ESAB W82 Aristo Instruction manual

Aristo®

Instruction manual

0460 971 101 US 20140521 Valid for: W82:905-,944- xxx-xxxx RetrofitW82:419-xxx-xxxx

1 SAFETY ................................................................................................................ 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......................................................................................13

6 MAINTENANCE..................................................................................................14

6.1 Inspection and cleaning ....................................................................................14

7 ORDERING SPARE PARTS............................................................................... 15

DIAGRAM ..................................................................................................................16

ORDERING NUMBERS .............................................................................................19

ACCESSORIES .........................................................................................................20

Rights reserved to alter specifications without notice.

0460 971 101 © ESAB AB 2014

1 SAFETY

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 unauthorised 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 equpment

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 extinquishing equipment must be clearly marked and close at hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

0460 971 101

CAUTION!

This product is solely intended for arc welding.

- 4 -

1 SAFETY

WARNING!

Arc welding and cutting may cause injury to yourself and others. Take precautions when welding and cutting. Ask for your employer's safety practices, which should be based on the manufacturer's hazard data.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with applicable standards

• Do not touch live electrical parts or electrodes with bare skin, wet gloves, or wet clothing

• Insulate yourself from the ground and the workpiece

• Ensure your working stance is safe

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

FIRE HAZARD

• Sparks (spatter) can cause a fire. Therefore, make sure that there are no inflammable materials nearby

NOISE - Excessive noise can damage hearing

• Protect your ears. Use earmuffs or other hearing protection. Protect your ears. Use earmuffs or other hearing protection

• Warn bystanders of the risk

MALFUNCTION - Call for expert assistance in the event of a malfunction.

Read and understand the instruction manual before installing or operating.

PROTECT YOURSELF AND OTHERS!

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.

0460 971 101

- 5 -

1 SAFETY

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.

CAUTION!

Read and understand the instruction manual before installing or operating.

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

0460 971 101

- 6 -

2 INTRODUCTION

W82is a control unit and it exists in two different chassis:



2.1 Equipment

Aristo® W8

W82is 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.

W82is 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® W8

Retrofit Aristo® W82is retrofitted on top of supported ESAB power sources. It connects to the CANbus internally. Communication

protocol: WeldLink.

For information about supported power sources, contact your ESAB sales representative.



Aristo® W8

• W82DeviceNet, W82Profibus, W82CANopen and W82Ethernet are supplied with USB memory and an instruction manual.

• W82Integrated is supplied with an instruction manual.



Retrofit Aristo® W8

• Retrofit Aristo® W82is supplied with the WeldLink software and an instruction manual.



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

0460 971 101

- 7 -

3 TECHNICAL DATA

Aristo® W8

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

Supply voltage (from robot) 24 V DC

Supply voltage (from power source) 12 V DC

Weight 8.8lbs (4kg)

Dimensions (l × w × h) 14.4 × 4 × 6.26in (366 × 101 × 159mm)

Enclosure class IP 23

Retrofit Aristo® W8

Supply voltage (from power source) 12 V DC

Supply current (max) 1.0 A (12 V DC)

Weight 8.8lbs (3.6 kg)

Dimensions (l × w × h) 14.4 × 4 × 6.26in (477 × 250 × 90 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.

0460 971 101

- 8 -

4 INSTALLATION

The installation must be carried out by a professional.

See the service manual for Aristo® W82.

4.1 Electrical supply

NOTE! Mains supply requirements

High power equipment, due to the primary current drawn from the mains supply, may influence the power quality of the grid. Therefore, connection restrictions or requirements regarding the maximum permissible mains impedance, or the required minimum supply capacity at the interface point to the public grid, may apply for some types of equipment (see technical data). In this case, it is the responsibility of the installer or user of the equipment to ensure, in consultation with the distribution network operator if necessary, that the equipment may be connected.

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 W82onto the welding power

source.

3. Screw the W82and the handle into place

in the same screw holes.

Connection of Retrofit Aristo® W82

For instructions on how to connect the Retrofit Aristo® W82, see the Service manual for W8 or contact the nearest ESAB Service Center or distributor.

Connection of Aristo® W82 to ESAB's Mig 3001i, Mig 4001i and Mig 6502c power sources

Connect the W82with a 6.5ft (2 m) cable and place it on the floor or on a stand next to the power source.

0460 971 101

- 9 -

4 INSTALLATION

4.3 System description

It is possible to configure the U82unit for standalone usage (standalone unit) or presentation usage (presentation unit). The presence of a W82unit within the welding system determines which unit is to be used.

The standalone unit is used when there is no W82unit in the system.

The presentation unit is used when there is a W82unit in the system.

It is necessary to convert the U82standalone unit to a U82presentation unit before it is used together with a W82unit.

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 U82stand-alone unit to a presentation unit before it can be used together with a W82unit.

4.4.1 Save your stored data

1. Connect the U82standalone 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 U82memory to USB memory (see chapter Export/Import in the U82instruction manual).

4. Turn off the power source's main switch.

5. Remove the USB memory.

0460 971 101

- 10 -

4 INSTALLATION

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 W82unit.

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.

0460 971 101

- 11 -

4 INSTALLATION

0460 971 101

- 12 -

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

5.2 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.

0460 971 101

- 13 -

6 MAINTENANCE

NOTE!

Regular maintenance is important for safe, 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.

0460 971 101

- 14 -

7 ORDERING SPARE PARTS

W82is 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.

0460 971 101

- 15 -

DIAGRAM

Aristo® W8

0460 971 101

- 16 -

DIAGRAM

0460 971 101

- 17 -

DIAGRAM

Retrofit Aristo® W8

0460 971 101

- 18 -

ORDERING NUMBERS

Ordering no. Denomination

0460 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

0465 826 881 Retrofit Aristo® W8

0459 839 038 Spare parts list W8

0740 800 203 Service manual W8

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

0460 971 101

- 19 -

ACCESSORIES

0456 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®

W82Integrated*

7.5 m

0462 062 001 USB memory 2 Gb

0459 314 880 Terminating resistor*

*Not applicable for Retrofit Aristo® W82with ordering number 0465 826 881.

0460 971 101

- 20 -

ACCESSORIES

0460 971 101

- 21 -

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V. Heist-op-den-Berg Tel: +32 15 25 79 30 Fax: +32 15 25 79 44

BULGARIA

ESAB Kft Representative Office Sofia Tel: +359 2 974 42 88 Fax: +359 2 974 42 88

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03

FINLAND

ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71

GREAT BRITAIN

ESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03

ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74

FRANCE

ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24

GERMANY

ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218

HUNGARY

ESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186

ITALY

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

THE NETHERLANDS

ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44

NORWAY

AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03

POLAND

ESAB Sp.zo.o. Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277

ROMANIA

ESAB Romania Trading SRL Bucharest Tel: +40 316 900 600 Fax: +40 316 900 601

RUSSIA

LLC ESAB Moscow Tel: +7 (495) 663 20 08 Fax: +7 (495) 663 20 09

SLOVAKIA

ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41

SPAIN

ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22

ESAB International AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55

UKRAINE

ESAB Ukraine LLC Kiev Tel: +38 (044) 501 23 24 Fax: +38 (044) 575 21 88

North and South America

ARGENTINA

CONARCO Buenos Aires Tel: +54 11 4 753 4039 Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A. Contagem-MG Tel: +55 31 2191 4333 Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc. Missisauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A. Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 57 48

Asia/Pacific

AUSTRALIA

ESAB South Pacific Archerfield BC QLD 4108 Tel: +61 1300 372 228 Fax: +61 7 3711 2328

CHINA

Shanghai ESAB A/P Shanghai Tel: +86 21 2326 3000 Fax: +86 21 6566 6622

INDIA

ESAB India Ltd Calcutta Tel: +91 33 478 45 17 Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama Jakarta Tel: +62 21 460 0188 Fax: +62 21 461 2929

JAPAN

ESAB Japan Tokyo Tel: +81 45 670 7073 Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd USJ Tel: +603 8023 7835 Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Pacific Pte Ltd Singapore Tel: +65 6861 43 22 Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63

Africa

EGYPT

ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13

SOUTH AFRICA

ESAB Africa Welding & Cutting Ltd Durbanvill 7570 - Cape Town Tel: +27 (0)21 975 8924

Distributors

For addresses and phone numbers to our distributors in other countries, please visit our home page

www.esab.com

ESAB W82 Aristo Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

1 SAFETY

2 INTRODUCTION

2.1 Equipment

3 TECHNICAL DATA

4 INSTALLATION

4.1 Electrical supply

4.2 Assembly instruction

4.3 System description

4.4 How to setup the U82 for use with W82

4.4.1 Save your stored data

4.4.2 Convert the U82 standalone unit to a presentation unit

4.5 Systems diagrams

5 OPERATION

5.1 Connections and control devices

5.2 Overheating protection

6 MAINTENANCE

6.1 Inspection and cleaning

7 ORDERING SPARE PARTS

DIAGRAM

ORDERING NUMBERS

ACCESSORIES