ESAB WO1002 Aristo® User manual

GB

Valid from program version 1.60444 534 074 GB 110428

Aristo

WO100

2

Instruction manual

- 2 -

TOCe

Rights reserved to alter specifications without notice.

1 INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Selection of language 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Control panel 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SETTING RANGE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 WELDING PARAMETERS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Sectors 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Welding current 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Pulsed current/continuous current 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Wire feed 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Rotation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Gas 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Preheating 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Slope 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 MENU STRUCTURE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 MENUS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Weld area 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Parameters 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.2 File manager 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.3 Information 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.4 Joint information 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.5 Settings 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.6 Limits 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Design area 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Settings 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Appearance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2 Users settings 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Login 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Library 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.1 Weld programs 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.2 Search filter 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Manual mode 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.1 Motor selection 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.2 Gas valve control 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.3 Run motor 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 Tool editor 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.1 Load/save 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.2 Edit settings 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.3 Edit motor data 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 Logs 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8.1 Event log 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8.2 Quality data 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9 Manual welding 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10 Generate 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 TECHNICAL TERMS 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING NUMBER 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 INTRODUCTION

The manual describes the use of a control panel. WO100

2

For general information about operation, see the instruction manual for the power

source and control unit.

The text displayed in the panel is available in the following languages: Swedish,

Norwegian, Danish, Finnish, English, German, French, Dutch, Spanish, Italian,

Portuguese, Greek, Polish, Czech, Hungarian, Slovenian and Russian.

1.1 Selection of language

The first time you start up the machine, the following is displayed.

On delivery the system is set to English. To select your preferred language:

S Press the ”Menu” button

so that the menu is

activated and shows the

options available at this

level.

S Turn the knob until

”Settings” is highlighted,

then press the knob.

S ”Appearance” is

highlighted, press the knob.

S ”General” is highlighted,

press the knob. The

”Language” field with the

word ”English” is framed.

Turn the knob to select

your preferred language.

S Activate your preferred language by pressing the knob.

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1.2 Control panel

1 Knob

For moving, activating and setting parameter values.

There are three knob functions:

S Turn to the left

S Turn to the right

S Press the knob, activate

2 Display

There are four view fields in the

display:

Upper status field (A)

Information about the weld area's

program name, user, which type of

tool is connected and the tube

dimension.

Main menu field (B)

Different menus, see chapter 5 ”Menu

Structure”.

View field (C)

For editing weld programs, saving programs, information, appearance, etc.

Status field (D)

Shows general information, error messages and current welding data (position,

voltage, current)

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3 Quick stop/Restart

Immediate stop of the welding process. Gas postflow occurs according

to information from end sector.

Pressing the button again initiates restart with parameters from start

sector; the welding process continues from the point in the weld

program at which the interruption occurred.

4 Left arrow

Moving to the left in the menus and back in the main menus

5 Right arrow

Moving to the right in the menus and forward in the main menus

6 Main menu

Moving to the main menu field

2 SETTING RANGE

Parameter Setting range

Sector

Breakpoints

Degrees

0 - 50

0.000 - 9.999

0 - 3599°

Welding current

1)

Peak current

Background current

Pulse time

Background time

3 - 400 A

2)

3 - 400 A

2)

0.01 - 25 s

Wire feed

Peak wire feed speed

Background wire feed speed

15 - 250 cm/min

Rotation

Rotation speed

Rotation direction

Pulsed rotation

5 - 100 % of the welding tool's maximum speed

Forwards and Backwards

0.05 - 25 s

Gas

Weld gas preflow time

Weld gas postflow time

Start gas

Root gas

0 - 6000 s

Preheating

Preheating time 0 - 600 s

Slope

Slope up time

Slope down time

0.1 - 25 s

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1)

The maximum welding current for air-cooled tube welding tools is 100 A.

The maximum welding current for water-cooled tube welding tools is 400 A.

See also the instruction manual for the tube welding tool in question.

2)

Depends on power source

3 WELDING PARAMETERS

3.1 Sectors

A program for tube welding can be divided into different sections: sectors. Each

sector corresponds to one section of the tube's circumference. The maximum

number of sectors for one program is 50.

A sector can be assigned its own set of values

for different welding parameters, such as

current, rotation speed and wire feed speed, etc.

This allows the welding to be performed using

different welding parameter settings for different

sections of the tube joint.

Sector 4 Sector 1

Sector 3 Sector 2

The division into sectors is done by

indicating different breakpoints or degrees

around the circumference of the tube. Each

breakpoint or degree constitutes the starting

point for a new sector. In the figure,

breakpoint 0.000, 0 degrees, is the starting

point for sector 1, breakpoint 0.250, 90

degrees, the starting point for sector 2, and

so on.

The power source allows welding of up to

10 turns in the same weld joint. (The

welding tool can be rotated 10 times around

the tube.)

0.000

Sector 4 Sector 1

0.750 0.250

Sector 3 Sector 2

0.500

Note: A sector may not be less than 10 thousandths, or 3.6 degrees, of a turn.

S Turn 1 =

breakpoints 0.000 - 0.999

0 - 359 degrees

S Turn 2 =

breakpoints 1.000 - 1.999

360 - 719 degrees

S Turn 3 =

breakpoints 2.000 - 2.999

720 - 1079 degrees

S Turn 4 =

breakpoints 3.000 - 3.999

1080 - 1439 degrees

S Turn 5=

breakpoints 4.000 - 4.999

1440 - 1799 degrees

S Turn 6=

breakpoints 5.000 - 5.999

1800 - 2159 degrees

S Turn 7=

breakpoints 6.000 - 6.999

2160 - 2519 degrees

S Turn 8 =

breakpoints 7.000 - 7.999

2520 - 2879 degrees

S Turn 9=

breakpoints 8.000 - 8.999

2880 - 3239 degrees

S Turn 10 =

breakpoints 9.000 - 9.999

3240 - 3599 degrees

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To conclude a weld program, a so-called end sector is indicated.

For a sector to be counted as an end sector the following two conditions must be

fulfilled:

S There is no subsequent sector.

S The welding current value for the sector is 0 ampere.

3.2 Welding current

Six parameters are represented in the parameter group for welding current:

S Peak current

S Background current

S Pulse time

S Background time

S Special pulsing

S Slope, see point 3.7.

Pulse time

Background time

Peak current

Background current

TIG welding with pulsed current

Welding current can be pulsed or continuous (not pulsed).

3.2.1 Pulsed current/continuous current

When welding using a pulsed current, peak current, background current, pulse

time and background time must be given a value.

When welding using a continuous current, however, you need only enter a

parameter value for peak current. Entering a value for background current will result

in a pulsed current.

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3.3 Wire feed

Wire feed speed is used to indicate the feed speed for the filler wire in cm/minute.

Speed can be pulsed or continuous (not pulsed).

Three parameters are represented in the parameter group for wire feed:

S Peak wire feed

S Background wire feed

S Slope, see point 3.7.

For welding using a continuous (not pulsed) wire feed, only the peak wire feed

parameter needs to be entered.

For welding with a pulsed wire feed speed, both the peak wire feed and the

background wire feed parameters need to be entered.

The pulsed wire feed speed is always automatically synchronized with the welding

current so that the wire feed speed is high when using peak current and low when

using background current.

3.4 Rotation

Used to indicate the rotation speed of the electrode around the workpiece. It is

indicated in mm/min.

The rotation speed can be pulsed or continuous (not pulsed).

Four parameters are represented in the parameter group for rotation:

S Rotation speed

S Rotation direction

S Pulsed rotation

S Slope, see point 3.7.

Pulsed rotation is automatically synchronized with the welding current so that the

welding tool is stationary at peak current and rotates at background current.

3.5 Gas

Three parameters are represented in the parameter group for shielding gas:

S Weld gas

S Start gas

S Root gas

Weld gas refers to the shielding gas on the upper side of the weld joint. The weld

gas parameter indicates how long the shielding gas is to flow on the upper side of

the joint before and after welding. The weld gas is monitored by a flow guard min.

4.5 l/min.

Some shielding gases, for example, helium (He), can cause problems with regard to

igniting the arc. If this type of shielding gas is to be used as weld gas, it may be

advisable to use a different gas mixture at the actual instance of starting, a so-called

start gas.

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Root gas refers to the shielding gas on the underside of the weld joint. The root gas

parameter indicates how long the shielding gas is to flow on the underside of the

joint before and after welding.

If one value is entered for weld gas and another for start gas in sector 1, only the

start gas will flow. The weld gas starts flowing once the arc is ignited.

3.6 Preheating

Preheating is used to heat the workpiece at the starting point in order to ensure

correct penetration of the molten pool and is defined as the time elapsing between

arc ignition and the start of the rotary motion. If no value has been entered for

preheating, rotation will start as soon as the arc ignites.

3.7 Slope

A slope may be indicated for certain parameters. A slope is the time during which the

value of the parameter gradually changes from the value in the preceding sector to

the value entered for the current sector.

Slope up = gradual increase, if the preceding value is lower than the entered value.

Slope down = gradual decrease, if the preceding value is higher than the entered

value.

The maximum period a slope can run depends on the duration of a particular sector.

If the slope time is of the same duration as the sector, this is called a `sector slope'.

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4 MENU STRUCTURE

Weld area

Parameters File manager Information Joint info. Settings Limits

Table

· Edit table

· Show/hide

· Weld

control

· Edit

Graphical

· Current

· Wire feed

· Rotation

· Gas

· General

· Description

· Tube

· Electrode

· Wire

· Gas

· Visualization

· Parameter

values

· Tool

settings

· Tube

settings

Design area

Parameters File manager Information Joint info. Settings Limits

Table

· Edit table

· Show/hide

· Edit

Graphical

· Current

· Wire feed

· Rotation

· Gas

· General

· Description

· Tube

· Electrode

· Wire

· Gas

· Visualization

· Parameter

values

· Tool

settings

· Tube

settings

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Settings Login Library Manual

mode

Appearance User · Weld

program

· Motor selection

· Gas valve control

· Search filter · Run motor

· General

· Quality

data

Tool

editor

Logs Manual

welding

Generate

Load/

save

· Tool

selection

· Tool

action

Change

settings

· General

· Parameter

limits

Change

motor data

· Change

parameter

· Show para

meters

Event

log

Quality data

· Quality data

files

· Contents

5 MENUS

There are two work areas where you can view and edit welding parameters, Weld

area (see chapter 5.1) and Design area (see chapter 5.2).

5.1 Weld area

In this view, you can view and edit parameters in a weld program and control the

welding process. The weld program in the weld area controls the welding process.

You can enter the weld area's parameters by loading a weld program from the

library, generating a basic weld program or editing the parameters manually.

5.1.1 Parameters

This menu option is solely an archive for other menu options.

Weld area --> Parameters --> Table

Here you can view and edit welding parameters in table form and start and stop the

welding process.

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Each parameter in a parameter group is highlighted in the group's colour.

A selected welding parameter in the table is indicated by a blue box with two arrows.

S To move through the table, turn the knob.

S To change direction, press the knob.

S To change a parameter value, click on the right arrow and change the parameter

values using the knob.

Menu shortcuts:

S Edit table

Highlights the table with welding parameters

S Show/hide

Shows or hides groups of welding parameters in the table.

Here you can choose which parameters are to be shown in the table by selecting

groups of parameters.

S Weld control

Highlights the start button in the weld control box.

The buttons in this box control the welding process. You can start, stop, direct

stop, continue or simulate the start of the welding process.

S Edit sectors

Highlights the button 'Add sector after' in the Edit sectors box.

The number of sectors can be increased or decreased using this box. It is

possible to add new sectors before or after an existing sector and remove

sectors in the weld program.

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Weld area --> Parameters --> Graphical--> Current

In this view, you can view and edit welding parameters for current in a graphical

representation.

The current's peak and background values are represented in a coordinate system.

The Y-axis represents the current's value in ampere, while the X-axis represents

time.

The current's various values per sector are connected and form a line.

Green indicates the peak current value per sector, while blue indicates the

background current value per sector.

Slope is represented as an angled line from the start of the sector, which ends where

the slope time stops on the X-axis.

S Zoom

Here you can adjust the scale of the X-axis in the coordinate system.

S Weld control

The buttons in this box control the welding process. You can start, stop, direct

stop, continue or simulate the start of the welding process.

S Sector information

The figures in this field show the other parameters concerned with the parameter

group for current. The sector's breakpoint is represented by a dash in a circle

(cross-section of a tube).

If the weld program extends over more than one turn, these turns are shown as

a sequence of slightly smaller circles.

The preheating time is shown in tenths of a second under the breakpoint

information.

Special pulsing on or off is shown as an image, where a red cross indicates that

special pulsing is not being used.

The relationship between pulse times is shown as a pulse cycle. Separate times

for peak and background pulse.

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S Figure for breakpoints

It is possible to move, add or remove breakpoints using the knob in the figure for

breakpoints. By skipping forward to the figure and highlighting it, you can turn the

knob and move a white dash or `cursor'.

Moving a breakpoint:

S Press the knob once the cursor is on or directly next to the breakpoint cursor

(black) to be moved.

The breakpoint is `collected' by the cursor and follows this when it is turned

around in the circle.

S To confirm the new breakpoint, press the knob.

Creating a new breakpoint

S Move the cursor by turning the knob and press the knob once at the point

where you want the new breakpoint to be created.

Removing a breakpoint:

S Press the knob once the cursor is on or directly next to the breakpoint cursor

to be removed.

The breakpoint is `collected' by the cursor and follows this when it is turned

around in the circle.

S Turn the knob to the previous or next breakpoint and press the knob once.

Weld area --> Parameters --> Graphical--> Wire feed

Here you can view and edit parameters that control wire feed per sector.

The coordinate system shows the speed at which the wire will be fed out at the peak

and background value per sector.

Slope is represented as an angled line from the start of the sector for the duration

entered for the slope.

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Weld area --> Parameters --> Graphical--> Rotation

Rotation speed is viewed and edited in a coordinate system with one line for each

value and time slope. The coordinate system shows breakpoints as dashed lines.

If pulsed rotation is off, this is shown by a pulse that is crossed out.

Weld area --> Parameters --> Graphical--> Gas

Times for weld, start and root gas are viewed and edited in this view.

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5.1.2 File manager

This view is used to save, copy, clear and verify weld programs.

S Save weld program

To save a weld program, select where you want the program to be saved, either

on the control unit (User defined programs) or on a USB memory device

(External memory).

Specify a file name and click the 'Save weld program' button using the knob.

S Copy weld program to another area

Depending on which work area is active, it is possible to copy the contents of

one area to another area by clicking the 'Copy this wld program to design area'

button or 'Copy this weld program to weld area' button.

S Clear, reset weld program

If you want to begin a brand new weld program, click the 'Clear weld area'

button or 'Clear design area' button.

S Verify

This function is used to check whether the weld program in the current work area

fulfils the system's requirements as follows:

S A tool is selected for the weld program.

S The connected tool is the same as the one the program is designed for (only

applies to weld area).

S The program has at least two sectors (start and stop sector).

S The final sector in the program is a stop sector (the welding current is zero).

S Selected tube diameter is supported by the selected tool.

S The welding parameters in each sector are within the limits (min. and max.

values) for the selected tool.

5.1.3 Information

Used to enter information about the weld program. This information does not affect

the welding process, but is an aid for describing the program in words.

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S General

Program name is shown at the top of the list. This is not the same as file name in

file manager. If a program name is assigned, this is the suggestion offered for

the file name.

S Description

S Tube

S Electrode

S Wire

S Gas

5.1.4 Joint information

In this view, you can view and change how the joint will look to suit the weld

program. This is only information about the weld program. It does not affect the

welding process.

In the ”Visualization, Visualization” field, it is possible to view a graphical

representation of the joint. In the ”Parameters” field, you can view those values

relevant to the joint. Values that affect the joint can be changed in both fields.

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Visualization

S Turn the knob and a blue line will indicate which parameter has been selected.

S Press the knob and the line will turn red. The value can be changed by turning

the knob.

Parameter

S Use the arrows to move between the various parameters.

S Turn the knob to change the value.

Gap

Nose

Nose length

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Radius

Bevel angle

Material thickness

5.1.5 Settings

This view allows you to select tools and the external tube dimension for which the

weld program has been created. In the ”Tool settings” field, you can scroll through

the tools and look at an overview of the tools under ”Tool illustration”. To select a

tool, press the knob and then select the type of tool by turning and pressing the

knob.

The external tube dimension is selected by turning the knob. To confirm, press the

knob. The selected tool (”Tool ”) and dimension (”Ø:”) are visible in the top status

field, when using views from a work area.

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5.1.6 Limits

This view can be used to limit how much a user can change preset parameter values

in a weld program.

In order for the restrictions to be activated, the check box ”Limits activated” must be

checked.

5.2 Design area

Weld programs can be created in the design area for use in the weld area or saved

in the library for subsequent use. To see how the design area works, refer to chapter

5.1Weld Area. The design area works in a similar way to the weld area.

The greatest difference between the two areas is that you cannot control the welding

process from the design area.

5.3 Settings

You can change the appearance of the panel and manage users in the system via

the Settings menu.

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ESAB WO1002 Aristo®, WO1002 Aristo User manual

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