Instruction manual

Robot – torch
Power Joint 5
Air cooled

Art. Nr. : 71.9-0

Version : 2.3 GB Austraße 2A D-66849 Landstuhl
Stand : 01.09.09 TEL. : +49 (0) 6371 / 92 67-0
Druck : 21.09.09 FAX. : +49 (0) 6371 / 92 67-19
e-mail : info@sks-welding.de
 Table of contents

1 SAFETY INSTRUCTIONS ........................................................................................................................ 3

2 ASSEMBLIES ............................................................................................................................................. 6
2.1 POWER JOINT SYSTEM ........................................................................................................................ 6
2.2 GOOSENECK, ......................................................................................................................................... 7
2.3 POWER JOINT WITHOUT MOUNTING SET ............................................................................................. 8
2.4 MOUNTING SETS .................................................................................................................................. 8
2.5 POWER CABLE...................................................................................................................................... 9
3 SPARE AND EXPENDABLE PARTS ..................................................................................................... 9
3.1 GOOSENECK ........................................................................................................................................ 9
3.2 GAS NOZZLES, SURVEY...................................................................................................................... 11
3.3 POWER JOINT- SPARE PARTS AND CONNECTION MATERIAL ............................................................. 12
3.4 LINERS ............................................................................................................................................... 13
3.5 PROGRAMMING TIPS .......................................................................................................................... 13
3.6 TORCH CABLE..................................................................................................................................... 13
3.7 MISCELLANEOUS PARTS .................................................................................................................... 14
3.8 CABLE OF COLLISION PROTECTION .................................................................................................... 14
3.9 CUTTER OVERVIEW ............................................................................................................................ 15
3.9.1 Cutter for ZK nozzle holder Z15 .............................................................................................. 15
3.9.2 Cutter for Tough Lock nozzle holder ...................................................................................... 16
4 DIRECTION FOR HANDLING AND MAINTENANCE ....................................................................... 17
4.1 POWER CABLE.................................................................................................................................... 17
4.2 TORCH ................................................................................................................................................ 17
4.3 MAINTENANCE OF SEALS ................................................................................................................... 17
4.4 TROUBLESHOOTING ........................................................................................................................... 17
5 INSTRUCTION FOR CHANGE AND INSTALLATION ...................................................................... 18
5.1 CHANGE OF GOOSENECK ................................................................................................................... 18
5.2 MOUNTING OF POWER JOINT............................................................................................................. 19
6 TECHNICAL DATA .................................................................................................................................. 21
6.1 CRASH PROTECTION .......................................................................................................................... 21
6.2 TCP ACCURACY (WHEN CHANGING SPARE PARTS)........................................................................... 21
6.3 TCP- DRAWINGS ................................................................................................................................ 22

2-25
1 Safety instructions

Non-observance of following safety measures can be perilous!

Follow regulations for prevention of industrial accidents

Set-up is reserved to persons with the according knowledge of the handling of arc
welding machines.
Wear prescribed protective clothing, eye and ear protection according UVV 26.0, VBG
15. Protect eyes and face with protective shield.

Hot sparks and spatter!

During welding hot flying sparks and spatter appear.
Flying sparks and spatter may cause explosion and fire.
Remove containers with inflammable and explosive liquids. Do not heat
explosive liquids, dust or gases by welding or thermal cutting.
Seemingly harmless looking materials may explode when heated in
closed containers.

Strong electric and electromagnetic field!

During welding, strong electromagnetic radiation appears at the welding
unit.
The function of cardiac pacemakers can be disturbed near the welding
system. Malfunction on electronic devices (e.g. computers) may occur
near the welding site.
Keep away persons with cardiac pacemakers from the welding unit. Do
not use electronic devices near the welding unit or protect devices from
electromagnetic radiation.

Radiation!
Arc emits ultraviolet (UV) radiation.
Burns on unprotected skin and blindness possible.
Wear safety glasses or install protectors. Protect bare skin (hands, face)
from irradiation. Protect non-involved persons with curtains and
protectors from optical radiation and dazzling.

3-25
 Burn hazard!
Contact tip, retainer, gas nozzle and gooseneck may be hot.
Burn possible on contact.
Wear heat protection gloves. Await cooling down before maintenance
work.

Electrical voltage!
Contact tip and retainer 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.

Vapours of chlorinated hydrocarbon may convert into toxic phosgene under ultraviolet
radiation.

Fumes and gases!

Toxic fumes and gases may be generated during welding.
Inhalation can lead to toxication and breathlessness.
Do not inhale fumes and gases. Provide sufficient ventilation. Keep away
vapours and solvents from arc radiation area.

If necessary, provide ventilation and exhaust to ensure non excess of MAK- values
(MAK= Maximale Arbeitsplatzkonzentration gesundheitsschädlicher Arbeitsstoffe =
maximum concentration of noxious substances for work places).

Noise!
High noise levels may be generated during welding.
Noise of more than 70 dBA can cause permanent aural damage and
deafness.
Wear appropriate ear protection and ear plugs. Ensure that other
persons in the working area are not disturbed by noise.

High pressure!
Gas containers and gas supply systems are under high pressure.
May explode if handled wrong.
Follow instructions of the gas producers and the pressure gas
regulation concerning handling. Secure gas containers. Place shielding
gas containers in provided collets and secure with retaining chain.
Protect gas containers against toppling, do not throw or heat.
Disconnect gas container from welding machine during crane transport.

4-25
Operational error.
Incorrect operation and maintenance may cause malfunction and
damage to property.
Read and follow instruction manual of all welding components, e.g.
power source, wire feeder and cooling unit. Do not excess limit values of
load.

Handling
Cable
Improper treatment of cables can lead to breach of insulation and thus to
loss of usability
Do not drag cables across sharp edges. Keep away from splash zone.
Do not lay on hot parts.

5-25
2 Assemblies

2.1 Power Joint system

Consisting of:
Gooseneck with clamping cap, retainer, insulator, gas nozzle und contact tip
Power Joint with aluminium protection cap
Mounting set for robot
Power cable with liner, disconnect cable and Power Pin connector

6-25
2.2 Gooseneck,

4
3 6
1 2 5 7

Position Description Item number

1 Gooseneck 30° TCP 500mm, w/o equipment 58-4-330-500-1
2 Gooseneck 45° TCP 450mm, w/o equipment 58-4-345-450-1
3 Gooseneck 45° ZK short TCP 400mm, w/o 58-1-245-400-1
equipment
4 Gooseneck 22° TCP 350mm, w/o equipment 58-1-22-350-1
5 Gooseneck 22° TCP 400mm, w/o equipment 58-1-22-400-1
6 Gooseneck 45° TCP 350mm, w/o equipment 58-1-45-350-1
7 Gooseneck 45° TCP 400mm, w/o equipment 58-1-45-400-1
The goosenecks Item 1 and Item 2 are adaptations of the Power Clutch
system. If these are used for the Power Joint system, the actual TCP
does not match the item description.
See also TCP list and drawings in Chapter 6.3 Fehler! Verweisquelle konnte
nicht gefunden werden.. This does not affect the functionality, spare parts
and consumables.

7-25
2.3 Power Joint without mounting set
Consisting of:
Power Joint 5 with rubber sleeve and aluminium protection
cap

Position Description Item number

1 Power Joint PJ5 71-9-0

2.4 Mounting sets

Consisting of:
Fixing cover, connecting flange, clamping bush and sealing
grommet

Name Item number

Mounting set for Power Joint on 71-9-0-1
Motoman SSA2000/EA1400N and
EA1900N
Mounting set for Power Joint on 71-9-0-2
Motoman EA1800N
Mounting set for Power Joint on ABB 71-9-0-3
IRB 1600iD
Mounting set for Power Joint on 71-9-0-4
Fanuc Arc Mate 100iC , 100iC 6L
und 120iC 10L
Mounting set for Power Joint on 71-9-0-5
Kuka KR5 arc HW
Mounting set for Power Joint on 71-9-0-6
Fanuc Arc Mate 120iC

8-25
2.5 Power cable

Consisting of:
- Highly flexible coaxial- cable with Power Pin and Power Joint- connector and
corrugated tube sheathing
- External disconnect cable M8, 3-pin
- Velcro for attaching disconnect cable to coaxial cable (3 pcs.)

Description Item number

Power cable 72mm² PF5 – PJ5 on Motoman 1400N 61-9-1400
Power cable 72mm² PF5 – PJ5 on Motoman 1900N 61-9-1900
Power cable 72mm² PF5 – PJ5 on Motoman EA1800N 61-9-1800
and ABB IRB 1600iD
Power cable 72mm² PF5 – PJ5 on Fanuc Arc Mate 100iC 61-8-100
Power cable 72mm² PF5 – PJ5 on Kuka KR5 arc HW 61-9-5
Power cable 72mm² PF5 – PJ5 on Fanuc Arc Mate 100iC 6L 61-8-100-6
Power cable 72mm² PF5 – PJ5 on Fanuc Arc Mate 120iC 10L 61-8-120-10
Power cable 72mm² PF5 – PJ5 on Fanuc Arc Mate 120iC 61-8-120

3 Spare and expendable parts

8
3.1 Gooseneck 1

2
5

4
1
3

Pos. Description Item number

1 Gas nozzle (insulated), long
Standard gas nozzle 13mm tapered 401-4-50
9-25
Pos. Description Item number
Heavy duty gas nozzle 13mm tapered 401-6-50
Standard gas nozzle 13mm bottle shaped 401-42-50
Standard gas nozzle 16mm tapered 401-4-62
Heavy duty gas nozzle 16mm tapered 401-6-62
Gas nozzle (insulated), short
Standard gas nozzle 13mm bottle shaped 401-48-50
Standard gas nozzle 16mm tapered 401-8-62
Gas nozzle ZK ZK15 15 bottle shaped, cylindric inside 41-6-115
2 Gooseneck insulator 58-1-5
Gooseneck insulator for ZK-Z15 for retainer 43-8-6 43-6-4-2
3 Tough Lock retainer (including O- and clamping ring) 404-31
Retainer ZK-Z15 for gooseneck ZK-design (58-1-245-400) 43-8-6
(including O- and clamping ring)
4 Clamping ring for retainer 454-1-2
5 O – ring for retainer 404-31 und 43-8-6 402-6
6 TOUGH LOCK- contact tip for wire 1,0mm HD-Cu, 403-20-1.0F
8x34mm
TOUGH LOCK- contact tip for wire 0,8mm HD-CuCrZr, 403-27-0.8F
8x34mm
TOUGH LOCK- contact tip for wire 1,0mm HD-CuCrZr, 403-27-1.0F
8x34mm
TOUGH LOCK- contact tip for wire 1,2mm HD-CuCrZr, 403-27-1.2F
8x34mm
TOUGH LOCK- contact tip for wire 1,4mm HD-CuCrZr, 403-27-1.4F
8x34mm
TOUGH LOCK- contact tip for wire 1,6mm HD-CuCrZr, 403-27-1.6F
8x34mm
Contact tip Power Lock for wire 0,8mm Heavy Duty 40-4-7-0.8S
CuCrZr 8x34mm
Contact tip Power Lock for wire 0,9mm Heavy Duty 40-4-7-0.9S
CuCrZr 8x34mm
Contact tip Power Lock for wire 1,0mm Heavy Duty 40-4-7-1.0S
CuCrZr 8x34mm
Contact tip Power Lock for wire 1,2mm Heavy Duty 40-4-7-1.2S
CuCrZr 8x34mm
Contact tip Power Lock for wire 1,4mm Heavy Duty 40-4-7-1.4S
CuCrZr 8x34mm
Contact tip Power Lock for wire 1,6mm Heavy Duty 40-4-7-1.6S
CuCrZr 8x34mm
7 Gooseneck 22° TCP 400mm, w/o equipment 58-1-22-400-1
Gooseneck 45° TCP 400mm, w/o equipment 58-1-45-400-1
Gooseneck 22° TCP 350mm, w/o equipment 58-1-22-350-1
Gooseneck 45° TCP 350mm, w/o equipment 58-1-45-350-1
Gooseneck 45° ZK short w/o equipment TCP 400mm 58-1-245-400-1
Gooseneck 30° TCP 500mm ,w/o equipment 58-4-330-500-1
Gooseneck 45° TCP 450mm, w/o equipment 58-4-345-450-1
8 Bayonet clamping cap for gooseneck quick change system 71-3-24

10-25
Always switch off power source before working at the torch!

3.2 Gas nozzles, survey

Standard short Heavy duty short
Ø 16 Ø 13 Ø 16
3
21

401-8-62 41-8-13-TS 401-48-50 401-81-62-G

67

67

67
Ø 24 Ø 24 Ø 24 Ø 27
tapered bottle shaped tapered
tapered
Standard long
Ø 16 Ø 13
3

Standard ZK short
28

Ø 15

3
73

73

401-4-62 401-4-50 401-42-50

32
46

41-6-115

Ø 24 Øtapered
24 Ø 24 Ø 25
tapered bottle shaped

Heavy duty long

401-6-50
73

Ø 27
bottle shaped
tapered

11-25
3.3 Power Joint- spare parts and connection material

1
6

Positio Description Item number

n
1 Aluminium protection cap for Power Joint PJ5 71-9-13
2 Clamping bush complete with grub screw for PJ5 Version 71-9-29
sub-miniature switch for Motoman
SSA 2000/EA1400N/1900N
Clamping bush complete with grub screw for PJ5 Version 71-9-37
sub-miniature switch for Motoman EA1800N
Clamping bush complete with grub screw for PJ5 Version 71-9-38
sub-miniature switch for ABB IRB 1600iD /Fanuc Arc Mate
100iC, 100iC 6L, 120iC und 120iC 10L
3 Connecting flange for Power Joint on Motoman 71-9-23
SSA 2000/EA1400N/1900N
Connecting flange for Power Joint on Motoman EA1800N 63-9-1
Connecting flange for Power Joint on ABB IRB 1600iD 63-9-2
Connecting flange for Power Joint on Fanuc Arc Mate 63-9-5
100iC 100iC 6L, 120iC und 120iC 10L
Connecting flange for Power Joint on Kuka KR5 arc HW 63-9-4
4 Fixing cover for Power Joint on Motoman EA 1400N/1900N 71-9-22
Fixing cover for Power Joint on Motoman EA 1800N 71-9-42
Fixing cover for Power Joint on ABB IRB 1600iD 71-9-41
Fixing cover for Power Joint on Fanuc Arc Mate 100iC, 71-9-46
100iC 6L und 120iC 10L
12-25
 Fixing cover for Power Joint on Fanuc Arc Mate 120iC 71-9-49
Fixing cover for Power Joint on Kuka KR5 arc HW 71-9-45
5 Rubber cup for Power Joint PJ5 71-9-14
6 Switch, subminiature for PJ5 71-9-34
7 Sealing grommet for Power Joint for Motoman EA 71-9-31
1400N/1800N/1900N
Sealing grommet for Power Joint for ABB IRB 1600iD/ 71-9-40
Fanuc Arc Mate 100iC, 100iC 6L, 120iC und 120iC 10L /
Kuka KR5 arc HW

3.4 Liners
1 2

Quick Load Liner for steel wire

Position Description Item number

1 Quick Load Liner 1,8m for steel wire 0,8-1,0mm 415-35-6Q
Quick Load Liner 1,8m for steel wire 1,2-1,6mm 415-116-6Q
2 Liner retainer 415-26

3.5 Programming tips

Stick out length Description Item number
12 mm TOUGH LOCK programming tip stick out 65-2
length 12mm, 8mm
15 mm TOUGH LOCK programming tip stick out 65-4
length 15mm, 8mm
20 mm TOUGH LOCK programming tip stick out 65-5
length 20mm, 8mm
12mm Programming tip Z13/Z15 stick out 65-6
length12mm
15mm Programming tip Z13/Z15 stick out length 65-7
18mm
20mm Programming tip Z13/Z15 stick out length 65-8
20mm

3.6 Torch cable

Pos. Description Item number

1 O-Ring 13x2,5 for Power Pin 91-2-130-25
13-25
2 End cap for Power Pin type M 61-2-0-2-2
3 Disconnect cable 1m 3x0,34mm² with M8 socket/plug for 541031801
PF5
4 Corrugated tube PUR NW 23 suitable for power cable for 91-3-2-300
Motoman SSA2000/ EA1400N
Corrugated tube PUR NW 23 suitable for power cable for 91-3-2-400
Motoman EA1800N und ABB IRB 1600iD
Corrugated tube PUR NW 23 suitable for power cable for 91-3-2-500
Fanuc Arc Mate 100iC
Corrugated tube PUR NW 23 suitable for power cable for 91-3-2-600
Motoman EA1900N/ Kuka KR5 arc HW
Corrugated tube PUR NW 23 suitable for power cable for 91-3-2-700
Fanuc Arc Mate 100iC 6L und 120iC
Corrugated tube PUR NW 23 suitable for power cable for 91-3-2-800
Fanuc Arc Mate 120iC 10L
No picture Velcro back to back 571040300

3.7 Miscellaneous parts

Calibration tool for TCP review
Calibration tool for each gooseneck available on demand

3.8 Cable of collision protection

PF5

Robot Power Joint 5

1 1 1
+24 V
Contact 4 4
0V 3 3 4
Supply hose 4 4
1 3 3 1 3
M8 socket M8 plug
4
1 3

Colour- combination of wires

Colour combination Wire 1 Wire 3 Wire 4
white/green/brown white green brown
brown/blue/black brown blue Black

14-25
3.9 Cutter overview

3.9.1 Cutter for ZK nozzle holder Z15

Gas nozzle Cutter

41-6-115 gas nozzle ZK Z15 66-3-12 SKS cutter für
41-6-115 41-6-115
15mm bottle-shaped, Thielmannn nozzle cleaning
internally cylindrical for nozzle station for 41-6-115
holder 43-8-6

Dead stop

15-25
3.9.2 Cutter for Tough Lock nozzle holder

Gas nozzle Cutter

401-48-50 Standard 66-3-6 SKS cutter für
gas nozzle 13mm Thielmannn Tough Lock cleaning
bottle-shaped long unit for 401-48-50
401-8-62 Standard 66-3-7 SKS cutter für
gas nozzle 16mm Thielmannn Tough Lock cleaning
tapered short unit for 401-8-62 and 401-81-62
401-81-62 heavy duty 66-3-7 SKS cutter für
gas nozzle 16mm Thielmannn Tough Lock cleaning
tapered short unit for 401-8-62 and 401-81-62
401-4-62 Standard 66-3-8 SKS cutter für
gas nozzle 16mm Thielmannn Tough Lock cleaning
tapered long unit for 401-4-62 and 401-6-62
401-6-62 heavy duty 66-3-8 SKS cutter für
gas nozzle 16mm Thielmannn Tough Lock cleaning
tapered long unit for 401-4-62 and 401-6-62
401-4-50 Standard 66-3-9 SKS cutter for
gas nozzle 13mm Thielmannn Tough Lock cleaning
tapered long unit for 401-4-50, 401-42-50 and
401-6-50
401-42-50 Standard 66-3-9 SKS cutter for
Dead stop gas nozzle 13mm Thielmannn Tough Lock cleaning
bottle-shaped long unit for 401-4-50, 401-42-50 and
401-6-50
401-6-50 heavy duty 66-3-9 SKS cutter for
gas nozzle 13mm Thielmannn Tough Lock cleaning
tapered long unit for 401-4-50, 401-42-50 and
401-6-50

16-25
4 Direction for handling and maintenance

Burn hazard!
Contact tip, retainer, gas nozzle and gooseneck may be hot.
Burn possible on contact.
Wear heat protection gloves. Await cooling down before maintenance
work.

Electrical voltage!
Contact tip and retainer 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.

4.1 Power cable

Review screw connections, retighten if necessary.
Send in for repair or replace damaged, deformed or worn parts.

4.2 Torch
Check parts for correct fit. Retighten loose screw connections of retainer
and contact tip.

4.3 Maintenance of seals

Grease O- ring for Power Pin slightly. Make sure to leave gas holes open

4.4 Troubleshooting

Problem Possible reason

No arc Power cable to part or torch
broken
Power source or control
unit defect
Electrode defect
control line broken

Torch body or power Welding current too high

cable overheated Contact tip not tightened

17-25
5 Instruction for change and installation

5.1 Change of gooseneck

1. Twist bayonet clamping cap

anticlockwise
2. Draw back clamping cap
3. Pull gooseneck out of fit
4. Push new gooseneck into fit; pay
attention to orientation of adjusting
pins
5. Push clamping cap towards torch body
6. Twist clamping cap clockwise as far as
it will go
7. Check if gooseneck is fixed

18-25
5.2 Mounting of Power Joint
If the Power cable is attached to the wire feeder, release Power Pin from wire
feeder before mounting.

c d
1. Screw power cable (c) to PJ-
e cable junction (f)

f
2. Insert end of power cable into
clamping cap (d) and push
B locating pins over spanner flat of
PJ- cable junction (f) . Insert
disconnect cable (A) into clamping
cap (d) and fix with o-rings (B).

A 3. Fix connection flange (a) with

screws (b) on robot arm
Make sure adjust pin of the robot
arm rests in corresponding hole of
the connection flange

4. Insert power cable (c) and

disconnect cable (A) into feed
through in hand of robot

a
b

19-25
 5. Tighten Power Joint to connection
flange with screws (g)
Make sure that adjust pin of the
robot arm rests in corresponding
fit drill of Power Joint

h
6. Align groove (h) of the clamping
cap to tap hole (i) of the robot

7. Align small holes of sealing socket

g with adjust pins of the clamping
cap and put disconnect cable into
slitting of the sealing socket
k
8. Tighten arresting flange (i) with
screw (k) to tap hole (j). Make sure
the arresting flange rests in the
A locating pins of the clamping cap
to prevent torsion..
Push disconnect cable through
i
robot arm at cut out part of the
arresting flange (i) (CAUTION: Do
not squeeze cable)
j

9. Connect disconnect cable of PJ5

(A) and disconnect cable of the
power cable (C)

Insert Power Pin of the power

cable into corrugated tube and
A C push into upper hole of the Power
Pin connector as far as it will go.
Tighten upper clamping screw
of the Power Pin connector.
Connect disconnect cable of the
power cable (C) and disconnect
cable to the robot (D)
Additional information on mounting
of the PJ5 can be found at
www.powerjoint.com

C D

20-25
6 Technical data

Maximum welding current

* *
Power Joint 100% duty cycle 60% duty cycle
Robot torch air cooled 340 A 420 A
* at cycle duration of 10 minutes and 40°C ambient temperature

6.1 Crash protection

Maximum deflection 10°
Accuracy of TCP after deflection 0,2 mm (approx. 8 mil)

6.2 TCP accuracy (when changing spare parts)

TCP-accuracy in x- direction: 0,2mm

TCP- accuracy in y- direction: 0,2mm
TCP- accuracy in z- direction: 0,5mm

21-25
6.3 TCP- drawings
58-1-22-350

58-1-22-400

22-25
58-1-45-350

58-1-45-400

23-25
58-1-245-400

58-4-330-500

24-25
58-4-345-450

25-25