ESAB W82 User manual

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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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

○ 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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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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2 INTRODUCTION

is a control unit and it exists in two different chassis:

Aristo® W8

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.

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

• W8

DeviceNet, W8

Profibus, W8

CANopen and W8

Ethernet are supplied with a

USB memory and an instruction manual.

• W8

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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3 TECHNICAL DATA

Aristo® W8

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 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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4 INSTALLATION

The installation must be carried out by a professional.

See the service manual for Aristo® W8

, 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

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.

4 INSTALLATION

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Connection of Aristo® W82 to ESAB's Mig 3001i, Mig 4001i 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.

4.3 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.

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.

It is necessary to convert the U8

stand-alone unit to a U8

presentation unit before it is used

together with a W8

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

stand-alone unit to a presentation unit before it

is used together with a W8

unit.

4.4.1 Save your stored data

1. Connect the U8

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

2. Turn on the power source's main switch.

3. Export weld data sets from the U8

memory to a USB memory (see chapter

Export/Import in the U8

instruction manual).

4 INSTALLATION

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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

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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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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7 ORDERING SPARE PARTS

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

DIAGRAM

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DIAGRAM

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Retrofit Mig 4004i WeldCloud™

ORDERING NUMBERS

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ORDERING NUMBERS

Ordering no. Denomination

0460 891 880 Aristo® W8

, Integrated

0460 891 881 Aristo® W8

, DeviceNet

0460 891 882 Aristo® W8

, Profibus

0460 891 883 Aristo® W8

, CANopen

0460 891 884 Aristo® W8

, Ethernet

0445 302 880 Retrofit Aristo® Mig 4004i WeldCloud™

0459 839 038 Spare parts list W8

Retrofit Mig 4004i WeldCloud™

0740 800 203 Service manual W8

Retrofit Mig 4004i WeldCloud™

Instruction manuals and the spare parts list are available on the Internet at: www.esab.com

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ESAB W82, Retrofit Mig 4004i WeldCloud™, W82, Retrofit Mig 4004i WeldCloud™ User manual

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