w82, retrofit mig 4004i weldcloud™ -...

Aristo®

Instruction manual

0460 971 301 GB 20161014Valid for: W82 serial no. 544-, 628-xxx-xxxx

Retrofit Mig 4004i WeldCloud™ serial no. 550-xxx-xxxx

W82,Retrofit Mig 4004i WeldCloud™

TABLE OF CONTENTS

0460 971 301 © ESAB AB 2016

1 SAFETY ........................................................................................................... 41.1 Meaning of symbols ...................................................................................... 4

1.2 Safety precautions ........................................................................................ 4

2 INTRODUCTION .............................................................................................. 72.1 Equipment ...................................................................................................... 7

3 TECHNICAL DATA .......................................................................................... 8

4 INSTALLATION................................................................................................ 94.1 Assembly instruction .................................................................................... 9

4.2 System description ....................................................................................... 9

4.3 How to set-up the U82 for use with W82 ..................................................... 10

4.3.1 Save your stored data ................................................................................. 10

4.3.2 Convert the U82 stand alone unit to a presentation unit ............................. 10

4.4 System diagrams........................................................................................... 11

5 OPERATION .................................................................................................... 135.1 Connections and control devices ................................................................ 13

5.2 Overheating protection ................................................................................. 14

5.3 Arc voltage feedback .................................................................................... 14

6 MAINTENANCE ............................................................................................... 166.1 Inspection and cleaning................................................................................ 16

7 ORDERING SPARE PARTS ............................................................................ 17

DIAGRAM ............................................................................................................... 18

ORDERING NUMBERS .......................................................................................... 21

ACCESSORIES ...................................................................................................... 22

Rights reserved to alter specifications without notice.

1 SAFETY

0460 971 301 - 4 - © ESAB AB 2016

1 SAFETY

1.1 Meaning of symbolsAs 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 oflife.

CAUTION!Means hazards which could result in minor personal injury.

WARNING!Before use, read and understand the instruction manualand follow all labels, employer´s safety practices andMaterial Safety Data Sheets (MSDSs).

1.2 Safety precautionsNOTE!The unit is tested by ESAB in a general set-up. The responsibility for safety andfunction, of the specific set-up, lies with the integrator.

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone whoworks on or near the equipment observes all the relevant safety precautions. Safetyprecautions must meet the requirements that apply to this type of equipment. The followingrecommendations should be observed in addition to the standard regulations that apply tothe workplace.

All work must be carried out by trained personnel well-acquainted with the operation of theequipment. Incorrect operation of the equipment may lead to hazardous situations which canresult in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:○ its operation○ location of emergency stops○ its function○ relevant safety precautions○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:○ no unauthorised person is stationed 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

0460 971 301 - 5 - © ESAB AB 2016

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 burns5. 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 can be injurious to yourself and others. Take precautionswhen 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 safeELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician 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 yourbody. Secure them with tape when possible. Do not place your bodybetween the torch and work cables. Never coil the torch or work cablearound your body. Keep welding power source and cables as far awayfrom your body as possible.

○ Connect the work cable to the workpiece as close as possible to thearea being welded.

FUMES AND GASES - Can be dangerous to 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 lensand wear protective clothing.

• Protect bystanders with suitable screens or curtains.NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY

0460 971 301 - 6 - © ESAB AB 2016

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have onlyqualified people remove covers for maintenance and troubleshooting asnecessary. Reinstall panels or covers and close doors when service isfinished 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 fire. Make sure that there are no inflammablematerials 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 residentiallocations where the electrical power is provided by thepublic low-voltage supply system. There may be potentialdifficulties in ensuring electromagnetic compatibility of classA equipment in those locations, due to conducted as wellas radiated disturbances.

NOTE!Dispose of electronic equipment at the recyclingfacility!

In observance of European Directive 2012/19/EC on WasteElectrical and Electronic Equipment and its implementationin accordance with national law, electrical and/or electronicequipment that has reached the end of its life must bedisposed of at a recycling facility.

As the person responsible for the equipment, it is yourresponsibility to obtain information on approved collectionstations.

For further information contact the nearest ESAB dealer.

ESAB can provide you with all necessary welding protection and accessories.

2 INTRODUCTION

0460 971 301 - 7 - © ESAB AB 2016

2 INTRODUCTIONAristo® W82

W82 is a control unit that enables communication between weldingequipment and automation equipment, such as robots andcomputers. Communication protocols: DeviceNet, Profibus,CANopen and Ethernet.

W82 is used together with ESAB CANbus equipped power sourcesfor welding automation. For power source and wire feed unithandling, see the relevant instruction manual.Retrofit Mig 4004i WeldCloud™

Retrofit Mig 4004i WeldCloud™ is retrofitted on top of supportedESAB 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 orderingnumbers 0445 302 880 (without connection for ethernet andcommunication with robot system) and 0445 302 881 (withconnection for ethernet and communication with robot system).

For information about supported power sources, contact your ESABsales representative.

2.1 Equipment

Aristo® W82

• W82 DeviceNet, W82 Profibus, W82 CANopen and W82 Ethernet are supplied with aUSB memory and an instruction manual.

• W82 Integrated is supplied with an instruction manual.

Retrofit Mig 4004i WeldCloud™

• Retrofit Mig 4004i WeldCloud™ is supplied with the software WeldCloud™ and aQuick start guide.

Measurement cable kit and connection cables for different power sources are available asaccessories, see "ACCESSORIES" chapter and separate spare parts list.

3 TECHNICAL DATA

0460 971 301 - 8 - © ESAB AB 2016

3 TECHNICAL DATA

Aristo® W82

Supply voltage (to feed unit through W82) 42 V, 50 - 60 Hz

Supply voltage (from robot) 24 V DCSupply voltage (from power source) 12 V DCWeight 4 kg (8.8 lb.)Dimensions (l × w × h) 366 × 101 × 159 mm (14.41 × 3.98 × 6.26 in.)Enclosure class IP23

Retrofit Aristo® Mig 4004i WeldCloud™ (0445 302 880)Supply voltage (to feed unit through WeldCloud™) 42 V, 50 - 60 HzSupply voltage (from power source) 12 V DCWeight 6 kg (13.2 lb.)Dimensions (l × w × h) 527 × 257 × 115 mm

(20.75 × 10.12 × 4.52 in.)Enclosure class IP23

Retrofit Aristo® Mig 4004i WeldCloud™ (0445 302 881)Supply voltage (to feed unit through WeldCloud™) 42 V, 50 - 60 HzSupply voltage (from power source) 12 V DCWeight 6 kg (13.2 lb.)Dimensions (l × w × h) 527 × 257 × 105 mm

(20.75 × 10.12 × 4.13 in.)Enclosure class IP23

Enclosure classThe IP code indicates the enclosure class, i.e. the degree of protection against penetrationby solid objects or water.

Equipment marked IP23 is intended for indoor and outdoor use.

4 INSTALLATION

0460 971 301 - 9 - © ESAB AB 2016

4 INSTALLATIONThe installation must be carried out by a professional.

See the service manual Aristo® W82, Retrofit Mig 4004i WeldCloud™, WeldCloud™Mobile.

For Retrofit Aristo® Mig 4004i WeldCloud™, make sure the antenna on the top box is notcovered or blocked.

4.1 Assembly instructionConnection of Aristo® W82 to Mig 5000i, Mig 5000iw, Mig U5000i, Mig U5000iw powersource

1. Remove the screws on the rear handle ofthe power source.2. Put the W82 onto the welding powersource.

3. Screw the W82 and the handle into placein the same screw holes.

Connection of Retrofit Aristo® Mig 4004i WeldCloud™For instructions on how to connect the Retrofit Aristo® Mig 4004i WeldCloud™, see theservice manual for Aristo® W82, Retrofit Mig 4004i WeldCloud™ or contact the nearestESAB Service Center or distributor.

Connection of Aristo® W82 to Mig 3001i, Mig 4001i, Mig 4002c, Mig 5002c and Mig6502c power sourcesConnect the W82 with a 2 m cable and place it on the floor or on a stand next to the powersource.

4.2 System descriptionIt is possible to configure the U82 unit for stand-alone usage (stand-alone unit) orpresentation usage (presentation unit). The presence of a W82 unit within the welding systemdetermines which unit that is to be used.

4 INSTALLATION

0460 971 301 - 10 - © ESAB AB 2016

The stand-alone unit is used when there isno W82 unit in the system.

The presentation unit is used when thereis a W82 unit in the system.

During unit start-up it is possible to see if the unit is a presentation unit or not.

4.3 How to set-up the U82 for use with W82NOTE!It is necessary to change the U82 stand-alone unit to a presentation unit before itis used together with a W82 unit.

4.3.1 Save your stored data1. Connect the U82 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 U82 memory to a USB memory (see chapter

Export/Import in the U82 instruction manual).4. Turn OFF the main switch on the power source.5. Remove the USB memory.

4.3.2 Convert the U82 stand alone unit to a presentation unit1. 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

0460 971 301 - 11 - © ESAB AB 2016

3. Open the cover on the left-hand end of thecontrol panel.

4. Insert the enclosed USB-memory into theUSB connector.

5. Close the cover.6. Turn ON the main switch on the power

source. One “beep” indicates that convertprocess is started. It is finished when two“beeps” are heard.

7. Turn OFF the main switch on the powersource.

8. Open the cover and remove the enclosedUSB memory.

9. Close the cover. The unit is now ready to be used together with a W82 unit.

4.4 System diagramsSchematic 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 ESAB wire feeder unit is not used, a separate arc voltage feedback isrequired to the measurement contact on the control unit.

4 INSTALLATION

0460 971 301 - 12 - © ESAB AB 2016

5 OPERATION

0460 971 301 - 13 - © ESAB AB 2016

5 OPERATIONGeneral 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-xxxxOrange indicating lamp - Overheating

2. External CAN and termination option3. Fieldbus

Connection for communication with robot system4. Measure

Connection for measurement cable for arc voltage feedback and emergency stopsignal, measurement kit

5. Internal CANConnections for communication with ESAB wire feed unit and control panel

6. LANConnection to network, Ethernet

7. CAN to welding power sourceConnection for communication with welding power source

8. USBUSB memory connection

5 OPERATION

0460 971 301 - 14 - © ESAB AB 2016

1. Antenna2. Indicating LED, white,

Power supply ON3. Indicating LED, red

Connection status (lit LED = connection error)4. USB

USB memory connection5. CAN connection6. Arc voltage monitoring (+), red banana socket7. Arc voltage monitoring (-), black banana socket8. Fieldbus Connection for communication with robot system9. Ethernet connection

5.2 Overheating protectionThe control unit has overheating protection that operates if the temperature becomes toohigh. When this occurs the welding current is interrupted and the orange lamp illuminates.

The overheating protection resets automatically when the temperature has fallen and thelight goes out.

5.3 Arc voltage feedbackTo achieve a good welding result, the arc voltage feedback is a crucial factor. In MIG/MAGwelding, 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 interconnectioncable is used! This method of measuring the arc voltage, compensates for the voltage dropin the welding cable to the wire feeder. With an ESAB torch supporting "TrueArcVoltage", thevoltage drop all the way to the contact tip is compensated.

5 OPERATION

0460 971 301 - 15 - © ESAB AB 2016

WARNING!The external arc voltage inputs (the red and black banana sockets) at the backend of the WeldCloud™ top box should not be used, unless the equipment hasbeen configured for this setup by authorised ESAB service personnel.

NOTE!To compensate the voltage drop in the return cable, the power source can beconfigured (by authorised ESAB service personnel) to use an external arc voltagesense wire from the workpiece.

6 MAINTENANCE

0460 971 301 - 16 - © ESAB AB 2016

6 MAINTENANCENOTE!Regular maintenance is important for safe and reliable operation.

CAUTION!Only those persons who have appropriate electrical knowledge (authorizedpersonnel) may remove the safety plates.

CAUTION!All warranty undertakings from the supplier cease to apply if the customerattempts any work to rectify any faults in the product during the warranty period.

6.1 Inspection and cleaningRegularly check that the control unit is in electrical contact with the power source and thatthe connections are fault-free and correctly connected.

7 ORDERING SPARE PARTS

0460 971 301 - 17 - © ESAB AB 2016

7 ORDERING SPARE PARTSW82 and Retrofit Mig 4004i WeldCloud™ are designed and tested in accordance with theinternational and European standards IEC/EN 60974-1 and IEC/EN 60974-10. It is theobligation of the service unit which has carried out the service or repair work to make surethat the product still conforms to the said standard.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the backcover of this document. When ordering, please state product type, serial number, designationand spare part number in accordance with the spare parts list. This facilitates dispatch andensures correct delivery.

ORDERING NUMBERS

0460 971 301 - 21 - © ESAB AB 2016

ORDERING NUMBERS

Ordering no. Denomination0460 891 880 Aristo® W82, Integrated

0460 891 881 Aristo® W82, DeviceNet

0460 891 882 Aristo® W82, Profibus

0460 891 883 Aristo® W82, CANopen

0460 891 884 Aristo® W82, Ethernet

0445 302 880 Retrofit Aristo® Mig 4004i WeldCloud™0445 302 881 Retrofit Aristo® Mig 4004i WeldCloud™0459 839 038 Spare parts list W82 , Retrofit Mig 4004i WeldCloud™

0740 800 203 Service manual W82, Retrofit Mig 4004i WeldCloud™,WeldCloud™ Mobile

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

ACCESSORIES

0460 971 301 - 22 - © ESAB AB 2016

ACCESSORIES0456 527 885 Control cable (connectors included)*

0.45 m, 12 poles

0462 000 880 Control cable (connectors included)*2 m, 10 - 12 poles

0461 182 880 Connection set CAN Robot for Aristo®W82 Integrated*7.5 m

0462 062 001 USB memory 2 Gb

0459 314 880 Terminating resistor*

0445 501 880

0445 501 881

0445 501 882

0445 501 883

Robot Interface Kit Devicenet WeldCloud™

Robot Interface Kit Profibus WeldCloud™

Robot Interface Kit CANopen WeldCloud™

Robot Interface Kit EtherNet IP WeldCloud™

*Not applicable for Retrofit Aristo® W82 with ordering number 0465 826 881.

ESAB subsidiaries and representative offices

www.esab.com

EuropeAUSTRIAESAB Ges.m.b.HVienna-LiesingTel: +43 1 888 25 11Fax: +43 1 888 25 11 85

BELGIUMS.A. ESAB N.V.Heist-op-den-BergTel: +32 15 25 79 30Fax: +32 15 25 79 44

BULGARIAESAB Kft Representative OfficeSofiaTel: +359 2 974 42 88Fax: +359 2 974 42 88

THE CZECH REPUBLICESAB VAMBERK s.r.o.VamberkTel: +420 2 819 40 885Fax: +420 2 819 40 120

DENMARKAktieselskabet ESABHerlevTel: +45 36 30 01 11Fax: +45 36 30 40 03

FINLANDESAB OyHelsinkiTel: +358 9 547 761Fax: +358 9 547 77 71

GREAT BRITAINESAB Group (UK) LtdWaltham CrossTel: +44 1992 76 85 15Fax: +44 1992 71 58 03

ESAB Automation LtdAndoverTel: +44 1264 33 22 33Fax: +44 1264 33 20 74

FRANCEESAB France S.A.Cergy PontoiseTel: +33 1 30 75 55 00Fax: +33 1 30 75 55 24

GERMANYESAB Welding & Cutting GmbHLangenfeldTel: +49 2173 3945-0Fax: +49 2173 3945-218

HUNGARYESAB KftBudapestTel: +36 1 20 44 182Fax: +36 1 20 44 186

ITALYESAB Saldatura S.p.A.Bareggio (Mi)Tel: +39 02 97 96 8.1Fax: +39 02 97 96 87 01

THE NETHERLANDSESAB Nederland B.V.AmersfoortTel: +31 33 422 35 55Fax: +31 33 422 35 44

NORWAYAS ESABLarvikTel: +47 33 12 10 00Fax: +47 33 11 52 03

POLANDESAB Sp.zo.o.KatowiceTel: +48 32 351 11 00Fax: +48 32 351 11 20

PORTUGALESAB LdaLisbonTel: +351 8 310 960Fax: +351 1 859 1277

ROMANIAESAB Romania Trading SRLBucharestTel: +40 316 900 600Fax: +40 316 900 601

RUSSIALLC ESABMoscowTel: +7 (495) 663 20 08Fax: +7 (495) 663 20 09

SLOVAKIAESAB Slovakia s.r.o.BratislavaTel: +421 7 44 88 24 26Fax: +421 7 44 88 87 41

SPAINESAB Ibérica S.A.San Fernando de Henares(MADRID)Tel: +34 91 878 3600Fax: +34 91 802 3461

SWEDENESAB Sverige ABGothenburgTel: +46 31 50 95 00Fax: +46 31 50 92 22

ESAB International ABGothenburgTel: +46 31 50 90 00Fax: +46 31 50 93 60

SWITZERLANDESAB Europe GmbHBaarTel: +41 1 741 25 25Fax: +41 1 740 30 55

UKRAINEESAB Ukraine LLCKievTel: +38 (044) 501 23 24Fax: +38 (044) 575 21 88

North and South AmericaARGENTINACONARCOBuenos AiresTel: +54 11 4 753 4039Fax: +54 11 4 753 6313

BRAZILESAB S.A.Contagem-MGTel: +55 31 2191 4333Fax: +55 31 2191 4440

CANADAESAB Group Canada Inc.Missisauga, OntarioTel: +1 905 670 0220Fax: +1 905 670 4879

MEXICOESAB Mexico S.A.MonterreyTel: +52 8 350 5959Fax: +52 8 350 7554

USAESAB Welding & CuttingProductsFlorence, SCTel: +1 843 669 4411Fax: +1 843 664 5748

Asia/PacificAUSTRALIAESAB South PacificArcherfield BC QLD 4108Tel: +61 1300 372 228Fax: +61 7 3711 2328

CHINAShanghai ESAB A/PShanghaiTel: +86 21 2326 3000Fax: +86 21 6566 6622

INDIAESAB India LtdCalcuttaTel: +91 33 478 45 17Fax: +91 33 468 18 80

INDONESIAP.T. ESABindo PratamaJakartaTel: +62 21 460 0188Fax: +62 21 461 2929

JAPANESAB JapanTokyoTel: +81 45 670 7073Fax: +81 45 670 7001

MALAYSIAESAB (Malaysia) Snd BhdUSJTel: +603 8023 7835Fax: +603 8023 0225

SINGAPOREESAB Asia/Pacific Pte LtdSingaporeTel: +65 6861 43 22Fax: +65 6861 31 95

SOUTH KOREAESAB SeAH CorporationKyungnamTel: +82 55 269 8170Fax: +82 55 289 8864

UNITED ARAB EMIRATESESAB Middle East FZEDubaiTel: +971 4 887 21 11Fax: +971 4 887 22 63

AfricaEGYPTESAB EgyptDokki-CairoTel: +20 2 390 96 69Fax: +20 2 393 32 13

SOUTH AFRICAESAB Africa Welding & CuttingLtdDurbanvill 7570 - Cape TownTel: +27 (0)21 975 8924

DistributorsFor addresses and phonenumbers to our distributors inother countries, please visit ourhome page

www.esab.com

w82, retrofit mig 4004i weldcloud™ -...

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