ESAB Aristo W82 User manual

Aristo®
Instruction manual
0460 971 101 GB 20140521 Valid for: W82:905-,944- xxx-xxxx RetrofitW82:419-xxx-xxxx
W82

TABLE OF CONTENTS
0460 971 101 © ESAB AB 2014
1 SAFETY ................................................................................................................ 4
2 INTRODUCTION................................................................................................... 7
2.1 Equipment............................................................................................................. 7
3 TECHNICAL DATA ............................................................................................... 8
4 INSTALLATION..................................................................................................... 9
4.1 Mains supply ........................................................................................................ 9
4.2 Assembly instruction...........................................................................................9
4.3 System description ............................................................................................10
4.4 How to set-up the U82 for use with W82..........................................................10
4.4.1 Save your stored data ...................................................................................... 10
4.4.2 Convert the U82 stand alone 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.

1 SAFETY
0460 971 101 -4- © ESAB AB 2014
1 SAFETY
NOTE!
The unit is tested by ESAB in a general set-up. The responsibility for 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 can
result 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
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
CAUTION!
This product is solely intended for arc welding.

1 SAFETY
0460 971 101 -5- © ESAB AB 2014
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should
be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
• Install and earth 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 earth and the workpiece
• Ensure your working stance is safe
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 lens
and wear protective clothing
• Protect bystanders with suitable screens or curtains
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore 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 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 those locations, due to conducted
as well as radiated disturbances.

1 SAFETY
0460 971 101 -6- © ESAB AB 2014
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of 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.

2 INTRODUCTION
0460 971 101 -7- © ESAB AB 2014
2 INTRODUCTION
W82is a control unit and it exists in two different chassis:
Aristo® W82
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® W82
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.

2.1 Equipment

Aristo® W82
• W82DeviceNet, W82Profibus, W82CANopen and W82Ethernet are supplied with a
USB memory and an instruction manual.
• W82Integrated is supplied with an instruction manual.

Retrofit Aristo® W82
• Retrofit Aristo® W82is supplied with the software WeldLink 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

3 TECHNICAL DATA
0460 971 101 -8- © ESAB AB 2014
3 TECHNICAL DATA
Aristo® W82
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 4 kg
Dimensions (l × w × h) 366 × 101 × 159 mm
Enclosure class IP 23
Retrofit Aristo® W82
Supply voltage (from power source) 12 V DC
Supply current (max) 1.0 A (12 V DC)
Weight 3.6 kg
Dimensions (l × w × h) 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.

4 INSTALLATION
0460 971 101 -9- © ESAB AB 2014
4 INSTALLATION
The installation must be carried out by a professional.
See the service manual for Aristo® W82.
4.1 Mains supply
NOTE!
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains
supply, 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, by 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 welding power source's rear
handle 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 W82
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 2 m cable and place it on the floor or on a stand next to the power
source.

4 INSTALLATION
0460 971 101 - 10 - © ESAB AB 2014
4.3 System description
It is possible to configure the U82unit for stand-alone usage (stand-alone unit) or
presentation usage (presentation unit). The presence of a W82unit within the welding system
determines which unit that is to be used.
The stand-alone 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 U82stand-alone unit to a U82presentation unit before it is used
together with a W82unit.
During unit start-up it is possible to see if the unit is a presentation unit or not.
4.4 How to set-up the U82 for use with W82
NOTE!
It is necessary to change the U82stand-alone unit to a presentation unit before it
is used together with a W82unit.
4.4.1 Save your stored data
1. Connect the U82stand-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 U82memory to a USB memory (see chapter
Export/Import in the U82instruction manual).
4. Turn off the power source's main switch.
5. Remove the USB memory.