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 ob
served 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 equip
ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in
jury to the operator and damage to the equipment.
1.Anyone who uses the equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding and cutting
2.The operator must ensure that:
S no unauthorized person is stationed within the working area of the equipment when it is
started up.
S no-one is unprotected when the arc is struck
3.The workplace must:
S be suitable for the purpose
S be free from drafts
4.Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves.
S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5.General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
CAUTION
Read and understand the instruction manual before
installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
SInstall and earth the unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse 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.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
ESAB can provide you with all necessary welding protection and accessories.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/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.
Applied Interface Robot S4 A360 checks and converts the CAN bus signals from
the power source to the welding robot and is used for CAN bus controlled power
sources, such as AristoMig 400/500 with Aristot U8 I/O.
Applied Interface Robot S4 A360 converts analog and digital signals to field bus
communication (CAN) and from field bus signals to digital and analog signals.
2.1Equipment
Applied Interface Robot S4 A360 is supplied with an instruction manual.
3TECHNICAL DATA
Applied Interface Robot S4 A360
Mains voltage42 V 50 - 60 Hz
Mains voltage 2 (from robot)24 V DC
Fuse1 A
External power source robot+/- 15V to robot
Robot connection48 pin connection socket
Weight6.1 kg
Dimensions (l x w x h)365 x 351 x 110 mm
Protection classIP23
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 designed for indoor and outdoor use.
4INSTALLATION
The installation must be executed by a professional.
CAUTION
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.
WARNING
When welding in an environment with increased electrical danger, only power
sources intended for this environment may be used. These power sources are
marked with the symbol
Applied Interface Robot S4 A360 is installed above the power source. Remove the
rubber mat (C) on the power source and then slide the flange of the interface box (A)
into the side profiles (B) of the power source, see the illustration below.
IMPORTANT! Screw the 3 screws into place on the front of the interface box,
sufficiently hard in the screw threads that electrical connection is made. Check that
electrical connection has been established.
4.2Connection instructions
AH 0738
Complete descriptions of the power source / wire feed unit are available in separate instruction
manuals.
The button stops the robot and the welding process.
Button B – Runs the robot program without weaving
The INHIBIT WEAVING button prevents weaving in the robot program when pressed
(lights yellow). The robot program can be run with and without weaving.
Button C – Runs the robot program without the welding process
The INHIBIT PROCESS button blocks the welding process when pressed (lights
yellow). One can run the robot program and test the movement pattern without
welding.
6MAINTENANCE
Regular maintenance is important for safe, reliable operation.
CAUTION
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any faults.
6.1Inspection and cleaning
Regularly check that the interface box has electrical connection with the power
source and that the connections are correctly connected and not faulty.
6.2Fault-tracing
SHas the indicator lamp (white) on the front gone out?
Check that the fuse is intact.
SEnsure that the wiring is correctly located in its connectors.
Complete descriptions of the power source, wire feed unit and control panel are available in separate
instruction manuals.
Applied Interface Robot S4- A360 is designed and tested in accordance with the inter
national and European standards 60974-1 and 60974-10 . It is the obligation of the
service unit which has carried out the service or repair work to make sure that the pro
duct still conforms to the said standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
* * *
NOTE! 8. FUNCTION DESCRIPTION OF I/O SIGNALS is only in English and is
primarily meant for the integrator and installation of the Interface box on page 13.
The Aristot Retrofit I/O is the interface between the welding robot and the welding
equipment. The Aristot Retrofit I/O converts the robot's I/O signals to field bus
signals to the welding equipment. The Aristot Retrofit I/O also converts the field bus
signals from the welding equipment to I/O signals to the welding robot.
8.1Configuration of the I/O-version (Aristot U8 I/O)
With the service function 38 in the Aristot U8 I/O unit you can activate or deactivate
the different blocks of I/O's.
For more information, please read the Service manual for AristoPendant U8.
8.2Input data I/O signal from control equipment (robot) to the
welding equipment
Welding start
The signal starts the welding process but before the welding process starts the quick
stop and stop signals are checked to ensure that they are not active.
Stop
The signal shuts off the robot and the welding process.
Quick stop
The signal stops the equipment if it is active in the welding process, it carries out a
normal stop without crater filling. The function is used when a quick stop is required
but it gives a normal burnback time to prevent the wire sticking in the weld pool. The
signal also blocks the start command.
Wire inching
Used when one wants to feed wire without welding voltage.
The signal starts the wire feed without the welding voltage being activated. The wire
feed unit feeds wire at the set speed. If the signal is active during the welding
process, the command is ignored.
If both welding and wire inching are activated at the same time the equipment will
ignore the wire inching command and start the welding process.
Gas flushing
Gas flushing is used when measuring the gas flow or to flush any air or moisture
from the gas hoses before welding starts. Gas flushing is carried out without voltage
or wire feed occurring.
Welding start always activates the gas valve even if the manual gas command is
given. In the same way the gas valve for gas post flow is always closed if it is not
closed already.
Gas flushing operates parallel to the functions gas pre-flow and gas post-flow. To
control the welding gas from the robot, set the gas pre-flow to minimum and the gas
post-flow to maximum, and then control the welding gas using the gas flushing
functions.
The signal controls the valve for air cleaning welding spatter.
Touch Sense Response
This command is used by the robot to sense where the wire is.
When the function is active, the power source will give out current limited idle voltage
to see if the wire is in contact with the workpiece. On contact, the output signal
”Touch Sense Response” is activated.
Active analog
The signal is used to switch between the analog and digital remote modes.
Analogue active allows analog control of the welding parameters, voltage, arc
voltage and the wire feed speed.
NOTE! On AristotRetrofit I/O the function is always activated.
If the welding method Aristot SuperPulse is to be used, the ”analog active” signal
must be deactivated.
When the analogue method is activated the power source will not use the preset
values for wire feed speed and voltage when new welding data is selected. When
”analog active” is activated the robot controls arc voltage and wire feed speed using
analog signals.
With the analog active signal deactivated, welding data is exchanged with preset
welding data such as voltage, wire feed speed to fixed set welding parameters.
The pre-programmed welding data (schedules) is requested from the
Aristot U8 I/O welding data memory.
Welding data
With the signals memory 1, 2, 4, 8, one accesses saved welding data (schedules) in
Aristot U8 I/O.
The binary coded combinations of these signals can be used to recall the memories
1-15 in the Aristot U8 I/O memory bank.
A complete set of welding data includes all settings that can be made in
Aristot U8 I/O, see the instruction manual for AristoPendant U8.
Voltage reference
This signal is used by the robot for analog control of the welding voltage if analog
active is selected. It stretches from 0-10V and corresponds to welding voltage socket
as follows.
0V reference gives a deviation on the selected arc voltage of -10V
10V reference gives a deviation on the selected arc voltage of +10V
If the machine is in non-synergy mode, the equipment will use the appreciated value.
0V reference gives arc voltage 8V
10V reference gives arc voltage 60V
The signal is used by the robot to make analog adjustments to the wire feed speed.
The internal solution is 0.1 m/min.
Input voltage
0 VMini. value for wire feed (normally 0.8 m/min) (RoboFeed)
10 VMax. value for wire feed (normally 25 m /min)
8.3Output I/O signal from welding equipment to control
equipment
Arc Acknowledge
The signal is activated after established welding start if the voltage and current
strength lie within weldable limits. The signal disappears if welding cannot be
established.
The criterion for establishing a welding arc is that the process control has passed the
start- procedure, which means that there it not sufficient with only a short circuit to
meet the criteria. Normal delay from the first contact, which is acknowledged by the
welding arc (wire feed time for this that the first contact is established ) is in the
interval 2 to 20 ms. If there is a poor start to the welding arc the ”Arc acknowledge” is
further delayed.
Touch Sense Response
This signal indicates contact in the welding circuit, i.e. that the wire is in contact with
the workpiece. To obtain ”touch sense response” the ”touch sense” input signal must
be activated.
Collision robot (AntiCollisionDetect)
The signal comes via the internal CAN bus from the feeding mechanism
(RoboFeed). The signal indicates that the robot's breaker has activated. The
interface activates a relay which breaks two safety loops from the robot, at which the
robot orders a quick stop of both robot and the welding equipment.
The output is high when the welding gun breaker is tripped (the signal is sent to the
robot).
Machine faults
The signal is low when an error has been detected in the welding equipment.
8.4Others
0-cable 4 mm
2
SThe 0-cable 4mm2 between the power source and the robot cabin is delivered in length of 15
m and is to be cut to the length required at installation.
Start up time
SThe start up time of the Interface box when current/power is activated can be delayed up to