ESAB Retrofit Mig 4004i WeldCloud™ User manual

Aristo®

Service manual

0740 800 203 GB 20161215

Valid for: W82serialno.905-, 944-, 544-, 628-xxx-xxxx

RetrofitW82serialno.419-xxx-xxxx

RetrofitMig4004iWeldCloud™serialno.550-,627-xxx-xxxx

WeldCloud™Mobileserialno. from637-xxx-xxxx

W82,

RetrofitMig4004iWeldCloud™,

WeldCloud™Mobile

TABLE OF CONTENTS

0740 800 203 © ESAB AB 2016

READ THIS FIRST.........................................................................................

6

BEFORE STARTING SERVICE.....................................................................

7

What is ESD? ............................................................................................

7

INTRODUCTION............................................................................................

9

W82 ............................................................................................................

9

WeldCloud™ .............................................................................................

9

Schematic system design .......................................................................

10

TECHNICAL DATA ........................................................................................

13

WIRING DIAGRAM........................................................................................

15

INSTALLATION..............................................................................................

21

Installation of W82....................................................................................

21

Installation of WeldCloud™ Mobile with ESAB Mig 5000i power

source........................................................................................................ 22

Installation of Retrofit Mig 4004i WeldCloud™......................................

25

Install Retrofit W82 to ESAB Mig 4004i Pulse power source ...............

29

System description W82 ..........................................................................

30

How to set-up the U82 for use with W82................................................ 31

System diagrams......................................................................................

32

Thermal protection ...................................................................................

33

Parameter setting .....................................................................................

33

Checklist ...................................................................................................

33

Configuration of the arc voltage feedback, WeldCloud™ ....................

34

Welding with the filler wire positive or negative, using external voltage

sensing from the wire, without external sensing from the workpiece ..... 35

Welding with the filler wire positive or negative, without any external

voltage sensing from the wire or the workpiece ..................................... 36

Welding with the filler wire positive, using external voltage sensing

from the wire and the workpiece ............................................................ 37

Welding with the filler wire negative, using external voltage sensing

from the wire and the workpiece ............................................................ 38

DESCRIPTION OF OPERATION...................................................................

39

Self-test .....................................................................................................

39

24AP1 Welding data board ......................................................................

39

24AP1:1 Circuit board identity................................................................ 39

24AP1:2 Power supply ........................................................................... 40

24AP1 Starting sequence....................................................................... 41

24AP1:3 Internal CAN bus ..................................................................... 42

24AP1:4 External CAN bus, only W82 Integrated.................................. 43

24AP1:5 USB memory ........................................................................... 44

24AP1:6 Network connection (Ethernet) ................................................ 45

24AP1 Component positions.................................................................. 47

25AP1 SBC board.....................................................................................

48

25AP1 Component positions.................................................................. 48

SBC board 2188 (ordering no. 0445 325 001).................................... 48

SBC board 2189 (ordering no. 0445 325 002).................................... 49

TABLE OF CONTENTS

0740 800 203 © ESAB AB 2016

W82 FIELDBUS .............................................................................................

50

Fieldbus connection.................................................................................

50

W82 DEVICENET ..........................................................................................

51

DeviceNet network ...................................................................................

52

Tap for DeviceNet at Weld Data Unit.......................................................

53

Termination ...............................................................................................

53

24AP4 Fieldbus board – DeviceNet ........................................................

54

Fieldbus connector ..................................................................................

54

Configuration ............................................................................................

54

Baud rate................................................................................................ 55

Node address (Mac ID) .......................................................................... 55

LED indicators ........................................................................................ 55

EDS file .................................................................................................. 56

Functional I/O Data Map – DeviceNet .....................................................

56

Input from Controller to Welding Equipment........................................... 56

Output from Welding Equipment to Controller........................................ 57

W82 CANOPEN .............................................................................................

58

Network connection .................................................................................

59

CANopen network ....................................................................................

59

Termination ...............................................................................................

59

24AP4 Fieldbus board – CANopen .........................................................

60

Fieldbus connector ..................................................................................

60

Configuration ............................................................................................

60

Baud rate................................................................................................ 60

Node address ......................................................................................... 61

LED indicators ........................................................................................ 61

EDS file .................................................................................................. 62

Functional I/O Data Map – CANopen ......................................................

62

Input from Controller to Welding Equipment........................................... 62

Output from Welding Equipment to Controller........................................ 63

W82 PROFIBUS ............................................................................................

64

Profibus network ......................................................................................

64

Module overview ......................................................................................

64

Termination ...............................................................................................

65

24AP4 Fieldbus board – Profibus DP .....................................................

66

Fieldbus connector ..................................................................................

66

Configuration ............................................................................................

67

Baud rate................................................................................................ 67

Node address ......................................................................................... 67

LED indicators ........................................................................................ 67

GSD file .................................................................................................. 68

Functional I/O Data Map – Profibus DP ..................................................

68

Input from Controller to Welding Equipment........................................... 69

Output from Welding Equipment to Controller........................................ 69

TABLE OF CONTENTS

0740 800 203 © ESAB AB 2016

W82 INTEGRATED VERSION.......................................................................

70

DeviceNet (Integrated version) ...............................................................

70

Network connection .................................................................................

71

DeviceNet network (Integrated version).................................................

72

Termination ...............................................................................................

72

Functional I/O Data Map – DeviceNet (Integrated version)...................

72

Input from Controller to Welding Equipment........................................... 72

Output from Welding Equipment to Controller........................................ 73

FUNCTIONAL DESCRIPTION OF I/O...........................................................

74

Input from controller to welding equipment ..........................................

74

Weld status bits ...................................................................................... 74

Weld data number .................................................................................. 75

Numerical welding parameters............................................................... 75

Output from Welding Equipment to Controller......................................

76

Weld Status Bits ..................................................................................... 76

Default error types.................................................................................. 77

Weld Data Number................................................................................. 78

Numerical Welding Parameters.............................................................. 78

Measured Values.................................................................................... 78

Error Mask.............................................................................................. 78

WELDCLOUD™.............................................................................................

79

General description of operation ............................................................

79

The SBC board (25AP1) ........................................................................ 79

Power supply.......................................................................................... 80

Ethernet.................................................................................................. 80

Antenna .................................................................................................. 80

The WeldCloud™ function...................................................................... 80

Which SBC board variant is there in the present WeldCloud™ unit?..... 80

Error codes for WeldCloud™ ..................................................................

81

Reset button – rebooting WeldCloud™..................................................

81

Troubleshooting WeldCloud™ ................................................................

82

FAULT INDICATIONS ....................................................................................

85

Error log ....................................................................................................

85

Error code description – W82 .................................................................

85

SERVICE INSTRUCTIONS............................................................................

90

Service aid ................................................................................................

90

Replacing the battery in the W82 ............................................................

91

Software update........................................................................................

91

Update with update.txt .............................................................................

92

Reset of W82 with reset.txt......................................................................

93

Dismantle and assemble WeldCloud™ Mobile......................................

93

SPARE PARTS AND ACCESSORIES ..........................................................

94

KNOWN ISSUES ...........................................................................................

95

TABLE OF CONTENTS

0740 800 203 © ESAB AB 2016

W82 Integrated..........................................................................................

95

Rights reserved to alter specifications without notice.

READ THIS FIRST

0740 800 203

- 6 -

READ THIS FIRST

Maintenance and repair work must be performed by an experienced person, and electrical

work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for

help in connection with fault-tracing and repair.

Use the wiring diagram as a form of index for the description of operation. The circuit boards

are divided into numbered blocks, which are described individually in more detail in the

description of operation. Component names in the wiring diagram are listed in the

component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see the "SPARE PARTS" chapter

in this manual.

This manual contains details of design changes that have been made up to and including

May 2016.

The manual is valid for:

Aristo

®

W8

2

with serial no. 905-xxx-xxxx, 944-xxx-xxxx, 544-xxx-xxxx and 628-xxx-xxxx.

Retrofit Aristo

®

W8

2

with serial no. 419-xxx-xxxx.

Retrofit Mig 4004i WeldCloud™ with serial no. 550-xxx-xxxx, 608-xxx-xxxx and 627-xxx-xxxx.

WeldCloud™ Mobile with serial no. 606-xxx-xxxx. TO BE CONFIRMED

WARNING!

Before use, read and understand the instruction manual

and follow all labels, employer´s safety practices and Safety

Data Sheets (SDSs).

WARNING!

Disconnect power before performing any service.

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

BEFORE STARTING SERVICE

0740 800 203

- 7 -

BEFORE STARTING SERVICE

What is ESD?

A sudden transfer or discharge of static electricity from one object to another. ESD stands

for Electrostatic Discharge.

How does ESD damage occur?

ESD can cause damage to sensitive electrical components, but is not dangerous to people.

ESD damage occurs when an ungrounded person or object with a static charge comes into

contact with a component or assembly that is grounded. A rapid discharge can occur,

causing damage. This damage can take the form of immediate failure, but it is more likely

that system performance will be affected and the component will fail prematurely.

How do we prevent ESD damage?

ESD damage can be prevented by awareness. If static electricity is prevented from building

up on you or on anything at your work station, then there cannot be any static discharges.

Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold static

charge, so you should not bring unnecessary nonconductive items into the work area. It is

obviously difficult to avoid all such items, so various means are used to drain off any static

discharge from persons to prevent the risk of ESD damage. This is done by simple devices:

wrist straps, connected to ground, and conductive shoes.

Work surfaces, carts and containers must be conductive and grounded. Use only antistatic

packaging materials. Overall, handling of ESD-sensitive devices should be minimized to

prevent damage.

ESAB can offer a number of service tools that will simplify the service.

Antistatic service kit

Ordering no. 0740 511 001

The kit makes it easier to protect sensitive

components from electrostatic discharge.

Contents:

• A conductive mat (size 610x610mm /

24×24in.)

• A 1.5 metre (3.28 ft) long ground cable

with a crocodile clip

• An adjustable wrist strap and cable with

an inbuilt protective resistor

Antistatic service kit

BEFORE STARTING SERVICE

0740 800 203

- 8 -

ESAT service kit

The software update is made from a PC, it has to be managed by a trained serviceman. For

this a PC program called ESAT, ESAB Software Administration Tool, is needed. The PC is

connected to the welding equipment by a cable connector and a CAN reader. From the

ESAT it is possible to update the software. ESAT also contains service functions by which it

is possible to control, change or read the different functions of the equipment.

For the installation and use of the ESAT you need a PC with operating system Windows.

The ESAT service kit contents:

• CAN adapter with connection cables

• CD with software

• Instruction manual for ESAT

USB2CAN for connection to the USB port of the PC - ordering no: 0458 847 881

NOTE!

The software of the W8

2

can be updated from a USB memory stick, without using

the ESAT service tool. This is described in “Software update”, page91.

INTRODUCTION

0740 800 203

- 9 -

INTRODUCTION

W82

The main function of the Aristo

®

W8

2

in an ESAB welding system, is to control the welding

process as a welding data unit (WDU). The Aristo

®

W8

2

is also used as an interface between

ESAB CAN bus based welding equipment and other automation equipment, such as robots.

Furthermore the Aristo

®

W8

2

is used for recording of welding data for statistical and quality

assurance purposes.

As an interface the unit converts messages between ESAB CAN bus and different field

buses, for example DeviceNet, Profibus etc. Since the field bus option is a modular design,

the user can choose from several different types of field buses.

NOTE!

The Retrofit Aristo

®

W8

2

for the Mig 4004i Pulse unit does not have the field bus

option, only USB and Ethernet is available.

The W8

2

is available in several versions:

•

Aristo

®

W8

2

Integrated with DeviceNet for communication with an ABB robot

•

Aristo

®

W8

2

DeviceNet

•

Aristo

®

W8

2

Profibus

•

Aristo

®

W8

2

CANopen

•

Aristo

®

W8

2

Ethernet/IP

•

Retrofit Aristo

®

W8

2

for Mig 4004i Pulse

The design features, construction, installation and method of operation of the W8

2

are

described in this manual. A description of its use, however, is in the instruction manual, which

can be downloaded from the Internet: www.esab.com. For document numbers, see “SPARE

PARTS AND ACCESSORIES”, page94.

Aristo

®

W8

2

• W8

2

DeviceNet, W8

2

Profibus and W8

2

CANopen are supplied with a USB memory

and an instruction manual.

• W8

2

Integrated is supplied with an instruction manual.

Retrofit Aristo

®

W8

2

•

Retrofit Aristo

®

W8

2

is supplied with an instruction manual.

WeldCloud™

For information about WeldCloud™, refer to WeldCloud™ instruction manual.

The WeldCloud™ unit connects the welding power source to a remote WeldCloud™ server

through Wi-Fi, Wired LAN or 3G. The WeldCloud™ unit can have a GPS unit to track the

location of the welding power source.

Variants of WeldCloud™ containing a SBC board 2189 board (see section “General

description of operation”, page79), also have a Bluetooth interface to enable connection

to a Bluetooth device (e.g. a Bluetooth enabled bar code scanner).

The WeldCloud™ unit Wi-Fi is enabled after power up of the power source. It will start as a

hotspot with a default hotspot name. This hotspot appears as an available Wi-Fi network.

INTRODUCTION

0740 800 203

- 10 -

After establishing the connection, it is possible to access the web interface of the power

source.

The WeldCloud™ unit is available for retrofit in three versions:

•

Retrofit Aristo

®

Mig 4004i WeldCloud™ (0445 302 880), without connection for

ethernet and communication with robot system.

•

Retrofit Aristo

®

Mig 4004i WeldCloud™ (0445 302 881), with connection for ethernet

and communication with robot system.

• WeldCloud™ Mobile (0464 550 880), can be used with all power sources that are

fitted with a W8

2

control unit with serial number 628-xxx-xxxx.

Retrofit Aristo

®

Mig 4004i WeldCloud™ is supplied with the WeldCloud™ software.

WeldCloud™ Mobile is supplied with an instruction manual, a control cable for connection to

a W8

2

control unit and two Ethernet cables for LAN connections.

The WeldCloud™ unit can also be factory installed on top of the power source. Information

regarding WeldCloud™ in this manual, also applies to factory installed WeldCloud™ units.

Schematic system design

Schematic system design for Aristo

®

W8

2

with fieldbus DeviceNet, CANopen or Profibus

INTRODUCTION

0740 800 203

- 11 -

Schematic system design for Aristo

®

W8

2

Integrated

Schematic system design Retrofit Aristo

®

W8

2

INTRODUCTION

0740 800 203

- 12 -

Schematic system design Retrofit Aristo

®

Mig 4004i WeldCloud™

TECHNICAL DATA

0740 800 203

- 13 -

TECHNICAL DATA

Aristo

®

W8

2

Supply voltage (to feed unit through W8

2

) 42 V, 50-60 Hz

Supply voltage (from robot) 24 V DC

Supply voltage (from power source) 12 V DC

Weight 4 kg (8.8 lb.)

Dimensions (l × w × h) 366 × 101 × 159 mm (14.41×3.98×6.26in.)

Enclosure class IP23

Retrofit Aristo

®

W8

2

Supply voltage (from power source) 12 V DC

Supply current (max) 1.0 A (12 V DC)

Weight 3.6 kg (7.9lb)

Dimensions (l × w × h) 477 × 250 × 90 mm (18.78×9.84×3.54in.)

Enclosure class IP23

Retrofit Aristo

®

Mig 4004i WeldCloud™ (0445 302 880)

Supply voltage (to feed unit through WeldCloud™) 42 V, 50-60 Hz

Supply voltage (from power source) 12 V DC

Weight 6 kg (13.2 lb.)

Dimensions (l × w × h) 527 × 257 × 115 mm

(20.75×10.12×4.52in.)

Enclosure class IP23

Retrofit Aristo

®

Mig 4004i WeldCloud™ (0445 302 881)

Supply voltage (to feed unit through WeldCloud™) 42 V, 50-60Hz

Supply voltage (from power source) 12 V DC

Weight 6 kg (13.2 lb.)

Dimensions (l × w × h) 527×257×105mm

(20.75×10.12×4.13in.)

Enclosure class IP23

WeldCloud™ Mobile

Supply voltage from power source through W8

2

32-50 V AC, 50-60 Hz

Weight 2.15 kg (4.74lb)

Dimensions (l × w × h) 205 × 135 × 189 mm

(8.07×5.31×7.44in.)

Enclosure class IP23

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration

by solid objects or water.

TECHNICAL DATA

0740 800 203

- 14 -

Equipment marked IP23 is intended for indoor and outdoor use.

WIRING DIAGRAM

0740 800 203

- 15 -

WIRING DIAGRAM

W82 Fieldbus

The W8

2

fieldbus version includes three boards:

• 24AP1 Welding data board – Processor and communication board

• 24AP3 Dual socket panel board – Internal CAN bus communication

• 24AP4, 24AP5 or 24AP6 communication board – An add-on board for each type of

fieldbus

WIRING DIAGRAM

0740 800 203

- 16 -

W82 Integrated

The W8

2

Integrated version includes three boards:

• 24AP1 Welding data board – Processor and communication board

• 24AP2 Dual plug panel board – External CAN bus communication to robot

• 24AP3 Dual socket panel board – Internal CAN bus communication to wire feeder etc.

WIRING DIAGRAM

0740 800 203

- 17 -

Retrofit Mig 4004i WeldCloud™ (0445 302 880)

WIRING DIAGRAM

0740 800 203

- 18 -

Retrofit Mig 4004i WeldCloud™ (0445 302 881)

WIRING DIAGRAM

0740 800 203

- 19 -

WeldCloud™ Mobile

WIRING DIAGRAM

0740 800 203

- 20 -

Retrofit W82 (for Mig 4004i Pulse)

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