q80 and Q84r/s) can be directly integrated into existing corporate networks via their Ethernet
interfaces.
The result: A complete documentation of the welding data up to traceability.
Working locally with Q8Tool4 software
The Q8Tool4 software allows the implementation of a precise, comprehensive process control. With this
software, welding parameters can be additionally saved and administered on a PC for documentation purposes.
Besides basic functions as the reading, modifying and documenting of welding parameters, new welding
parameters can be created and transmitted to the SKS Weld Process Controller. Welding parameters such as
current, voltage, wire feeding speed can be easily managed using the software. The integrated recording of
measured values visualizes the aforementioned welding parameters (graphically/numerically). Additionally, the
functions of the auto compensation feature and the Synchroweld process (heat input per unit length, TCP
speed) are shown on the display. Both, individual jobs as well as the complete content can be stored on the
computer and restored on the controller.
Content that has been stored is portable, and the set-up of new systems or the upgrading of existing systems to
integrate new technologies is made much easier. Up and above this, the Q8Tool4 software allows the reading
and exporting of measured values and alarm messages. The graphical and numerical recording of measured
values allows for quick identification and optimization of parameters for new work pieces. Thus, users are
getting a powerful tool to analyze and document their welding processes.
In addition to creating, storing, saving, and transmitting of programs, the Q8Tool as well as Q8Tool4 software has extensive
visualization capabilities. The Q8Tool software supports as a further development of Q8Tool4 comprehensive network
functionalities.

Q8Tool Software
Advanced functionality offers our Q8Tool software. In conjunction with the software Q8Tool, our Weld Process
Controllers (Q80 and Q84r/s) can be directly integrated into existing corporate networks via their Ethernet
interfaces.
The result: A complete documentation of the welding data up to traceability.
Connected working with the software Q8Tool
In addition to local features of Q8Tool4 software, the Q8Tool comes with additional network functionality.
Ethernet interfaces, the welding process controllers can be directly integrated into existing corporate networks.
The result: A complete documentation of the welding data to object-oriented welding data documentation:
TRACEABILITY.
In addition to creating, storing, saving, and transmitting of programs, the Q8Tool as well as Q8Tool4 software has extensive
visualization capabilities. The Q8Tool software supports as a further development of Q8Tool4 comprehensive network
functionalities.

Networking of Weld Process Controllers
Advanced functionality offers our Q8Tool software. In conjunction with the software Q8Tool, our weld process
controllers (Q80 and Q84r/s) can be directly integrated into existing corporate networks via their Ethernet
interfaces.
The result: A complete documentation of the welding data with traceability function.
Standard Documentation
During the production process, all relevant data of the weld process controllers can be recorded with the Q8Tool
software on a standard windows PC.
Live Documentation
For further processing of the weld data, a DCOM software interface can be added. This provides access and
many possibilities of analyzing recorded data as well as live data.
With the SKS Welding data documentation, many possibilities open up for further processing and the use of
data.
All RELEVANT data can be documented and evaluated
 TRACEABILITY.
Networking of welding machines with the Q8Tool software in a corporate network.

Weld Data Documentation (DCOM)
Perfect Integrate into your applications
The Distributed Component Object Model is an interface defined by Microsoft to allow the communication of the
COM technology via a network. With this upgradable interface for Q8Tool software, an access to the data
stream of the Q8Tool service from external applications is provided (e.g. MS Office, Visual Basic, etc.). The data
can be further processed and visualized online with standard programs.
Interface to DCOM – Advantages
 Software interface provides full access to the data stream.

 Easy processing of the data with standard software for customer specific and supplementary reports.
 Online evaluation for better reaction times
 Relevant data can be selected from the entire data stream: transparency for relevant process data.
Dongle for DCOM Interface

KEY4COM Version „Time“ – 90 day license 77-7201-00
KEY4COM Version „Life“ – permanent license 77-7201-01
Networking of welding machines with the Q8Tool software and processing of the data
using the DCOM interface in a corporate network.

Weld Process Controllers: Overview of functions
Weld Process Controllers: Overview of functions
Connectors / Interfaces Q1 Q4 Q6pw Q80 Q84s* Q84r*
RS232 (local) - -  - - -
USB (local)    - - -
Ethernet / UDP (for NWDE) - - -   
SPW bus connection (L700)  internally    
SD card slot - - -   
Programs Q1 Q4 Q6pw Q80 Q84s* Q84r*

START      
Weld programs 14 93 93 744 744(x4) 744(x4)
Filling of end crater  FILL FILL P7 P7 P7
END End pulse     
Programs total 14 186 186 992 992(x4) 992(x4)
Processes Q1 Q4 Q6pw Q80 Q84s* Q84r*

MIG/MAG (GMAW)      
I-Pulse      
U-Pulse -     
KF-Puls -     
TIG-DC -     
PlasmaTIG - - -   
TIG-Pulse - - -   
Dual Wire - - -   
microMIG / microMIG-cc - - -   
General functions Q1 Q4 Q6pw Q80 Q84s* Q84r*

Display of measurement values      
Saving of measurement values - - -   
Display of alarms      
Saving of alarms - - -   
RWDE supported (Robot- Welder Data Exchange):
serial communication to robot -     
provides Synchroweld functionality
Touch screen
- - -   
with graphical visualization
Internally expandable
- - - -  
with a maximum of four Q81 weld cards
Wall mounting - ()    
Monitoring funcitons Q1 Q4 Q6pw Q80 Q84s* Q84r*

Weld current monitoring (current window) -     
Auto compensation -     
Arc monitoring -     
Ignition monitoring -     
Motor current monitoring      
Gas monitoring      
Water monitoring      
PC functions Q1 Q4 Q6pw Q80 Q84s* Q84r*

Administration of weld parameters (local)      
NWDE (Network Welder Data Exchange):
Networking for central administration - - -   
Recording of weld data
Remote administration via VNC - - - -  
- : Function not available  : Function available (w) : only Q8pw

* : Denoted functionality is for a Q84r/s configuration with a single Q81 weld card.

Notes

Notes

SKS Welding Systems GmbH | Marie-Curie-Str. 14 | 67661 Kaiserslautern/Germany | Phone +49 6301/7986-0 | Fax +49 6301/7986-119
Änderungen vorbehalten.

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Weld Process Controllers

Document no.: DOC-0118EN | Revision: sks1109.en.2.i.ms

Weld Process Controllers – System design Page

Weld Process Controller

Q84r Weld Process Controller Page

Q84s Weld Process Controller Page

Q80 Weld Process Controller Page

Q6pw Weld Process Controller Page

Q4 Weld Process Controller Page

Q1 Weld Process Controller Page

Q1Tool Software Page

Q8Tool4 Software Page

Q8Tool Software Page

Weld data documentation (DCOM) Page

Weld Process Controllers: Overview of functions Page

2 Weld Process Controllers – Overview of functions | Issued: 15. June 2015

Weld Process Controllers – Overview of functions | Issued: 15. June 2015 3

Available versions of Q84r Weld Process Controller

Mounting parts for Q84r Weld Process Controller

Overview Q84r replacement parts and accessories

4 Weld Process Controllers – Overview of functions | Issued: 15. June 2015

Example configuration with a Q84r in a Power Clutch Weld Package

Views of the Q84r Weld Process Controller

Weld Process Controllers – Overview of functions | Issued: 15. June 2015 5

Q84s Weld Process Controllers

Mounting parts for Q84r Weld Process Controller

Overview Q84s replacement parts and accessories

6 Weld Process Controllers – Overview of functions | Issued: 15. June 2015

Example configuration with a Q84s in a Power Clutch Weld Package

Views of the Q84s Weld Process Controller

Weld Process Controllers – Overview of functions | Issued: 15. June 2015 7

The Q80 is the alternative to the Q84r/s.

Q80 Weld Process Controllers

Mounting parts for Q84r Weld Process Controller

Overview Q80 replacement parts and accessories

8 Weld Process Controllers – Overview of functions | Issued: 15. June 2015

Example configuration with a Q80 in a Power Clutch Weld Package

Views of the Q80 Weld Process Controller

Weld Process Controllers – Overview of functions | Issued: 15. June 2015 9

Q6pw Weld Process Controller

Overview Q6pw replacement parts and accessories

10 Weld Process Controllers – Overview of functions | Issued: 15. June 2015

With the Q8Tool software the Q6pw can be programmed over

Example configuration with a Q6pw in a Power Clutch Weld Package

Views of the Q6pw Weld Process Controller

Weld Process Controllers – Overview of functions | Issued: 15. June 2015 11

According to customer needs, a cost optimized solution was created.

Q4 Weld Process Controller

Overview Q4 replacement parts and accessories

LSQ3 / LSQ5 Power Source for Q4 Weld Process Controller

Overview LSQ5 and LSQ3 Power Sources

12 Weld Process Controllers – Overview of functions | Issued: 15. June 2015

With the Q8Tool software the Q4 can be programmed over USB

Example configuration with a Q4 in a Power Clutch Weld Package

Views of the Q4 Weld Process Controller

Q4 Weld Process Controller integrated Q4 Weld Process Controller integrated

Weld Process Controllers – Overview of functions | Issued: 15. June 2015 13

Q1 Weld Process Controller

Overview Q1 replacement parts and accessories