ESAB WeldCloud Mobile User manual

Instruction manual
0463 601 001 GB 20220401 Valid for: serial no. OP132YY-XXXXXX
WeldCloud™ Universal
Connector

TABLE OF CONTENTS
0463 601 001 © ESAB AB 2022
1SAFETY ....................................................................................................... 4
1.1 Meaning of symbols ............................................................................... 4
1.2 Safety precautions ................................................................................. 4
2INTRODUCTION.......................................................................................... 7
2.1 Equipment ............................................................................................... 7
2.2 Before setup of your WeldCloud™ Universal Connector................... 7
2.2.1 Charging the lithium-ion battery ........................................................... 7
3TECHNICAL DATA ...................................................................................... 8
4INSTALLATION............................................................................................ 9
4.1 Main components ................................................................................... 9
4.2 Inserting the lithium-ion battery into the electronics box .................. 10
4.3 Installing WeldCloud™UniversalConnector ...................................... 10
4.3.1 Replacing connector............................................................................. 11
4.4 Setup of WeldCloud™UniversalConnector........................................ 13
4.4.1 Setting up a site in WeldCloud ............................................................. 13
4.4.2 Downloading and installing the WeldCloudLink application ................ 15
4.4.3 Powering up the WeldCloud™ Universal Connector............................ 15
4.4.4 Pairing the Android device to the WeldCloud™ Universal Connector.. 15
4.4.5 Connecting the WeldCloud™ Universal Connector to a local Wi-Fi
network and to WeldCloudCloudPlatform...........................................
16
4.4.6 Setup additional weld parameters ........................................................ 17
4.4.7 Factory reset ........................................................................................ 18
5OPERATION ................................................................................................ 19
5.1 Power supply .......................................................................................... 19
5.2 Operation modes .................................................................................... 19
5.3 Status indication LEDs .......................................................................... 19
5.4 Measuring and storing data................................................................... 21
5.5 Welding system compatibility ............................................................... 21
5.5.1 Test voltage .......................................................................................... 21
6MAINTENANCE........................................................................................... 23
6.1 Inspection and cleaning......................................................................... 23
6.2 Validation ................................................................................................ 23
6.3 Charging the lithium-ion battery ........................................................... 23
6.3.1 Storing the Universal Connector .......................................................... 23
7TROUBLESHOOTING ................................................................................. 24
8ORDERING SPARE PARTS ........................................................................ 25
DIAGRAM ............................................................................................................ 26
ORDERING NUMBERS....................................................................................... 27
WEAR PARTS...................................................................................................... 28
ACCESSORIES ................................................................................................... 29
Rights reserved to alter specifications without notice.

1 SAFETY
0463 601 001 -4- © ESAB AB 2022
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
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

1 SAFETY
0463 601 001 -5- © ESAB AB 2022
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!
• WeldCloud™UniversalConnector contains a lithium-ion battery (located in
the electronics box). Charging of the battery is made during welding. If
charging of the battery is needed when no welding is performed, use the
included battery charger. Charging using any other type of charger may create
a risk of fire.
• When replacing the battery, only use a lithium-ion battery of the type specified
in the WEAR PARTS chapter of this manual. Using any other type of battery
may create a risk of injury and fire.
• If the battery is removed from the electronics box, keep it away from other
metal objects, like paper clips, coins, keys, nails, screws or other small metal
objects that can make a connection from one terminal to another. Shorting the
battery terminals together may cause burns or a fire.
• Under abusive conditions, liquid may be ejected from the battery. Avoid
contact with any liquid! If contact accidentally occurs, flush with water. If liquid
contacts eyes, additionally seek medical help. Liquid ejected from the battery
may cause irritation or burns.
• Do not use a battery that is damaged or modified. Damaged or modified
batteries may exhibit unpredictable behaviour resulting in fire, explosion or risk
of injury.
• Do not expose a battery to fire or excessive temperature. Exposure to fire or
temperature above +130°C (+266°F) may cause explosion.
WARNING!
Do not connect the WeldCloud™UniversalConnector to a welding power source
used in MMA mode. It can trigger or activate welding mode.
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
0463 601 001 -6- © ESAB AB 2022
NOTE!
WeldCloud™UniversalConnector is intended for maximum 15kVHF peak ignition
voltage in TIG welding. 15kV is maximum peak ignition voltage in standard welding
power sources of today. In older welding power sources, the maximum peak ignition
voltage sometimes can be higher.
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.
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
0463 601 001 -7- © ESAB AB 2022
2 INTRODUCTION
WeldCloud™ Universal Connector is a brand-agnostic welding measurement system used to
enable data collection of any welding power source (ESAB made or numerous other welding
power sources on the market). The welding current and welding voltage are measured and
the collected data is sent to the WeldCloud™ cloud via Wi-Fi and the local network.
To install WeldCloud™ Universal Connector, access to WeldCloud™ web service is required.
Register for a username and password to be able to access your WeldCloud™ account.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
WeldCloud™UniversalConnector is supplied with:
• Instruction manual
• Ratchet straps for attachment of the sensor box
• Two additional OKC connectors (95mm)
• Lithium-ion battery
• Battery charger for lithium-ion battery
2.2 Before setup of your WeldCloud™ Universal Connector
In order to complete the set-up of WeldCloud™ Universal Connector the following is needed:
• An Android device with operating system 8.0 or greater (recommended minimum
screen size 4.7")
• A torx screwdriver size T10
• A WeldCloud™ account
• A fully charged lithium-ion battery (see below)
• A Wi-Fi network (2.4 GHz, WPA2)
2.2.1 Charging the lithium-ion battery
1. Insert the lithium-ion battery into the battery charger included in the delivery.
2. Charge the lithium-ion battery for at least 24 hours.

3 TECHNICAL DATA
0463 601 001 -8- © ESAB AB 2022
3 TECHNICAL DATA
WeldCloud™UniversalConnector, Valid from serial no. 849-xxx-xxxx,
OP132YY-XXXXXX
Permissible load (I2):
60% duty cycle 500 A
100% duty cycle 400 A
MIG 15A/14.8V to 500A/39V
TIGHF 15A/10.6V to 500A/30V
U110–100 V
Current and power at U1=30 V:
I10.3 A
Pmax 9 W
Measurement accuracy (regarding measured
current and voltage)
±2%
Operating temperature -10 to +40°C (+14 to +104°F)
Battery data:
Technology Lithium-ion battery
Nominal voltage 3.7V(±0.1V)
Rated Capacity 3500mAh
Storage temperature -20 to +60°C (-4 to +140°F)
Charging temperature +5to+40°C (+41 to +104°F)
Dimensions (l × w × h):
Sensor box 318 × 234 × 74 mm (12.5 × 9.2 × 2.9 in.)
Electronics box 238 × 147 × 40 mm (9.4 × 5.8 × 1.6 in.)
Weight:
Sensor box 2.0 kg (4.4 lb)
Electronics box 0.7 kg (1.5 lb)
Totally including cables 7 kg (15.4 lb)
Enclosure class IP54
Application class
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP54 is designed for indoor and outdoor use.

4 INSTALLATION
0463 601 001 -9- © ESAB AB 2022
4 INSTALLATION
The installation must be carried out 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!
Assure cables make full contact!
NOTE!
If you at any time need assistance, the chat support in WeldCloud is manned and
available. Go to https://esabcloud.com, and find the support chat in the lower right
corner.
4.1 Main components
1. Sensor box 4. Connection to welding circuit
2. Electronics box 5. Push-button (to power up, shut down and
restart the WeldCloud™ Universal
Connector)
3. Connection to welding output terminals
on the power source

4 INSTALLATION
0463 601 001 - 10 - © ESAB AB 2022
4.2 Inserting the lithium-ion battery into the electronics box
1. Make sure the lithium-ion battery is fully charged.
2. Loosen the two screws at the back of the electronics box. Remove the battery lid.
3. Insert the lithium-ion battery. Attach the battery lid and the screws in the reverse order.
Tightening torque 0.6 Nm.
4.3 Installing WeldCloud™UniversalConnector
1. Attach the electronics box in a suitable position on the welding equipment, using
Velcro® tape on the back of the electronics box.
NOTE!
The electronics box contains a radio transmitter and receiver. Position it as
high as possible on the welding equipment.
a) Use alcohol to clean the area where the Velcro® tape is to be attached.
b) Remove the protection cover of the Velcro® tape and attach the electronics
box.
Once the adhesive tape on the back of the Velcro® tape is fastened to the welding
equipment, the electronics box can easily be attached and detached multiple times.
2. Connect the sensor box to the power source welding output terminals. It does not
matter which connector is connected to the +terminal and which is connected to the
-terminal of the power source.
If the power source doesn't have OKC connectors: disassemble the OKC connectors
from the sensor box cables and replace with the appropriate type of connectors.
WARNING!
The plugs may only be replaced by a specialist and must comply with the
applicable standards for welding current connections. The plugs and sockets
must be suitable for 400 A continuous current or 500 A 60% duty cycle.
Connecting non-permissible contact elements or improper installation can
lead to heating, cable fire and further consequential damage.
This will void the warranty.
3. Connect the torch and the work lead to the sensor box, ensure the correct polarity
(with respect to the welding output terminals) depending on the welding method used.

4 INSTALLATION
0463 601 001 - 11 - © ESAB AB 2022
Examples of how to position the electronics box and the sensor box on the welding
equipment. In the first case the ratchet straps included in the delivery are used to attach the
sensor box to the trolley.
NOTE!
To ensure ingress protection (IP) of the WeldCloud™UniversalConnector, the
sensor box and the electronics box must be positioned oriented according to one of
the alternatives below.
NOTE!
If the WeldCloud™ Universal Connector is used together with a power source with a
Voltage Reduction Device (VRD), check that VRD functionality is maintained after
the installation!
4.3.1 Replacing connector
CAUTION!
The connectors can cause burn injuries.
It is required to replace the non-ESAB cable connectors with the provided connectors if any
of the following conditions occur:
• The connections to the welding output terminals on the power source are not secure.
• The connector is damaged.
• The rubber surface of the connector is very hot.

4 INSTALLATION
0463 601 001 - 12 - © ESAB AB 2022
1. Pull the rubber housing (1) off the brass connector.
2. Remove the Allen screws from the brass connector (2).
3. Remove the brass connector from cable wiring (3).
4. If the cable wire shroud (4) is damaged or missing, add the provided cable wire
shroud. Insert the cable wire with the cable wire shroud into the provided brass
connector (5).
5. Tighten the Allen screws to fasten the cable wire in the brass connector (6). Tigthen
the Allen screws to be aligned with or below the surface of the brass connector.
6. Pull the rubber housing back (7) until it completely covers the brass connector (5).

4 INSTALLATION
0463 601 001 - 13 - © ESAB AB 2022
4.4 Setup of WeldCloud™UniversalConnector
After the physical installation of WeldCloud™UniversalConnector is completed, software
setup of the system must be performed. The software setup includes the following main
activities:
• Downloading and installing the application to the Android device from WledCloudLink.
(Operating system 8.0 or greater, recommended minimum screen size 4.7".)
• Powering up the WeldCloud™UniversalConnector
• Pairing the Android device to the WeldCloud™ Universal Connector
• Connecting the WeldCloud™ Universal Connector to the local Wi-Fi network
• Connecting the WeldCloud™ Universal Connector to WeldCloud™ Cloud Platform
Each activity is explained below.
NOTE!
Starting with software version 2.0 of the Universal Connector there have been
changes to the mobile application which are not compatible with older software
versions. Contact us if you face issues or have old devices (version 1.x.x).
It is recommended to follow the online instructions.
For more information visithttps://esab.com/weldcloud_guide.
4.4.1 Setting up a site in WeldCloud
Before setting up a Universal Connector, a Site in WeldCloud is required:
1. Go to https://esabcloud.com.
2. Login to your account.

4 INSTALLATION
0463 601 001 - 14 - © ESAB AB 2022
3. Go to Settings.
4. Go to Sites in the menu to the left.
5. Click on Create site to get a pop-up.
6. Enter your desired name for the site and an address to get the correct time zone
7. Click on Save to finish the creation.
8. If you want to organize your machines further, it is possible to add sib-sites.
Click on the 3 dots next to a site to open the menu.
9. Click on Add site under New site in the pop-up menu.

4 INSTALLATION
0463 601 001 - 15 - © ESAB AB 2022
4.4.2 Downloading and installing the WeldCloudLink application
1. Download the latest software version of the Android application WeldCloudLink from
the Google Play store.
The WeldCloudLink application is found in the Google Play store, scan the QR-code
below.
2. Install the WeldCloudLink application on the preferred Android device.
4.4.3 Powering up the WeldCloud™ Universal Connector
1. Initiate the WeldCloud™ Universal Connector by pressing the
push-button on the right side of the signal cable inlet on the
electronics box.
A steady green power LED on the electronics box indicates that the
WeldCloud™ Universal Connector is On. This takes approximately 20
seconds.
4.4.4 Pairing the Android device to the WeldCloud™ Universal Connector
NOTE!
Make sure that the Universal Connector is powered on. Use the push-button if it is
powered down or in sleep mode. A flashing blue Bluetooth LED indicates that the
UniversalConector is ready to be used with the mobile application.
1. Enable Bluetooth on the Android device.
2. Start the WeldCloudLink application on the Android device.
Click CONNECT and choose the desired device from the list. A new Universal
Connector will show up as Unprovisioned UC:<serial number>. This can take up to 2
minutes.
If the correct WeldCloud™UniversalConnector is not present in the list, click Cancel
try CONNECT again.
If the correct WeldCloud™UniversalConnector is not found, make sure it is powered
on.
If there still are issues, click SETTINGS to use the Android menu for connecting or
pairing a new device. Refer to the manual of your device, for help on how to perform
this.
On successful pairing the application automatically presents the Live view screen.
A steady blue Bluetooth LED on the electronics box confirms the connection to
WeldCloud™UniversalConnector.

4 INSTALLATION
0463 601 001 - 16 - © ESAB AB 2022
4.4.5 Connecting the WeldCloud™ Universal Connector to a local Wi-Fi
network and to WeldCloudCloudPlatform
1. 1. Create a site in WeldCloud or make sure there is an existing site that can be
accessed by your account. See XXX.
2. 2. In WeldCloudLink, click the menu button in the top left corner to open the menu.
3. Click on Welding Unit Setup.
4. Connect to the device.
5. Login to WeldCloud using an account with access to the intended site.
6. Click on NEW SETUP to setup a new Universal Connector.
IMPORT EXISTING SETUP can be used to re-configure a Universal Connector when
there already is an asset created in WeldCloud.
NETWORK SETTINGS can be used to change your Wi-Fi settings.
7. Login using your Welding unit password.
The default password for the Universal Connector is "gateway".
8. Set a new password and save this information.
If you ever forget your password, you can perform a factory reset using the service
password "gatewayreset".
9. Click on Wi-Fi and add SSID and Password.
Save as template if you wish to configure multiple devices.
If you have a previous template, this can be used by selecting it in the template list.
NOTE!
The UniversalConnector uses wireless communication. Wired connection is not
applicable for this product.
10. Click NEXT when complete.

4 INSTALLATION
0463 601 001 - 17 - © ESAB AB 2022
11. Enter a Display name which will be displayed in WeldCloud and for the Bluetooth
interface.
12. Click on Select site which will be used in WeldCloud.
13. Click on CONFIGURE SETUP
14. Wait for the setup to complete
4.4.6 Setup additional weld parameters
It is possible to add additional information to your weld sessions either in WeldCloudFleet or
in WeldCloudLink.
In WeldCloudFleet you add information in the machine pages.
1. Go to Machines & stations and List view.
2. Click the machine you wish to add information.
3. In the Weld information card, click Edit and enter Operator,WPS,Part ID,Work order
or Wire.
4. Click Save.
To add information through the mobile application WeldCloudLink, you must first create an
operator group with the UniversalConnector and any operator that will use the system.
1. Login to WeldCloud and go to WeldCloudFleet.
2. In the left-hand menu, go to Operator management and Operators.
3. Click Add operator and add any WeldCloud user as an Operator or invite a new user
using their email.
4. In the left-hand menu, go to Operator management and Groups.
5. Click Create group and enter a Group name.
6. In the MACHINES tab, click Add machine, select machines and click Add.
7. In the MACHINES tab, set permissions from the drop-down list.
8. In the OPERATORS tab, click Add operators, select operators and click Add.
9. Click Save.
In WeldCloudLink:
1. Connect to the Universal Connector.
2. Login with your WeldCloud account.
3. In the live view screen, click BEGIN SCANNING.
If an ID and Password is requested means that you either aren’t logged in in
WeldCloudLink or your operator ID was rejected. Make sure you have setup Operator
group as above. You can also try restarting the Universal Connector to update valid
operators.

4 INSTALLATION
0463 601 001 - 18 - © ESAB AB 2022
4. Click Scan to scan with camera or built-in barcode scanner, scan any barcode or QR
code to add information.
Select the type of the scanned item, such as Electrode, Electrode Batch, Flux, Flux
Batch, Gas, Part, Tag, Wire, Wire Batch, Work order or WPS.
The Tag type can be used for items that doesn’t fit into any other category.
NOTE!
The check mark indicates that the item has been sent to the
UniversalConnector. If the item isn’t sent correctly, you can try to click the
Refresh icon.
5. To remove items, click on the Trash can icon or the CLEAR button.
4.4.7 Factory reset
To clear all user data, configurations from the Universal connector and to reset the Welding
unit password, a Factory reset can be performed.
1. Connect to the UniversalConnector with WeldCloudLink.
2. Go to Welding Unit Setup in the left-hand menu.
3. Click FACTORY RESET.
4. Enter your Welding unit password or use the service password "gatewayreset".
5. Click PERFORM FACTORY RESET.
The factory reset will then be performed.
It can take a while before your mobile device will update the name of the
UniversalConnector back to Unprovisioned UC:<serial number>. If there are any problems
with the connection, restart the UniversalConnector or remove the pairing in the Bluetooth
settings of your mobile device.

5 OPERATION
0463 601 001 - 19 - © ESAB AB 2022
5 OPERATION
5.1 Power supply
The WeldCloud™ Universal Connector is powered from the welding circuit during welding.
There is no need for external power supply to the unit.
The WeldCloud™ Universal Connector has a lithium-ion battery as backup power when no
welding is conducted. The lithium-ion battery is charged during welding.
5.2 Operation modes
The WeldCloud™ Universal Connector has three operation modes:
•System off
Data collection is off. The system will start up at weld start or when the push-button on
the electronics box is pressed. Start up takes approximately 20 seconds, during this
time no welding data is collected. After a total of 60 seconds, Wi-Fi and Bluetooth will
be ready to use.
•Sleep mode
Battery saving mode. The system will wake up at weld start or when the push-button on
the electronic box is pressed. Wake up takes approximately 1 second, during this short
time no welding data is collected. If no welding is detected for 2 hours, the system will
shut down automatically.
•System on
The system is capable of data collection. Weld start detection takes approximately 1
second, during this short time no welding data is collected. The system will go to sleep
5 seconds after a weld.
If the mobile application is connected, the system will be on for 20 minutes.
If the system was started using the push-button, the system will also be on for 20
minutes
The WeldCloud™ Universal Connector can always be turned on or off manually by the
push-button on the electronics box.
5.3 Status indication LEDs
Four status indication LEDs (Light-Emitted Diodes) are located on the electronics box.
1. Battery LED 3. Bluetooth LED
2. Power LED 4. Wi-Fi LED

5 OPERATION
0463 601 001 - 20 - © ESAB AB 2022
1. Battery LED
Indication Explanation
System is Off or in Sleep mode
Green flashing
Charging
Red fixed
Low battery
Green fixed
Charging complete
Orange fixed
Discharging
Red short flashing
Battery missing or defect, or battery discharged
2. Power LED
Indication Explanation
Off
System off
Green flashing
Starting up
Green fixed
System on or Sleep mode
Orange fixed
Welding ongoing
3. Bluetooth LED
Indication Explanation
Off
Bluetooth off, No connection possible
Blue short flash every 2 seconds
Ready for pairing
Blue fixed
Connected