Aristo®
Instruction manual
0460 971 201 US 20160405 Valid for: W82 serial no.544-xxx-xxxx Retrofit Mig 4004i
WeldCloud™ serial no. 550-xxx-xxxx
W82,
Retrofit Mig 4004i WeldCloud™
TABLE OF CONTENTS
0460 971 201 © ESAB AB 2016
1 SAFETY ................................................................................................................ 4
1.1 Meaning of symbols.............................................................................................4
1.2 Safety precautions ...............................................................................................4
2 INTRODUCTION................................................................................................... 7
2.1 Equipment............................................................................................................. 7
3 TECHNICAL DATA ............................................................................................... 8
4 INSTALLATION..................................................................................................... 9
4.1 Electrical supply................................................................................................... 9
4.2 Assembly instruction...........................................................................................9
4.3 System description ............................................................................................10
4.4 How to setup the U82 for use with W82 ...........................................................10
4.4.1 Save your stored data ......................................................................................10
4.4.2 Convert the U82 standalone unit to a presentation unit ................................... 11
4.5 Systems diagrams ............................................................................................. 11
5 OPERATION ....................................................................................................... 13
5.1 Connections and control devices.....................................................................13
5.2 Overheating protection......................................................................................14
6 MAINTENANCE.................................................................................................. 15
6.1 Inspection and cleaning .................................................................................... 15
7 ORDERING SPARE PARTS ...............................................................................16
DIAGRAM ..................................................................................................................17
ORDERING NUMBERS.............................................................................................20
ACCESSORIES .........................................................................................................21
Rights reserved to alter specifications without notice.
1 SAFETY
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© ESAB AB 2016
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, make sure you read and understand the
instruction manual and follow all labels, employer's safety
practices, and Material Safety Data Sheets (MSDSs).
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
1 SAFETY
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3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
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
1 SAFETY
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© ESAB AB 2016
NOISE - Excessive noise can damage hearing
Protect your ears. Use ear defenders or other hearing protection.
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. Therefore, make sure that 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.
ESAB can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
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© ESAB AB 2016
2 INTRODUCTION
W8
2
is a control unit and it exists in two different chassis:
Aristo® W8
2
W8
2
is a control unit that adjusts the communication between
welding equipment and automation equipment, such as robots and
computers. Communication protocols: DeviceNet, Profibus,
CANopen and Ethernet.
W8
2
is used together with ESAB's CANbus equipped power sources
for welding automation. For power source and wire feed unit
handling, see the relevant instruction manual.
Retrofit Aristo® Mig 4004i WeldCloud™
Retrofit Aristo® Mig 4004i WeldCloud™ is retrofitted on top of
supported ESAB power sources. It connects to the CANbus
internally. Communication protocol: WeldCloud™.
For information about supported power sources, contact your ESAB
sales representative.
2.1 Equipment
Aristo® W8
2
• W8
2
DeviceNet, W8
2
Profibus, W8
2
CANopen and W8
2
Ethernet are supplied with a
USB memory and an instruction manual.
• W8
2
Integrated is supplied with an instruction manual.
Retrofit Aristo® Mig 4004i WeldCloud™
• Retrofit Aristo® Mig 4004i WeldCloud™ is supplied with the software WeldCloud™ and a
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.
Instruction manuals in other languages can be downloaded from the Internet:
www.esab.com
3 TECHNICAL DATA
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© ESAB AB 2016
3 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 4.2 lbs (4 kg)
Dimensions (l × w × h) 8 × 4.3 × 6.9 in (366 × 101 × 159 mm)
Enclosure class IP 23
Retrofit Aristo® Mig 4004i WeldCloud™
Supply voltage (from power source) 50 V DC
Supply current (max) 1.0 A (12 V DC)
Weight 4.2 lbs (5 kg)
Dimensions (l × w × h) 8 × 4.3 × 6.9 in (527 × 257 × 115 mm)
Enclosure class IP 23
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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© ESAB AB 2016
4 INSTALLATION
The installation must be carried out by a professional.
See the service manual for Aristo® W8
2
, Retrofit Mig 4004i WeldCloud™.
For Retrofit Aristo® Mig 4004i WeldCloud™, make sure the antenna on the top box is not
covered or blocked.
4.1 Electrical supply
NOTE!
Mains supply requirements
This equipment complies with IEC 61000-3-12 provided that the short-circuit
power is greater than or equal to S
scmin
at the interface point between the user's
supply and the public system. It is the responsibility of the installer or user of the
equipment to ensure, by consultation with the distribution network operator if
necessary, that the equipment is connected only to a supply with a short-circuit
power greater than or equal to S
scmin
. Refer to the technical data in the
TECHNICAL DATA chapter.
4.2 Assembly instruction
Connection of Aristo® W82 to ESAB's Mig 5000i power source
1. Remove the rear handle of the welding
power source by removing the screws.
2. Put the W8
2
onto the welding power
source.
3. Screw the W8
2
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
2
, Retrofit Mig 4004i WeldCloud™ or contact the nearest
ESAB Service Center or distributor.
4 INSTALLATION
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© ESAB AB 2016
Connection of Aristo® W82 to ESAB's Mig 3001i, Mig 4001i and Mig 6502c power
sources
Connect the W8
2
with a 2m cable and place it on the floor or on a stand next to the power
source.
4.3 System description
It is possible to configure the U8
2
unit for stand-alone usage (stand-alone unit) or
presentation usage (presentation unit). The presence of a W8
2
unit within the welding system
determines which unit is to be used.
The stand-alone unit is used when there is
no W8
2
unit in the system.
The presentation unit is used when there
is a W8
2
unit in the system.
It is necessary to convert the U8
2
stand-alone unit to a U8
2
presentation unit before it is used
together with a W8
2
unit.
During unit startup it is possible to see whether or not the unit is a presentation unit.
4.4 How to setup the U82 for use with W82
NOTE!
It is necessary to change the U8
2
stand-alone unit to a presentation unit before it
is used together with a W8
2
unit.
4.4.1 Save your stored data
1. Connect the U8
2
stand-alone unit to a power source or a wire feed unit.
2. Turn on the power source's main switch.
3. Export weld data sets from the U8
2
memory to a USB memory (see chapter
Export/Import in the U8
2
instruction manual).
4 INSTALLATION
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© ESAB AB 2016
4. Turn off the power source's main switch.
5. Remove the USB memory.
4.4.2 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"
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 power source's main switch.
One “beep” indicates that conversion
process has started. It is finished when two
“beeps” are heard.
7. Turn off the power source's main switch.
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
2
unit.
4.5 Systems diagrams
Schematic diagrams showing the connection between different units follow.
1. Connection between welding power source and W82 - “CAN to power source“.
2. Connection between W82 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 RoboFeed wire feed unit is not used, a separate arc voltage feedback is
required for 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 from serial number 944-xxx-xxxx
Orange indicating lamp - Overheating
2. Fieldbus
Connection for communication with robot system
3. Measure
Connection for measurement cable for arc voltage feedback and emergency stop signal,
measurement kit
4. Internal CAN
Connections for communication with ESAB wire feed unit and control panel
5. LAN
Connection to network, Ethernet
6. CAN to welding power source
Connection for communication with welding power source
7. USB
USB memory connection
5 OPERATION
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© ESAB AB 2016
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
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
lamp goes out.
6 MAINTENANCE
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6 MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
CAUTION!
Only individuals with the appropriate electrical knowledge (authorised 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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© ESAB AB 2016
7 ORDERING SPARE PARTS
W8
2
and Retrofit Mig 4004i WeldCloud™ are designed and tested in accordance with the
international and European standards 60974-1 and 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 may 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
2
DIAGRAM
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© ESAB AB 2016
DIAGRAM
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© ESAB AB 2016
Retrofit Mig 4004i WeldCloud™
ORDERING NUMBERS
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© ESAB AB 2016
ORDERING NUMBERS
Ordering no. Denomination
0460 891 880 Aristo® W8
2
, Integrated
0460 891 881 Aristo® W8
2
, DeviceNet
0460 891 882 Aristo® W8
2
, Profibus
0460 891 883 Aristo® W8
2
, CANopen
0460 891 884 Aristo® W8
2
, Ethernet
0445 302 880 Retrofit Aristo® Mig 4004i WeldCloud™
0459 839 038 Spare parts list W8
2
Retrofit Mig 4004i WeldCloud™
0740 800 203 Service manual W8
2
Retrofit Mig 4004i WeldCloud™
Instruction manuals and the spare parts list are available on the Internet at: www.esab.com
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