ESAB W82, Retrofit Mig 4004i WeldCloud™ User manual
- Category
- Welding System
- Type
- User manual
This manual is also suitable for
Aristo®
Instruction manual
0460 971 401 US 20181120
Valid for: W82serialno.710-xxx-xxxx;
RetrofitMig4004iWeldCloud™serialno. 627-,834-xxx-xxxx
W82,
RetrofitMig4004iWeldCloud™
TABLE OF CONTENTS
0460 971 401 © ESAB AB 2018
1
SAFETY ....................................................................................................... 5
1.1 Meaning of symbols ............................................................................... 5
1.2 Safety precautions ................................................................................. 5
2
INTRODUCTION.......................................................................................... 9
2.1 Equipment............................................................................................... 9
3
TECHNICAL DATA ...................................................................................... 10
4
INSTALLATION............................................................................................ 11
4.1 Assembly instruction ............................................................................. 11
4.2 System description ................................................................................ 11
4.3 How to setup the U82 for use with W82 ............................................... 12
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.................................................................................... 13
5
OPERATION ................................................................................................ 15
5.1 Connections and control devices ......................................................... 15
5.2 Overheating protection .......................................................................... 16
5.3 Arc voltage feedback ............................................................................. 16
6
MAINTENANCE........................................................................................... 18
6.1 Inspection and cleaning......................................................................... 18
7
ORDERING SPARE PARTS ........................................................................ 19
DIAGRAM ............................................................................................................ 20
ORDERING NUMBERS....................................................................................... 23
ACCESSORIES ................................................................................................... 24
Rights reserved to alter specifications without notice.
1 SAFETY
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© ESAB AB 2018
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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© ESAB AB 2018
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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© ESAB AB 2018
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 to you:
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”
2. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”
3. AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”
4. AWS SP - “Safe practices” - Reprint, Welding Handbook
5. ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and
Cutting of Containers That Have Held Hazardous Substances”
6. OSHA 29 CFR 1910 - "Safety and health standards"
7. CSA W117.2 - "Code for safety in welding and cutting"
8. NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and
Other Hot Work"
9. CGA Standard P-1, “Precautions for Safe Handling of Compressed
Gases in Cylinders”
1
0.
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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© ESAB AB 2018
2 INTRODUCTION
Aristo® W8
2
W8
2
is a control unit that enables communication between welding
equipment and automation equipment, such as robots and
computers. Communication protocols: DeviceNet, Profibus,
CANopen, Ethernet, and EtherCAT.
W8
2
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 0445302880 (without Ethernet connection and
communication with robot system) and 0445302881 (with Ethernet
connection and communication with robot system).
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, W8
2
EtherNet and W8
2
EtherCAT are
supplied with a USB memory connection and an instruction manual.
• W8
2
Integrated is supplied with an instruction manual.
Retrofit Mig 4004i WeldCloud™
• Retrofit Mig 4004i WeldCloud™ is supplied with the WeldCloud™ software 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.
3 TECHNICAL DATA
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© ESAB AB 2018
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 8.8 lb (4 kg)
Dimensions (l × w × h) 14.41×3.98×6.26in (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) 20.75×10.12×4.52in (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) 20.75×10.12×4.13in
(527×257×105mm)
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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© ESAB AB 2018
4 INSTALLATION
The installation must be carried out by a professional.
See the service manual Aristo® W8
2
, 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
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.
Connection of Aristo® W82 to Mig 3001i, Mig 4001i, Mig 4002c, Mig 5002c, 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.
4.2 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.
4 INSTALLATION
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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.
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
2
stand-alone unit to a presentation unit before it
is used together with a W8
2
unit.
4.3.1 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 main switch on the power source.
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. 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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© ESAB AB 2018
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
2
unit.
4.4 System diagrams
Schematic diagrams showing the connection between different units follow.
1. Connection between welding power source and W8
2
- "CAN to power source."
2. Connection between W8
2
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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© ESAB AB 2018
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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© ESAB AB 2018
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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© ESAB AB 2018
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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© ESAB AB 2018
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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© ESAB AB 2018
7 ORDERING SPARE PARTS
W8
2
and Retrofit Mig 4004i WeldCloud™ are designed and tested in accordance with the
international and European standards IEC/EN60974-1 and IEC/EN60974-10. 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
2
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ESAB W82, Retrofit Mig 4004i WeldCloud™ User manual
- Category
- Welding System
- Type
- User manual
- This manual is also suitable for
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