ESAB W82, Retrofit Mig 4004i WeldCloud™ User manual

Brand: ESAB

Model: W82, Retrofit Mig 4004i WeldCloud™

Category: Welding System

Type: User manual

This manual is also suitable for

Aristo®

Instruction manual

0460 971 501 US 20210225

Valid for: W82serialno.710-xxx-xxxx;

RetrofitMig4004iWeldCloud™serialno. 627-,834-xxx-xxxx

W82 Data serial no. 107-xxx-xxxx

W82,

RetrofitMig4004iWeldCloud™

TABLE OF CONTENTS

0460 971 501 © ESAB AB 2021

SAFETY

.......................................................................................................

1.1 Meaning of symbols

...............................................................................

1.2 Safety precautions

.................................................................................

INTRODUCTION

..........................................................................................

2.1 Equipment

...............................................................................................

TECHNICAL DATA

......................................................................................

INSTALLATION

............................................................................................

4.1 Assembly instruction

.............................................................................

4.2 System description

................................................................................

4.3 How to setup the U82 for use with W82

...............................................

4.3.1 Save your stored data .......................................................................... 12

4.3.2 Convert the U82 standalone unit to a presentation unit ....................... 12

4.4 System diagrams

....................................................................................

OPERATION

................................................................................................

5.1 Connections and control devices

.........................................................

5.2 Overheating protection

..........................................................................

5.3 Arc voltage feedback

.............................................................................

MAINTENANCE

...........................................................................................

6.1 Inspection and cleaning

.........................................................................

ORDERING SPARE PARTS

........................................................................

DIAGRAM

............................................................................................................

ORDERING NUMBERS

.......................................................................................

ACCESSORIES

...................................................................................................

Rights reserved to alter specifications without notice.

1 SAFETY

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1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!

Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!

Means potential hazards which could result in personal injury or loss of life.

CAUTION!

Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual

and follow all labels, employer's safety practices and

Safety Data Sheets (SDSs).

1.2 Safety precautions

NOTE!

The unit is tested by ESAB in a general set-up. The responsibility for the safety and

function of the specific set-up lies with the integrator.

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety

precautions must meet the requirements that apply to this type of equipment. The following

recommendations should be observed, in addition to the standard regulations that apply to

the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations, which

could result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ the location of emergency stops

○ its function

○ the relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorized person is within the working area of the equipment when it is

started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

1 SAFETY

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4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Arc welding and cutting may cause injury to yourself and others. Take precautions

when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves,

or wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Pose health risks

• Welders with pacemakers fitted should consult their doctor before welding.

EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to

EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your

body between the torch and work cables. Never coil the torch or work

cable around your body. Keep the welding power source and cables

as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to your health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases

away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens

and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

NOISE - Excessive noise can damage hearing

Protect your ears. Use ear defenders or other hearing protection.

1 SAFETY

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MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only

qualified people remove covers for maintenance and troubleshooting as

necessary. Reinstall panels or covers and close doors when service is

finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause a fire. Make sure there are no inflammable

materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Class A equipment is not intended for use in residential

locations where the electrical power is provided by the

public low-voltage supply system. There may be

potential difficulties in ensuring electromagnetic

compatibility of class A equipment in such locations,

due to conducted as well as radiated disturbances.

NOTE!

Dispose of electronic equipment at a recycling

facility!

To conform with the European Directive 2012/19/EC on

Waste Electrical and Electronic Equipment and its

implementation in accordance with national law,

electrical and/or electronic equipment that has reached

the end of its life must be disposed of at a recycling

facility.

As the person responsible for the equipment, it is your

responsibility to obtain information on approved

collection stations.

For further information contact the nearest ESAB dealer.

1 SAFETY

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CAUTION!

ADDITIONAL SAFETY INFORMATION

For more information on safe practices for electric arc welding and cutting

equipment, ask your supplier for a copy of “Precautions and Safe Practices for

Arc Welding, Cutting and Gouging.” Form 52-529.

The following publications are recommended:

• ANSI/ASC Z49.1 - “Safety in Welding and Cutting”

• AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”

• AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”

• AWS SP - “Safe practices” - Reprint, Welding Handbook

• ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of

Containers That Have Held Hazardous Substances”

• OSHA 29 CFR 1910 - "Safety and health standards"

• CSA W117.2 - "Code for safety in welding and cutting"

• NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other Hot

Work"

• CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in

Cylinders”

• ANSI Z87.1, "Occupational and Educational Personal Eye and Face

Protection Devices"

ESAB has an assortment of welding accessories and personal protection equipment

for purchase. For ordering information, contact your local ESAB dealer or visit us on

our website.

2 INTRODUCTION

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2 INTRODUCTION

Aristo® W8

is a control unit that enables communication between welding

equipment and automation equipment, such as robots and

computers. Communication protocols: DeviceNet, Profibus,

CANopen, Ethernet, EtherCAT and Data.

is used together with ESAB CANbus equipped power sources

for welding automation. For power source and wire feed unit

handling, see the relevant instruction manual.

Retrofit Mig 4004i WeldCloud™

Retrofit Mig 4004i WeldCloud™ is retrofitted on top of supported

ESAB power sources. It connects to the CANbus internally.

Communication protocol: WeldCloud™.

There are two versions of Retrofit Mig 4004i WeldCloud™ available,

with different functionality. The available versions have ordering

numbers 0445302880 (without Ethernet connection and

communication with robot system) and 0445302881 (with Ethernet

connection and communication with robot system).

For information about supported power sources, contact your ESAB

sales representative.



2.1 Equipment



Aristo® W8

• W8

DeviceNet, W8

Profibus, W8

CANopen, W8

EtherNet, W8

EtherCAT and

Data are supplied with a USB memory and an instruction manual.

• W8

Integrated is supplied with an instruction manual.



Retrofit Mig 4004i WeldCloud™

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

For more information about WeldCloud™, refer to the Quick start guide.



Measurement cable kit and connection cables for different power sources are available as

accessories, see "ACCESSORIES" chapter and separate spare parts list.

3 TECHNICAL DATA

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3 TECHNICAL DATA

Aristo

Supply voltage (to feed unit through W8

) 42 V, 50–60 Hz

Supply voltage (from robot) 24 V DC

Supply voltage (from power source) 12 V DC

Weight 8.8 lb (4 kg)

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

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 13.2 lb (6 kg)

Dimensions (l × w × h) 20.75×10.12×4.52in (527 ×

257 × 115 mm)

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 13.2 lb (6 kg)

Dimensions (l × w × h) 20.75×10.12×4.13in

(527×257×105mm)

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.

Equipment marked IP23 is intended for indoor and outdoor use.

4 INSTALLATION

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4 INSTALLATION

The installation must be carried out by a professional.

See the service manual Aristo® W8

, Retrofit Mig 4004i WeldCloud™, WeldCloud™

Mobile.

For Retrofit Aristo® Mig 4004i WeldCloud™, make sure the antenna on the top box is not

covered or blocked.

4.1 Assembly instruction

Connection of Aristo® W82 to Mig 5000i, Mig 5000iw, Mig U5000i, Mig U5000iw power

source

1. Remove the screws on the rear handle of

the power source.

2. Put the W8

onto the welding power

source.

3. Screw the W8

and the handle into place

in the same screw holes.

Connection of Retrofit Aristo® Mig 4004i WeldCloud™

For instructions on how to connect the Retrofit Aristo® Mig 4004i WeldCloud™, see the

service manual for Aristo® W8

, Retrofit Mig 4004i WeldCloud™ or contact the nearest

ESAB Service Center or distributor.

Connection of Aristo® W82 to Mig 3001i, Mig 4001i, Mig 4002c, Mig 5002c, and Mig

6502c power sources

Connect the W8

with a 2m cable and place it on the floor or on a stand next to the power

source.

Connection of Aristo® W82 to Aristo® 500ix power source

For detailed instructions, see Assembly Instruction 0446 944 001.

4.2 System description

It is possible to configure the U8

unit for stand-alone usage (stand-alone unit) or

presentation usage (presentation unit). The presence of a W8

unit within the welding system

determines which unit is to be used.

4 INSTALLATION

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The stand-alone unit is used when there is

no W8

unit in the system.

The presentation unit is used when there

is a W8

unit in the system.

During unit startup it is possible to see whether or not the unit is a presentation unit.

4.3 How to setup the U82 for use with W82

NOTE!

It is necessary to change the U8

stand-alone unit to a presentation unit before it is

used together with a W8

unit.

4.3.1 Save your stored data

1. Connect the U8

stand-alone unit to a power source or a wire feed unit.

2. Turn ON the main switch on the power source.

3. Export weld data sets from the U8

memory to a USB memory (see chapter

Export/Import in the U8

instruction manual).

4. Turn OFF the main switch on the power source.

5. Remove the USB memory.

4.3.2 Convert the U82 standalone unit to a presentation unit

1. Connect the enclosed USB memory to a PC. Make sure that the computer is set to show

file extensions.

2. Rename: "update.txt_" to "update.txt" and "reset.txt_" to "reset.txt"

4 INSTALLATION

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3. Open the cover on the left end of the

control panel.

4. Insert the enclosed USB memory into the

USB connector.

5. Close the cover.

6. Turn ON the main switch on the power

source. One "beep" indicates that convert

process has started. It is finished when two

"beeps" are heard.

7. Turn OFF the main switch on the power

source.

8. Open the cover and remove the enclosed

USB memory.

9. Close the cover. The unit is now ready to be used together with a W8

unit.

4.4 System diagrams

Schematic diagrams showing the connection between different units follow.

1. Connection between welding power source and W8

- "CAN to power source."

2. Connection between W8

and robot control cabinet - "Fieldbus."

3. Connection between welding power source and wire feed unit - “Internal CAN”.

4. Connection between welding power source and control panel - “Internal CAN”.

NOTE!

If the ESAB wire feeder unit is not used, a separate arc voltage feedback is required

to the measurement contact on the control unit.

4 INSTALLATION

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5 OPERATION

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5 OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY"

chapter of this manual. Read it through before you start using the equipment!

5.1 Connections and control devices

1. Indicating lamp

Orange indicating lamp - Overheating

2. External CAN and termination option

3. Fieldbus

Connection for communication with robot system

4. Measure

Connection for measurement cable for arc voltage feedback and emergency stop

signal, measurement kit

5. Internal CAN

Connections for communication with ESAB wire feed unit and control panel

6. LAN

Connection to network, Ethernet

7. CAN to welding power source

Connection for communication with welding power source

8. USB

USB memory connection

5 OPERATION

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1. Antenna

2. Indicating LED, white,

Power supply ON

3. Indicating LED, red

Connection status (lit LED = connection error)

4. USB

USB memory connection

5. CAN connection

6. Arc voltage monitoring (+), red banana socket

7. Arc voltage monitoring (-), black banana socket

8. Fieldbus Connection for communication with robot system

9. Ethernet connection

5.2 Overheating protection

The control unit has overheating protection that operates if the temperature becomes too

high. When this occurs, the welding current is interrupted and the orange lamp illuminates.

The overheating protection resets automatically when the temperature has fallen and the

light goes out.

5.3 Arc voltage feedback

To achieve a good welding result, the arc voltage feedback is a crucial factor. In MIG/MAG

welding, the power source is prepared to sense the arc voltage in the wire feeder.

Prerequisite for this functionality is that an ESAB wire feeder and an ESAB interconnection

cable is used! This method of measuring the arc voltage compensates for the voltage drop in

the welding cable to the wire feeder. With an ESAB torch supporting "TrueArcVoltage," the

voltage drop all the way to the contact tip is compensated.

5 OPERATION

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WARNING!

The external arc voltage inputs (the red and black banana sockets) at the back end

of the WeldCloud™ top box should not be used, unless the equipment has been

configured for this setup by authorized ESAB service personnel.

NOTE!

To compensate for the voltage drop in the return cable, the power source can be

configured (by authorized ESAB service personnel) to use an external arc voltage

sense wire from the workpiece.

6 MAINTENANCE

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6 MAINTENANCE

NOTE!

Regular maintenance is important for safe and reliable operation.

CAUTION!

Only persons with appropriate electrical knowledge (authorized personnel) may

remove the safety plates.

CAUTION!

All warranty undertakings from the supplier cease to apply if the customer attempts

any work to rectify any faults in the product during the warranty period.

6.1 Inspection and cleaning

Regularly check that the control unit is in electrical contact with the power source and that

the connections are fault free and connected correctly.

7 ORDERING SPARE PARTS

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7 ORDERING SPARE PARTS

and Retrofit Mig 4004i WeldCloud™ are designed and tested in accordance with the

international and European standards IEC/EN60974-1 and IEC/EN60974-10. It is the

obligation of the service unit that carried out the service or repair work to make sure that the

product still conforms to said standard.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back

cover of this document. When ordering, please state product type, serial number, designation

and spare part number in accordance with the spare parts list. This facilitates dispatch and

ensures correct delivery.

DIAGRAM

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DIAGRAM

Aristo® W8

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ESAB W82, Retrofit Mig 4004i WeldCloud™ User manual

Brand: ESAB

Model: W82, Retrofit Mig 4004i WeldCloud™

Category: Welding System

Type: User manual

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