LSQ5 Man-0964 V3.1.0 en

1 About this operating manual
Operating manual for the

DCT power source LSQ5
Item number: 77-1185-00
Please read this operating manual before initial start-up

Observe safety guidelines
Please retain for future reference
SKSde.21OCT20.ot.ot.v3.1.0
Page 1 of 48 MAN-0933EN | V2.0 Operating manual for LSQ5

1 About this operating manual SKS Welding Systems
Table of contents
1 About this operating manual ........................................................................................................................... 5

1.1 Target group ............................................................................................................................................ 5
1.2 Purpose of the operating manual ........................................................................................................... 5
1.3 Scope of validity of the operating manual .............................................................................................. 5
1.4 Overview of this document ..................................................................................................................... 5
2 Notes on the display of warning and safety instructions ................................................................................. 6
2.1 Note about action-related warnings ....................................................................................................... 6
2.2 Definition of warning information .......................................................................................................... 6
2.3 Definition of safety information.............................................................................................................. 7
2.4 Definition of signal words ....................................................................................................................... 7
2.5 Safety symbols ........................................................................................................................................ 8
2.5.1 Types of safety symbol .................................................................................................................... 8
2.6 Symbols ................................................................................................................................................... 8
3 Warning information ........................................................................................................................................ 9
4 For your safety .............................................................................................................................................. 11
4.1 Intended use ......................................................................................................................................... 11
4.2 Product safety ....................................................................................................................................... 11
4.3 Dangers if the system is used wrongly .................................................................................................. 11
4.4 Organisation, personnel ........................................................................................................................ 12
4.4.1 Safety instructions for operators .................................................................................................. 12
4.4.2 Storing the operating manual ....................................................................................................... 12
4.4.3 Technical condition of the power source LSQ5 ............................................................................ 12
4.4.4 Design changes and modifications to the power sources LSQ5 are not permitted...................... 12
4.4.5 Repair ............................................................................................................................................ 12
4.4.6 Obligation to report faults and damage........................................................................................ 12
4.4.7 Illustrations of the power source LSQ5 ......................................................................................... 13
4.4.8 Continuous improvement of the operating manual ..................................................................... 13
4.4.9 Name of the buyer when reselling ................................................................................................ 13
4.4.10 Copyright ....................................................................................................................................... 13
5 Arrangement of the LSQ5 power source in the robot welding system .......................................................... 14
5.1 Arrangement of the power source for single-wire application ............................................................ 14
5.2 Arrangement of the power source LSQ5 for double wire application .................................................. 15
6 Operating mode of the power source LSQ5.................................................................................................. 16
7 Welding power source LSQ5......................................................................................................................... 17
7.1 Note on setting up power sources ........................................................................................................ 17
7.1.1 Amount of clear space required around power sources .............................................................. 17
7.2 The different sides of the power source ............................................................................................... 18
7.3 Mounting the power source to the wall ............................................................................................... 19
Page 2 of 48 MAN-0964EN | V3.1.0 Operating manual for LSQ5
7.4 Maintaining access to the power source .............................................................................................. 20

7.5 Technical Data ....................................................................................................................................... 20
7.6 Dimensions ............................................................................................................................................ 21
8 Overview of the parts of the power source LSQ5 ......................................................................................... 22
8.1 Side with operating panel ..................................................................................................................... 22
8.2 Side with main switch ........................................................................................................................... 23
8.3 Rear side with fan ................................................................................................................................. 23
9 Mains voltage ................................................................................................................................................ 24
10 Changing the voltage on the power source LSQ5 ..................................................................................... 25
11 Programming / Setting up ........................................................................................................................... 26
11.1 Markers ................................................................................................................................................. 26
11.2 Displaying the current settings ............................................................................................................. 26
11.3 Changing the settings ............................................................................................................................ 27
11.4 Marker A (System structure) ................................................................................................................. 27
11.5 Marker B (Welding process).................................................................................................................. 27
11.6 Marker C (Welding process controller) ................................................................................................. 27
11.7 Marker D (Special) ................................................................................................................................. 27
12 LED functions in welding mode .................................................................................................................. 28
12.1 Status indicator ..................................................................................................................................... 28
12.2 Alarm display ......................................................................................................................................... 28
13 LSQ5 alarms............................................................................................................................................... 29
14 Stacking and synchronising welding power sources .................................................................................. 30
14.1 Stacking and synchronising welding power sources ............................................................................. 30
14.2 Synchronising power sources (Share Power or dual wire mode) ......................................................... 31
15 Maintenance and care ................................................................................................................................ 32
15.1 Re-testing in accordance with DIN EN 60974-4 (VDE 0544-4):2011 and BGR 500 (formerly BGV D1). 33
15.1.1 Quarterly inspection ..................................................................................................................... 33
15.1.2 Annual inspection.......................................................................................................................... 33
15.1.3 Visual inspection to ensure that the equipment is in perfect condition ...................................... 33
15.1.4 Measuring the earth cable's resistance ........................................................................................ 33
15.1.5 Measurement of insulation resistance ......................................................................................... 34
15.1.6 Measuring the open circuit voltage (to EN 60974-1 / VDE 0544-1).............................................. 35
15.1.7 Testing the welding machine's functions ...................................................................................... 35
15.1.8 Repair work ................................................................................................................................... 35
16 Part overview .............................................................................................................................................. 36
17 Spare parts ................................................................................................................................................. 37
18 Accessories ................................................................................................................................................ 38
19 Calibration of power sources ...................................................................................................................... 39
20 Wiring diagram ........................................................................................................................................... 40
21 Disposal ...................................................................................................................................................... 41
Operating manual for LSQ5 MAN-0964EN | V3.1.0 Page 3 of 48
22 EU declaration of conformity ...................................................................................................................... 42

23 CSA Mark ................................................................................................................................................... 43
24 Welding safety ............................................................................................................................................ 44
25 Index ........................................................................................................................................................... 45
26 Table of figures ........................................................................................................................................... 46
27 For your notes ............................................................................................................................................ 47

1 About this operating manual

1.1 Target group
This operating manual is intended for personnel who are responsible for the assembly, connection, installation,
start-up, operation, maintenance and repair of the power source LSQ5. Please read this entire operating manual
before putting the power source into operation.
Information about qualifications, education and training can be found in the section entitled "Organisation,
personnel".
1.2 Purpose of the operating manual

This operating manual provides an overview of how to assemble, connect, install, start up, operate, maintain
and repair the power source LSQ5 and information on how to use it safely.
It also contains practical information aimed at ensuring that the robot welding system is operated safety.
1.3 Scope of validity of the operating manual

This operating manual only applies to the power source LSQ5, which is used for single-wire and double wire
applications for MIG/MAG welding.
If you require information concerning the functionality of the overall system, please read the manual for the
overall welding system.
1.4 Overview of this document

This operating manual contains all of the information needed to assemble the power source LSQ5 in
accordance with the safety regulations and therefore to ensure that the robot welding system is operated safely.
The following points are dealt with in more detail following the information about warnings and safety
instructions:
▪ Arrangement of the LSQ5 power source in the robot welding system

▪ Operating mode of the power source LSQ5
▪ Welding power source LSQ5
▪ Overview of the parts of the power source LSQ5
▪ Mains voltage
▪ Changing the voltage on the power source LSQ5
▪ Programming / Setting up
▪ LED functions in welding mode
▪ LSQ5 alarms
▪ Stacking and synchronising welding power sources
▪ Maintenance and care
INFORMATION
This operating manual is a translation of the original operating manual.

2 Notes on the display of warning and safety instructions SKS Welding Systems
2 Notes on the display of warning and safety instructions

The following section explains the meaning of the:
▪ Warning and safety instructions

▪ Signal words
▪ Safety symbols
▪ Symbols
Safety instructions provided are not intended to inconvenience you, but for your protection.
Please read the entire operating manual and follow the instructions.
If you require information concerning the mode of operation of the overall system, please read the manual for
the overall welding system.
2.1 Note about action-related warnings

The Warning information section contains generally applicable safety instructions that have to be complied with.
Specific action or situation-related safety instructions can be found in the relevant action step and/or in section
in which an example situation us described.
2.2 Definition of warning information
WARNING!
Denotes a potentially hazardous situation.
Failure to avoid this hazard may result in death or severe injury.
CAUTION!
Denotes a potentially hazardous situation.
Failure to avoid this hazard may result in minor injuries (full healing
without consequential injuries) or damage to property.

2.3 Definition of safety information
NOTE
Indicates general information associated with a risk of damage to
property and without the risk of physical injury. Disregarding this
information will interfere with product handling, which may lead to minor
material damage in some cases.
INFORMATION
General information and notes concerning the optimum use of the
product.
2.4 Definition of signal words
Signal words
Signal word Explanation
Signal word for identifying a hazard with medium risk, possibly resulting in death or severe
Warning
physical injury if it is not avoided.
Signal word for identifying a hazard with low risk which may result in slight or moderate
Caution
physical injury or material damage if it is not avoided.
Signal word for marking general information without the risk of physical injury. Disregarding
Please note the note will interfere with product handling, which may lead to minor material damage in
exceptional cases.
Information Signal word for general information and references for optimal use of the product.

2.5 Safety symbols

2.5.1 Types of safety symbol
Safety symbols
Component Explanation Example
Safety symbol which warns against

Warning symbol
danger.
2.6 Symbols
Symbols
Symbol Explanation
Warning of dangerous electrical voltage
Indicates general information with the risk of damage

to property and without the risk of physical injury.
Disregarding this information will interfere with
product handling, which may lead to minor material
damage in some cases.
General information and notes concerning the

optimum use of the product.
Sections marked with "" are handling instructions

and operational prompts.
 Example:
 Ensure that this operating manual is always kept
close to the robotic welding system.
■ Lists are introduced with "■"

3 Warning information SKS Welding Systems
3 Warning information
WARNING!
Disregarding any of the safety instructions can result in significant
danger!
Disregarding the following safety instructions can lead to death.
• Observe the accident prevention regulations.
The system must only be commissioned by persons who have appropriate knowledge in the
use of arc welding equipment. Wear the prescribed protective clothing, eye protection and
ear defenders as specified in UVV 26.0, VBG 15. Protect eyes and face with a safety mask.
WARNING!
Electric shock from electrical voltage!
Risk of electric shocks if touched.
• Always disconnect the power source before performing any
maintenance work or changing parts, and protect it from being
reconnected.
Switching off or removing the fuse does not provide adequate electrical
protection.
WARNING!
If the voltage selector switch is operated while the unit is switched on, it
may generate an electric shock.
• Never operate the voltage selector switch when the unit is
switched on.
• Always switch off the power source and wait for 3 minutes before
changing the voltage setting.

3 Warning information SKS Welding Systems
CAUTION!
Poor air circulation can cause welding power sources to overheat!
If the cooler is not supplied with sufficient air, the welding power sources
will overheat.
• Always position welding power sources and surrounding objects in
such a way that the fan is not obstructed and able to take in
sufficient air and for this air to be able to flow through the heat sink
on the power source.
CAUTION!
The use of oppositely poled or different power sources can damage
the power sources!
Using power sources that are not of the same type will damage the
power sources.
• When using Share Power and/or dual wire mode, it is therefore vital
to always use the same type of power source (2x LSQ5).

4 For your safety SKS Welding Systems
4 For your safety

Safety instructions are not intended to inconvenience you but to protect you.
Read the operating manual carefully and follow the instructions.
4.1 Intended use

The LSQ5 is a powerful power source inverter for gas metal-arc welding (GMAW) in automatic robot welding
systems, and is designed to provide the power required for welding.
The power source must only be used in closed rooms and for industrial purposes. The power source must only
be operated by trained and authorised personnel.
Persons without sufficient physical, mental, locomotory or sensory capability may not use the LSQ5 power
source. Any other use is regarded as not being in accordance with the intended purpose.
The manufacturer shall not be liable for damage resulting from any use of the unit other than for its intended
purpose. Any risk shall be borne by the user. Observing this operating manual also constitutes "use for intended
purpose".
4.2 Product safety

The LSQ5 power source represent the state of the art and complies with the recognised safety regulations; in
spite of this, hazards may still occur.
The LSQ5 power source may only be used if it is in perfect condition and taking the operating manual into
consideration.
INFORMATION
The unit must only be commissioned by persons who have appropriate
knowledge in the use of arc welding equipment.
Wear the prescribed protective clothing, eye protection and ear
defenders as specified in UVV 26.0, VBG 15.
Protect eyes and face with a safety mask.
INFORMATION
This welding power source must only be operated with welding torches
conform with IEC 60974-7 / GB 15579.7
4.3 Dangers if the system is used wrongly
INFORMATION
Warning against unauthorised conversion or modification.
Unauthorised conversions or modifications are not allowed and will
result in the loss of any right to make warranty claims. The
manufacturer must always be informed of any unauthorised
conversions or modifications.

4.4 Organisation, personnel

4.4.1 Safety instructions for operators
This operating manual exclusively applies to the power source LSQ5.
The power source must only be operated by trained and qualified personnel.
Persons without sufficient physical, mental, locomotory or sensory capability may not use the units.
4.4.2 Storing the operating manual
• Keep the operating manual in a location where it is accessible at all times.

Make sure that this operating manual is always kept close to the robotic welding system.
4.4.3 Technical condition of the power source LSQ5

Always follow the instructions and prohibitions below to ensure that the unit is used safely and to its full extent.
4.4.4 Design changes and modifications to the power sources LSQ5 are not permitted
Unauthorized interference with the power source LSQ5 and unauthorized design changes of any kind to the
power source LSQ5 will result in the loss of any right to warranty and liability claims in the event of injuries or
material damage.
The power source LSQ5 complies with the relevant safety regulations.
4.4.5 Repair
Only authorised experts may carry out repairs on the unit. Contact your dealer.
When replacing parts, always use genuine spare parts.
When ordering spare parts, please indicate the type of unit, serial number and item number, and the type
description and item number of the spare part.
INFORMATION
If repair or maintenance work is carried out on the power source LSQ5 by
persons who are not trained and unauthorised for such work, the guarantee
will become void.
Any interference with the units or alterations will result in loss of warranty .
4.4.6 Obligation to report faults and damage

Please report faults and damage to us without delay so that our specialists can determine the cause of the fault
and rectify it immediately.

4.4.7 Illustrations of the power source LSQ5

Certain details of the physical power source LSQ5 may differ from the illustrations in this manual. However, this
has no effect on the operation of the LSQ5 power source.
4.4.8 Continuous improvement of the operating manual

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

Marie-Curie-Straße 14
67661 Kaiserslautern
Germany
Tel. +49(0)6301/7986-0
Fax. +49(0)6301/7986-119
E-Mail: info@de.sks-welding.com
4.4.9 Name of the buyer when reselling

If you resell the robotic welding system, please let us know the name and postal address of the new owner.
Please hand over the operating manual when you sell the product.
4.4.10 Copyright
The 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.
The information contained in this document is regularly checked, and corrections are included in subsequent
issues.
SKS Welding Systems GmbH

Marie-Curie-Straße 14
67661 Kaiserslautern
Germany
Tel. +49(0)6301/7986-0
Fax. +49(0)6301/7986-119
E-Mail: info@de.sks-welding.com
Since we work continuously on improvements, we reserve the right to make changes without prior notice.

5 Arrangement of the LSQ5 power source in the robot welding system SKS Welding Systems
5 Arrangement of the LSQ5 power source in the robot welding

system
5.1 Arrangement of the power source for single-wire application
Figure 1: Arrangement of the power source for single-wire application
Arrangement of the power source for single-wire application

Position Component
Welding power source
Welding process controller
Wire feeder
Field bus or universal interface (shown: Universal interface UNI5C-1)
Connecting hose bundle
Ground wire
Control lines
Welding torch system
Connection between welding process controller and PC
PC or laptop

5 Arrangement of the LSQ5 power source in the robot welding system SKS Welding Systems
5.2 Arrangement of the power source LSQ5 for double wire application
Figure 2: Arrangement of the power source for double wire application
Arrangement of the power source for double wire application

Position Component
Welding power source
Welding process controller
Wire feeder PF5-L and PF5-R
Field bus or universal interface (shown: Universal interface UNI5C-1)
Water cooler
Water return line (red)
Water supply line (blue)
Connecting hose bundle
Ground wire
Control lines
Welding torch system
Connection between welding process controller and PC
PC or laptop
Interconnect cable for connecting two similar LSQ5 welding power sources

6 Operating mode of the power source LSQ5 SKS Welding Systems
6 Operating mode of the power source LSQ5

The LSQ5 is a powerful power source inverter for gas metal-arc welding (GMAW) in automatic robot welding
systems, and is designed to provide the power required for welding.
The power source must only be used in closed rooms and for industrial purposes.
Unlike conventional inverter power sources, the LSQ5 with its Direct Control Technology controls the switching
transistors without a fixed clock frequency directly in accordance with the requirements of the welding process.
It therefore supplies the exact amount of energy that is required for the welding process without a time delay.
The LSQ5 power source can be configured through a panel that contains just four LED’s and two buttons.
As well as the status indicator that is shown in welding mode and the expanded alarm indicator, this unit can
also display the current settings.
The operating voltage and the operating mode can be adjusted for worldwide use without opening the power
source.

7 Welding power source LSQ5 SKS Welding Systems
7 Welding power source LSQ5

7.1 Note on setting up power sources
CAUTION!
Poor air circulation can cause welding power sources to overheat!
If the cooler is not supplied with sufficient air, the welding power sources
will overheat.
• Always position welding power sources and surrounding objects in
such a way that the fan is not obstructed and able to take in
sufficient air and for this air to be able to flow through the heat sink
on the power source.
NOTE
Set up the welding current source in such a way that it is electrically

isolated. The housing of the welding current source must not touch metal
objects. Additional earthing is not required.
7.1.1 Amount of clear space required around power sources
min. 100mm min. 200mm
Figure 3: Minimum amount of clear space required around the power source LSQ5
Figure 4: Ensure sufficient distance between fan and wall for air supply

7.2 The different sides of the power source
Figure 5: Front view Figure 6: View from the top
Figure 7: Side with main switch Figure 8: Side with operating panel

7.3 Mounting the power source to the wall

The power source LSQ5 can be mounted to the wall
with the LSQ5 wall bracket (Item no. 77-1180-01).
1. Slot the power source's handle into the

hanger at the top of the wall bracket.
2. Screw the supplied crews into the threaded
holes at the bottom of the power source to
secure it.
Figure 9: 77-1180-01_Wall bracket for LSQ5
Figure 10: Wall bracket (Item no. 77-1180-01) dimensioned for

welding power source LSQ5
LSQ5 wall bracket weight

approx. 3.0 kg
Figure 11: LSQ5 plus wall bracket

7.4 Maintaining access to the power source
INFORMATION
Make sure that the power sources can be easily accessed from every
side. The gap between the back of the power source and any
neighbouring objects must be large enough to be easily able to reach
into with arms and hands and access the cables, switches and operating
panel inside it.
7.5 Technical Data
Technical data for the power source LSQ5
Component Contents
Welding current / voltage adjustment range for TIG: 10 A / 10,4 V – 510 A / 30,4 V
Welding current / voltage adjustment range for MIG/MAG: 15 A / 14,8 V – 480 A / 38 V
Duty cycle at an ambient temperature of 40°C 40% duty cycle 480 A
Duty cycle 10 min (60%: 6min ON, 4min OFF)
No load voltage 70V
Mains voltage (tolerances) 3x400 V (-10%, +10%)
Mains voltage (tolerances) 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
cos / 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] 471x400x557
Weight 52 kg
Complies with the following 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

Connections
Electrical: 2x SPW system bus
LSQ Interconnect Bus (for using Share Power and dual wire)
Can be supplied with a field bus (type as per customer requirements)
2x 70mm² welding cable sockets
5pol 400V 32A 6h high voltage current mains connector
Mechanical: Wall mount
Set of connectors for stacked power sources
The power supply can be used for the following welding processes
MIG/MAG
I-pulse
U-pulse
KF-pulse
microMIG
TIG-DC
TIG-pulse with version LSQ5-PT
7.6 Dimensions
557mm
358mm
405mm
471mm
Figure 12: View from the top Figure 13: Rear side with fan

8 Overview of the parts of the power source LSQ5 SKS Welding Systems
8 Overview of the parts of the power source LSQ5

8.1 Side with operating panel
Figure 14: Side with operating panel
Overview of the parts of the power sourceLSQ5

Position Component
Welding cable sockets
Power cable socket
Carrying handle
LSQ Interconnect bus
Voltage selector switch
LEDs
ENT and SEL keys
Operating panel
SPW bus connectors
Fuse

8 Overview of the parts of the power source LSQ5 SKS Welding Systems
8.2 Side with main switch
Figure 15: Side with main switch
Overview of parts for side with main switch

Position Component
Main switch with positions ON and OFF
Carrying handle
8.3 Rear side with fan
Figure 16: Rear side with fan
Overview of parts for side with fan

Position Component
Fan

9 Mains voltage SKS Welding Systems
9 Mains voltage
The permissible mains voltages depend on the relevant mains voltage
± 10%, i.e. 360V – 440V for the setting of 400V and 432V – 528V for the setting of 480V.
The mains voltage selector switch is safeguarded against accidental operation.
WARNING!
• Never operate the voltage selector switch when the unit is
switched on.
• Always switch off the power source and wait for 3 minutes before
changing the voltage setting.
NOTE
Make sure the voltage selector switch is set correctly and appropriately
before using the equipment.
If the welding 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 → 3x 400V 400V
360V-435V --- 400V
436V-528V --- 480V

10 Changing the voltage on the power source LSQ5 SKS Welding Systems
10 Changing the voltage on the power source LSQ5
WARNING!
The following steps must never be performed while the welding power
source is switched on, as doing so might result in an electric shock.
Wait for
minutes!
Figure 17: Switch off the power source Figure 18: Wait for 3 minutes Figure 19: Remove the retaining screw
Figure 21: Move the selector switch to

Figure 20: Pull the switch slightly back Figure 22: Push the switch back in again
the required setting
Figure 23: Tighten the retaining screw Figure 24: Switch on the power source

11 Programming / Setting up SKS Welding Systems
11 Programming / Setting up
CAUTION!
the power sources!
Using power sources that are not the same type will damage the power
sources.
The LSQ5 service panel has 2 buttons (ENTER [ENT], SELECT [SEL]), and 4 LEDs. These LEDs act as status
indicators in welding mode, as additional alarm indicators and indicate the current settings.
Figure 25: Side view of the DCT welding power source LSQ5
11.1 Markers
The welding power sources configuration settings comprise four markers (A - D).
These markers are successively indicated and can be successively adjusted with the four LEDs.
11.2 Displaying the current settings

• Switch off the power source
• Press and hold the [ENT] or [SEL] buttons
• Switch on the power source
• The power source will now show each of the settings the A - D markers are set to for 1 second.
• Once completed, the welding source will switch to welding mode

11 Programming / Setting up SKS Welding Systems
11.3 Changing the settings

• Switch off the power source
• Press and hold the [ENT] and [SEL] buttons
• Switch on the power source
• Press [SEL], [SEL], [ENT]
• Use the [SEL] button to adjust marker A until the required LED lights up and confirm by pressing [ENT]
• Use the [SEL] button to adjust marker B until the required LED lights up and confirm by pressing [ENT]
• Use the [SEL] button to adjust marker C until the required LED lights up and confirm by pressing [ENT]
• Use the [SEL] button to adjust marker D until the required LED lights up and confirm by pressing [ENT]
(This marker does not currently have a function assigned and can therefore not be adjusted)
• The welding power source will show the markers A-D for 1 second each and then switch to welding
mode.
11.4 Marker A (System structure)
LED Explanation
Single welding power source
Master in a Share Power or dual wire system (only LSQ4 and LSQ5)
Slave in a Share Power or dual wire system (only LSQ4 and LSQ5)
Not used
11.5 Marker B (Welding process)
LED Explanation
MIG/MAG or pulse process
all TIG processes (only LSQ4 and LSQ5)
Not used)
Not used
11.6 Marker C (Welding process controller)
LED Explanation
The connected controller is LSP4 / Q4 / Q6pw / Q80 / Q8p / Q8pt / Q8pw / Q84s / Q84r
connected controller is Q8i
connected controller is Q8
connected controller is LSP
11.7 Marker D (Special)
LED Explanation
Not used
Not used
Not used
Not used

12 LED functions in welding mode SKS Welding Systems
12 LED functions in welding mode

In welding mode, the LEDs fulfil two functions.
▪ Status indicator
If the LSQ5 is operating smoothly in welding mode, the LEDs will indicate the LSQ5's current status.
▪ Alarm indicator
If the system issues an alarm that is related to the power source during welding, the alarm code will be
provided through the LSQ5's LEDs.
12.1 Status indicator
1 2 3 4 LEDs
Mains voltage on
SPW connection on
START signal on
Welding process is running
Figure 26: LED panel on welding power

Figure 27: LSQ5 status
source
12.2 Alarm display
1 2 3 4
LEDs
ALARM 101
ALARM 102
ALARM 103
ALARM 104
ALARM 105
ALARM 106
ALARM 107
Figure 28: LED panel on welding power

Figure 29: LSQ5 status
source

13 LSQ5 alarms SKS Welding Systems
13 LSQ5 alarms
LSQ5 alarms
Alarm number Description Measure
Sensor fault or sensor defective
Switch controller off and on again. If the
The controller detected a defective sensor
101 fault is then still indicated again, please
when the power source was switched on.
contact customer services.
The controller will indicate "ALARM 20".
102 Not currently used
103 Marker C "SYSTEM" set incorrectly Switch Marker C to the setting appropriate
The transmission protocol selected for to the controller used
transmissions between the controller and
power source is wrong.
STOP due to message in alarm buffer
The power source has detected a critical
104 entry in the alarm buffer and will therefore
not start. The controller will indicate
"ALARM 20".
Marker A "STRUCTURE" not compatible
105 A "slave" controller is being used without Select Marker A accordingly
a "master".

14 Stacking and synchronising welding power sources SKS Welding Systems
14 Stacking and synchronising welding power sources

14.1 Stacking and synchronising welding power sources
This information refers only to the operating modes Share Power and dual wire.
WARNING!
If the following steps are performed while the power source is switched
on, it may generate an electric shock.
• Only perform these steps with the power source switched off.
CAUTION!
the power sources!
Using power sources that are not the same type will damage the power
sources.
Figure 30: Remove the eye bolts and buffer Figure 31: Screw in the long threaded bolts
Figure 32: Place the second power source on top of the first
Figure 33: Screw in the short bolts and secure with nuts
one

14 Stacking and synchronising welding power sources SKS Welding Systems
14.2 Synchronising power sources (Share Power or dual wire mode)
Figure 34: Switch off the power sources Figure 35: Connect the connector labelled 'Master' on the synchronising cable to
and wait for 3 minutes the master power source. Connect the second connector to the slave power source
Figure 36: Switch on the master power source first, and then the slave power source.

15 Maintenance and care SKS Welding Systems
15 Maintenance and care
WARNING!
Risk of electric shocks if touched.
• Always disconnect the power source before performing any
maintenance work or changing parts, and protect it from being
reconnected.
Switching off or removing the fuse does not provide adequate electrical
protection.
NOTE
The cleaning, checking and repairing of welding units must only be
carried out by trained personnel. If a welding unit fails to pass one of the
inspections listed below, it must not be operated until the defect has
been repaired.
The LSQ5's individual components must be cleaned as follows:
• Power source: DISCONNECT THE MAINS PLUG FROM SOCKET OUTLET! Depending on the
amount of dust, blow the power source out with oil- and water-free compressed air.
• Blow out the fans
• Do not blow out electronics, printed circuit boards and electronic components with compressed air.
Use a vacuum cleaner.
• Regularly check for the incidence of dust at the power source, the fans and the cooling fins.
• The fans or cooling fins must not be blocked and/or contaminated by dust.
Blocked and/or contaminated fans or cooling fins do not dissipate heat well.
• Regularly check the fans and cooling fins.
• Blow out the power source, fans and cooling fins with a compressed air gun or use an industrial
vacuum cleaner.
Make sure that the fans are not damaged.
• Check the fans for damage and contaminations.

15.1 Re-testing in accordance with DIN EN 60974-4 (VDE 0544-4):2011 and

BGR 500 (formerly BGV D1)
INFORMATION
The description of the re-test provided below is only an excerpt of the
detailed test instruction.
The full test instruction can be obtained from specialist dealers.
We recommend inspecting your equipment at quarterly and annual intervals. Equipment also has to undergo an
annual inspection every time it has been repaired. Inspection sequence:
15.1.1 Quarterly inspection
• Visual inspection to ensure that the equipment is in perfect condition

• Measuring the earth cable's resistance
15.1.2 Annual inspection

• Visual inspection to ensure that the equipment is in perfect condition
• Measuring the earth cable's resistance
• Measuring the insulation's resistance after cleaning the inside of the welding power source
• Measuring the open circuit voltage
• Testing the welding machine's functions
15.1.3 Visual inspection to ensure that the equipment is in perfect condition

Visually inspect the unit 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
• Damage on welding cables, cable assembly, plug connectors, torch.
• Signs of overload and improper use
• Damage to the lifting points and housing
• Unauthorized interference and modifications
• Nameplate and warning symbol are present and legible.
15.1.4 Measuring the earth cable's resistance

Measure between the 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 < 0.1. Carry out the measurement with at least 200 mA.

15.1.5 Measurement of insulation resistance

The unit must not be connected to the mains supply!
WARNING!
• Always switch off the power source before opening the welding
unit.
• Wait for 3 minutes
• Protect it from being reconnected
Switching off or removing the fuse does not provide adequate
electrical protection.
• Open welding unit and clean carefully (as described above).

• Disconnect connector A (see image)
Figure 37: Disconnect connector A_Step 1 Figure 38: Disconnect connector A_Step 2

• Turn mains switch on.

• Insulation resistance, mains circuit - housing: Measure between one contact of the mains plug and
the housing. The resistance must be > 2.5M.
• Insulation resistance, welding circuit - housing: Measure between a welding socket and the earth
lead. The resistance must be > 2.5M.
• Insulation resistance, mains circuit - welding circuit: Measure between one of the contacts of the
mains plug and a welding socket. The resistance must be > 5.0M.
• Once the measurement has been completed, switch off the power source.
• Re-connect connector A
• Close the power source
15.1.6 Measuring the open circuit voltage (to EN 60974-1 / VDE 0544-1)
Connect the measurement circuit to the

welding current sockets as shown in the
illustration.
The voltmeter must show mean values.
During measurement, adjust the
potentiometer from 0k to 5k.
The measured voltage must not deviate from
the figure shown on the rating plate (U0) by
more than 10%.
Figure 39: Measuring the open circuit voltage
15.1.7 Testing the welding machine's functions
• Test the machine's functions in accordance with the type of machine.
15.1.8 Repair work
NOTE
Repair and maintenance work must only be carried out by trained
specialists.
Contact your dealer.
When replacing parts, use only original spare parts.
When ordering spare parts, please 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 authorised for such work, the guarantee will become
void.
Interfering with or changing the unit in any way will void the warranty.

16 Part overview SKS Welding Systems
16 Part overview
Figure 40: Spare parts
Accessory: Set of connectors for Accessory: Interconnect cable for Accessory: Wall mount 77-1180-
stacked LSQ5 power sources LSQ4-LSQ5 power sources 01 with associated parts

17 Spare parts SKS Welding Systems
17 Spare parts
List of spare parts

Pos. Item Item number
Front cover 77-1180-05
Main switch for LSQ4/5 77-1180-06
Cover for LSQ4/5 77-1180-07
Fan, single 77-1189-00
Wired-up fan block with box (framed; includes pos. + + ) 77-1189-01
Wired-up fan insert, consisting of 4x fans, without box 77-1189-04
Bogie wheel 77-1189-05
Fan guard for LSQ4/5 77-1190-16
Handle for LSQ4/5 power source 77-1190-18
Rubber foot 30 x 25 77-1190-32
Automatic circuit breaker 4A 77-1190-38
LSQ5 voltage selector switch 77-1190-39
Handle for LSQ5 power source 77-1190-48
Corner cover strips 77-1190-20
Fuse for LSQ5 control transformer 77-1190-37

18 Accessories SKS Welding Systems
18 Accessories
List of accessories
Pos. Item Item number
Set of connectors for stacked LSQ5 power sources 77-1180-02
Interconnect cable for LSQ4/LSQ5 power sources 77-1180-03
LSQ5 wall bracket (includes pos. and ) 77-1180-01
Knurled screw M8 x 20 91-1-1-1
Insulation sleeve 90-1-2-1
INFORMATION
Please only use original parts and original wearing parts from SKS.
By using high-quality original parts, the reliable function of system
components and TCP accuracy of the entire welding torch system is
ensured.
The material characteristics determined by SKS are based on the use of
original parts and wearing parts in a networked system, with which you will
achieve the best welding results.
The use of durable original parts minimises wear and tear.
The precision of original parts reduces the time required for replacing
wearing parts or during any fault finding or reprogramming.
Using original parts, you will achieve a constant arc quality due to optimum
energy transfer, in addition to a stable and precise wire feeding.
SKS assumes no liability for the use of third party products. Products from
other manufacturers can result in a deviation from standard values during
the welding process and unwanted welding results.
Please contact us if you have questions.

19 Calibration of power sources SKS Welding Systems
19 Calibration of power sources
INFORMATION
SKS can supply equipment for calibrating the welding power source.
The drift of the components that the manufacturers of these components guarantee is so low that from a
technical standpoint there is no need for a calibration over the expected service life. Furthermore, some
measurement components compensate zero drift automatically during operation.
Since the introduction of LSQ4, LSQ3 and LSQ5 no cases are known to us, in which a calibration deviation was
found that was outside the specified normal values.
If you would still like to perform a calibration, SKS has the corresponding equipment to offer.
.

20 Wiring diagram SKS Welding Systems
20 Wiring diagram
Figure 41: Wiring diagram

21 Disposal SKS Welding Systems
21 Disposal
Place contact the manufacturer if you have any questions concerning disposal.

22 EU declaration of conformity SKS Welding Systems
22 EU declaration of conformity
Figure 42: EU declaration of conformity

23 CSA Mark SKS Welding Systems
23 CSA Mark
Figure 43: CSA Mark

24 Welding safety SKS Welding Systems
24 Welding safety
For more information regarding welding safety, see Standard "CAN/CSA-W117.2-12".

25 Index SKS Welding Systems
25 Index
Access to the power source .................................................................................................................................. 20
Arrangement of the system components for single-wire application .................................................................... 14
Cleaning ................................................................................................................................................................ 32
clear space required around power sources ......................................................................................................... 17
Definition of safety information ................................................................................................................................ 7
Definition of signal words ........................................................................................................................................ 7
Definition of warning information ............................................................................................................................. 6
Direct Control Technology ..................................................................................................................................... 16
Intended use .......................................................................................................................................................... 11
LEDs ...................................................................................................................................................................... 28
Liability .................................................................................................................................................................. 12
LSQ5 alarms ......................................................................................................................................................... 29
LSQ5 Service panel .............................................................................................................................................. 26
Mains voltage ........................................................................................................................................................ 24
Maintenance and care ........................................................................................................................................... 32
Organisation, personnel ........................................................................................................................................ 12
Original parts from SKS......................................................................................................................................... 38
Overheating ......................................................................................................................................................... 17
Power source inverter ........................................................................................................................................... 11
Re-testing in accordance with DIN EN 60974-4 (VDE 0544-4)
2011 ................................................................................................................................................................... 33
Safety instructions for operators ........................................................................................................................... 12
Safety symbols
Types of safety symbol ........................................................................................................................................ 8
Stacking and synchronising welding power sources ............................................................................................. 30
Storing the operating manual ................................................................................................................................ 12
Symbols ................................................................................................................................................................... 8
Technical Data ...................................................................................................................................................... 20
Wall-mounting the power source ........................................................................................................................... 19
Warning information ................................................................................................................................................ 9
Warranty ................................................................................................................................................................ 12

26 Table of figures SKS Welding Systems
26 Table of figures
Figure 1: Arrangement of the power source for single-wire application ................................................................ 14
Figure 2: Arrangement of the power source for double wire application .............................................................. 15
Figure 3: Minimum amount of clear space required around the power source LSQ5 .......................................... 17
Figure 4: Ensure sufficient distance between fan and wall for air supply ............................................................. 17
Figure 5: Front view ............................................................................................................................................... 18
Figure 6: View from the top ................................................................................................................................... 18
Figure 7: Side with main switch ............................................................................................................................. 18
Figure 8: Side with operating panel ....................................................................................................................... 18
Figure 9: 77-1180-01_Wall bracket for LSQ5 ....................................................................................................... 19
Figure 10: Wall bracket (Item no. 77-1180-01) dimensioned for welding power source LSQ5 ............................ 19
Figure 11: LSQ5 plus wall bracket ........................................................................................................................ 19
Figure 12: View from the top ................................................................................................................................. 21
Figure 13: Rear side with fan ................................................................................................................................ 21
Figure 14: Side with operating panel..................................................................................................................... 22
Figure 15: Side with main switch ........................................................................................................................... 23
Figure 16: Rear side with fan ................................................................................................................................ 23
Figure 17: Switch off the power source ................................................................................................................. 25
Figure 18: Wait for 3 minutes ................................................................................................................................ 25
Figure 19: Remove the retaining screw ................................................................................................................ 25
Figure 20: Pull the switch slightly back ................................................................................................................. 25
Figure 21: Move the selector switch to the required setting ................................................................................. 25
Figure 22: Push the switch back in again.............................................................................................................. 25
Figure 23: Tighten the retaining screw .................................................................................................................. 25
Figure 24: Switch on the power source ................................................................................................................. 25
Figure 25: Side view of the DCT welding power source LSQ5 ............................................................................. 26
Figure 26: LED panel on welding power source ................................................................................................... 28
Figure 27: LSQ5 status ......................................................................................................................................... 28
Figure 28: LED panel on welding power source ................................................................................................... 28
Figure 29: LSQ5 status ......................................................................................................................................... 28
Figure 30: Remove the eye bolts and buffer ......................................................................................................... 30
Figure 31: Screw in the long threaded bolts ......................................................................................................... 30
Figure 32: Place the second power source on top of the first one ........................................................................ 30
Figure 33: Screw in the short bolts and secure with nuts ..................................................................................... 30
Figure 34: Switch off the power sources and wait for 3 minutes .......................................................................... 31
Figure 35: Connect the connector labelled 'Master' on the synchronising cable to the master power source.
Connect the second connector to the slave power source ................................................................................... 31
Figure 36: Switch on the master power source first, and then the slave power source. ...................................... 31
Figure 37: Disconnect connector A_Step 1 .......................................................................................................... 34
Figure 38: Disconnect connector A_Step 2 .......................................................................................................... 34
Figure 39: Measuring the open circuit voltage ...................................................................................................... 35
Figure 40: Spare parts........................................................................................................................................... 36
Figure 41: Wiring diagram ..................................................................................................................................... 40
Figure 42: EU declaration of conformity ................................................................................................................ 42
Figure 43: CSA Mark ............................................................................................................................................. 43

27 For your notes SKS Welding Systems
27 For your notes

27 For your notes SKS Welding Systems
SKS Welding Systems GmbH | Marie-Curie-Straße 14 | 67661 Kaiserslautern | Tel. (+49) 06301/7986-0 | Fax. (+49) 06301/7986-119
© SKS Welding Systems GmbH | Reprinting only permitted with written permission | The names of products are trade marks belonging to the respective companies | We reserve the right to
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1 About this operating manual

Operating manual for the

Please read this operating manual before initial start-up

Page 1 of 48 MAN-0933EN | V2.0 Operating manual for LSQ5

1 About this operating manual ........................................................................................................................... 5

7.4 Maintaining access to the power source .............................................................................................. 20

22 EU declaration of conformity ...................................................................................................................... 42

Page 4 of 48 MAN-0964EN | V3.1.0 Operating manual for LSQ5

1 About this operating manual

1.2 Purpose of the operating manual

1.3 Scope of validity of the operating manual

1.4 Overview of this document

▪ Arrangement of the LSQ5 power source in the robot welding system

Operating manual for LSQ5 MAN-0964EN | V3.1.0 Page 5 of 48

2 Notes on the display of warning and safety instructions

▪ Warning and safety instructions

2.1 Note about action-related warnings

2.2 Definition of warning information

Page 6 of 48 MAN-0964EN | V3.1.0 Operating manual for LSQ5

2.3 Definition of safety information

2.4 Definition of signal words

Operating manual for LSQ5 MAN-0964EN | V3.1.0 Page 7 of 48

2.5 Safety symbols

Safety symbol which warns against

Warning of dangerous electrical voltage

Indicates general information with the risk of damage

General information and notes concerning the

Sections marked with "" are handling instructions

■ Lists are introduced with "■"

Page 8 of 48 MAN-0964EN | V3.1.0 Operating manual for LSQ5

Operating manual for LSQ5 MAN-0964EN | V3.1.0 Page 9 of 48

Page 10 of 48 MAN-0964EN | V3.1.0 Operating manual for LSQ5

4 For your safety

4.1 Intended use

4.2 Product safety

4.3 Dangers if the system is used wrongly

Operating manual for LSQ5 MAN-0964EN | V3.1.0 Page 11 of 48

4.4 Organisation, personnel

4.4.2 Storing the operating manual

• Keep the operating manual in a location where it is accessible at all times.

4.4.3 Technical condition of the power source LSQ5

4.4.6 Obligation to report faults and damage

Page 12 of 48 MAN-0964EN | V3.1.0 Operating manual for LSQ5

4.4.7 Illustrations of the power source LSQ5

4.4.8 Continuous improvement of the operating manual

SKS Welding Systems GmbH

4.4.9 Name of the buyer when reselling

SKS Welding Systems GmbH

Operating manual for LSQ5 MAN-0964EN | V3.1.0 Page 13 of 48

5 Arrangement of the LSQ5 power source in the robot welding

Figure 1: Arrangement of the power source for single-wire application

Arrangement of the power source for single-wire application

Page 14 of 48 MAN-0964EN | V3.1.0 Operating manual for LSQ5

Figure 2: Arrangement of the power source for double wire application

Arrangement of the power source for double wire application

Operating manual for LSQ5 MAN-0964EN | V3.1.0 Page 15 of 48

6 Operating mode of the power source LSQ5

Page 16 of 48 MAN-0964EN | V3.1.0 Operating manual for LSQ5

7 Welding power source LSQ5

Set up the welding current source in such a way that it is electrically

min. 100mm min. 200mm

Operating manual for LSQ5 MAN-0964EN | V3.1.0 Page 17 of 48

7.2 The different sides of the power source