ESAB Aristo U82 User manual

Aristo®
Instruction manual
0460 896 274 GB 20130902 Valid from program version 1.15A
U82

TABLE OF CONTENTS
0460 896 274 © ESAB AB 2013
1 SAFETY ................................................................................................................ 5
2 INTRODUCTION................................................................................................... 7
2.1 Control panel Aristo U82 ..................................................................................... 7
2.1.1 Keys and knobs.................................................................................................. 7
2.2 Location ................................................................................................................ 8
2.3 USB connection ................................................................................................... 8
2.3.1 Insert the USB memory...................................................................................... 9
2.4 First step – choice of language ..........................................................................9
2.5 Display ................................................................................................................ 10
2.5.1 Symbols in the display ..................................................................................... 11
2.6 General information about settings .................................................................12
2.6.1 Setting of numerical values .............................................................................. 12
2.6.2 Setting with given alternatives.......................................................................... 12
2.6.3 Settings ON/OFF.............................................................................................. 12
2.6.4 QUIT and ENTER ............................................................................................ 12
3 MENUS ............................................................................................................... 13
3.1 Main menu .......................................................................................................... 13
3.1.1 Configuration menu.......................................................................................... 14
3.1.2 Tools menu....................................................................................................... 14
3.1.3 Weld data setting menu ................................................................................... 15
3.1.4 Measure ........................................................................................................... 16
3.1.5 Weld data memory meny ................................................................................. 17
3.1.6 Fast mode menu .............................................................................................. 17
4 MIG/MAG WELDING .......................................................................................... 18
4.1 Settings in the weld data setting menu............................................................18
4.1.1 MIG/MAG welding with short-/sprayarc............................................................ 18
4.1.2 MIG/MAG welding with pulsing ........................................................................ 19
4.1.3 MIG/MAG welding with SuperPulse, primary/secondary,
short-/sprayarc/pulsing ................................................................................. 20
4.2 Function explanations for settings ..................................................................22
4.2.1 QSet ................................................................................................................. 27
4.2.2 Synergy group.................................................................................................. 27
4.3 SuperPulse ......................................................................................................... 28
4.3.1 Wire and gas combinations..............................................................................29
4.3.2 Different pulsing methods ................................................................................ 29
4.3.3 Wire feed unit ................................................................................................... 29
5 MMA WELDING.................................................................................................. 32
5.1 MMA welding DC ................................................................................................ 32
5.2 MMA welding AC ................................................................................................ 32
5.3 Function explanations for settings ..................................................................33

TABLE OF CONTENTS
0460 896 274 © ESAB AB 2013
6 TIG WELDING..................................................................................................... 34
6.1 Settings in the weld data setting menu............................................................34
6.1.1 TIG welding without pulsing DC ....................................................................... 34
6.1.2 TIG welding with pulsing DC ............................................................................ 34
6.1.3 TIG welding without pulsing AC ....................................................................... 35
6.2 Function explanations for settings ..................................................................35
6.3 Other function explanations .............................................................................40
7 ARC AIR GOUGING ........................................................................................... 41
7.1 Settings in the weld data setting menu............................................................41
7.2 Function explanations .......................................................................................41
8 MEMORY MANAGEMENT ................................................................................. 42
8.1 Control panel working method ......................................................................... 42
8.2 Store .................................................................................................................... 43
8.3 Recall................................................................................................................... 44
8.4 Delete .................................................................................................................. 45
8.5 Copy .................................................................................................................... 45
8.6 Edit ...................................................................................................................... 46
8.7 Name ................................................................................................................... 48
9 CONFIGURATION MENU................................................................................... 49
9.1 Code lock ............................................................................................................ 49
9.1.1 Lock code status .............................................................................................. 50
9.1.2 Specify/edit lock code ...................................................................................... 50
9.2 Remote controls................................................................................................. 50
9.2.1 Forget override................................................................................................. 51
9.2.2 Configuration for digital remote control unit .....................................................51
9.2.3 Configuration for analogue remote control unit ................................................ 51
9.2.4 Scale on inputs................................................................................................. 52
9.3 MIG/MAG defaults ..............................................................................................52
9.3.1 Gun trigger mode (2-stroke/4-stroke)............................................................... 53
9.3.2 4-stroke configuration....................................................................................... 54
9.3.3 Soft key configuration....................................................................................... 55
9.3.4 Voltage measurement in pulsing ...................................................................... 56
9.3.5 AVC feeder ....................................................................................................... 56
9.3.6 Release pulse .................................................................................................. 56
9.4 MMA defaults...................................................................................................... 56
9.5 Fast mode soft keys........................................................................................... 56
9.6 Double start sources .........................................................................................57
9.7 Panel remote enable .......................................................................................... 57
9.8 WF supervision .................................................................................................. 57
9.9 Auto save mode ................................................................................................. 57

TABLE OF CONTENTS
0460 896 274 © ESAB AB 2013
9.10 Trigger weld data switch ..................................................................................58
9.11 Multiple wire feeders.......................................................................................... 59
9.12 Quality functions................................................................................................ 60
9.13 Maintenance ....................................................................................................... 60
9.14 Unit of length ...................................................................................................... 61
9.15 Measure value frequency ..................................................................................61
9.16 Register key........................................................................................................ 61
10 TOOLS ................................................................................................................ 63
10.1 Error log .............................................................................................................. 63
10.1.1 Error code descriptions .................................................................................... 64
10.2 Export/Import...................................................................................................... 67
10.3 File manager ....................................................................................................... 68
10.3.1 Delete a file/folder ............................................................................................ 69
10.3.2 Rename a file/folder ......................................................................................... 69
10.3.3 Create new folder............................................................................................. 70
10.3.4 Copy and paste files......................................................................................... 70
10.4 Edit setting limits ............................................................................................... 70
10.5 Edit measure limits ............................................................................................ 71
10.6 Production statistics.......................................................................................... 72
10.7 Quality functions................................................................................................ 73
10.7.1 Store quality data ............................................................................................. 73
10.8 User defined synergic data ...............................................................................74
10.8.1 Specify voltage/wire co-ordinates .................................................................... 75
10.8.2 Specify valid wire/gas combination .................................................................. 75
10.8.3 Create your own wire/gas alternative...............................................................76
10.9 Calendar.............................................................................................................. 77
10.10 User accounts .................................................................................................... 77
10.11 Unit information ................................................................................................. 78
11 ORDERING SPARE PARTS ............................................................................... 79
MENU STRUCTURE..................................................................................................80
WIRE AND GAS DIMENSIONS.................................................................................86
ORDERING NUMBERS.............................................................................................93
ACCESSORIES .........................................................................................................94
Rights reserved to alter specifications without notice.

1 SAFETY
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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 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

1 SAFETY
0460 896 274 -6- © ESAB AB 2013
NOTE!
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.

2 INTRODUCTION
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2 INTRODUCTION
To benefit as much as possible from your welding equipment, we recommend that you read
this instruction manual.
For general information about operation, see the instruction manuals for the power source
and the wire feed unit.
The text presented in the display is available in the following languages: English, Swedish,
Finnish, Norwegian, Danish, German, French, Italian, Dutch, Spanish, Portuguese,
Hungarian, Polish, American, Czech, Chinese and Turkish.
NOTE!
Differences in the panel function may occur, depending on in which product it is
installed.
2.1 Control panel Aristo U82
The control panel is supplied with a mounting bracket with screws and an English instruction
manual. A 1.2 m cable is mounted on to the panel. A USB memory and an extension cable
are available as accessories, see the "ACCESSORIES" chapter of this manual.
Instruction manuals in other languages can be downloaded from the Internet: www.esab.com
1. Place for USB memory
2. Knob for moving cursor
3. Display
4. Soft keys
5. Menu
6. Enter
7. Knob for increasing or decreasing set
values and setting the voltage, #
8. Knob for increasing or decreasing set
values and setting the wire feed speed, *
2.1.1 Keys and knobs
Soft keys (4)
The five keys in a row under the display have varying functions.
These are “soft” keys, i.e. they can have different functions
depending on which menu you are currently working in. The current
function for these keys can be seen from the text in the bottom row
of the display.
When the function is active, this is indicated by the key turning white:

2 INTRODUCTION
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Menu key (5)
Using the MENU key always takes you back to the main menu:
Enter key (6)
Using the enter key confirms a selection.
Cursor knob (2)
Using the left-hand knob moves the cursor to different rows in the display.
Plus/minus knobs (7, 8)
The right-hand knobs increase or decrease the value of a setting. To the side of the knobs
there is a symbol, a square # or a star *. Most numerical settings can be adjusted with either
knob, although certain settings have to be made with a particular knob.
2.2 Location
On the reverse of the control panel there is a
fold-out stand that enables you to put the
panel down and still view the display in an
upright position. The stand also acts as a
mounting device, enabling the control panel
to be hung on the wire feed unit.
2.3 USB connection
External USB memories can be used to transfer programs to and from the control panel.
See more in the "Export/Import" section.
The files that are produced in the control panel are stored as xml files. The USB memory
must be formatted as FAT 32 in order to work.
During normal use there is no risk of “viruses” being able to infect the equipment. To
eliminate this risk entirely, we recommend that the memory that is used together with this
equipment not be used for any other purpose.
Certain USB memories may not work with this equipment. We recommend using USB
memories from a reputable supplier. ESAB assumes no responsibility for any damage
caused as a consequence of the incorrect use of a USB memory.

2 INTRODUCTION
0460 896 274 -9- © ESAB AB 2013
2.3.1 Insert the USB memory
Proceed as follows:
• Turn off the power source's main switch.
• Open the cover on the left-hand end of the control panel.
• Insert the USB memory in the USB connector.
• Close the cover.
• Turn on the power source's main switch.
2.4 First step – choice of language
This menu appears in the display the first time you start up the equipment.
The control panel is set to English on delivery. To select your language, proceed as follows.
Press MENU to come to the main menu.
Using the left-hand knob, position the cursor on the CONFIGURATION row.
Press ENTER

2 INTRODUCTION
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Position the cursor on the LANGUAGE row. Press ENTER to bring up a list of the languages
that are available in the control panel.
Position the cursor on the row for your language and press ENTER.
2.5 Display
The cursor
The control panel's cursor is presented as a shaded field around the text, with the selected
text turning white. The selection is displayed in the instruction manual with bold text.

2 INTRODUCTION
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Arrows and scroll bars
Where there is more information behind a row, this is indicated with a black arrow behind the
text. A scroll bar is presented to the right of the display if there are more rows in the list:
Text boxes
At the bottom of the display are five boxes containing text that describes the current function
of the five keys directly below the boxes.
Energy saving mode
To increase the life of the background lighting, it is switched off after three minutes of no
activity.
2.5.1 Symbols in the display
AThe selected weld data set
BS = Setting limit activated
M = Measure limit activated
CThe selected wire feed unit
DA fault has occurred, see the "Error log"
section in the "TOOLS" chapter.
ERecalled memory position number
FSelect the plus/minus knob marked# to
increase or decrease a parameter
value.
GMeasured motor current
HSelect the plus/minus knob marked* to
increase or decrease a parameter
value.
IEditing mode, editing memory position

2 INTRODUCTION
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2.6 General information about settings
There are three main types of setting:
• Setting of numerical values
• Setting with given alternatives
• Setting of ON/OFF mode
2.6.1 Setting of numerical values
When setting a numerical value, one of the two plus/minus knobs is used to increase or
decrease a given value. A number of values can also be altered from the remote control unit.
2.6.2 Setting with given alternatives
Some settings are made by selecting an alternative from a list.
Such a list might look like this:
Here the cursor is placed on the row for MIG/MAG. By pressing ENTER in this position, the
MIG/MAG alternative is selected. If you want to choose another alternative instead, position
the cursor on the correct row by stepping up or down with the left knob. Then press ENTER.
If you want to exit the list without making a selection, press QUIT.
2.6.3 Settings ON/OFF
For some functions, it is possible to set the values ON and OFF. The synergy function during
MIG/MAG and MMA welding is an example of such a function. The ON or OFF settings can
be selected from a list of alternatives as described above.
2.6.4 QUIT and ENTER
The “soft” key farthest to the right is used primarily for QUIT, although it is occasionally used
for other functions.
• Pressing QUIT entails moving back to the previous menu or screen.
The key is called ENTER in this manual.
• Pressing ENTER entails the execution of a selected choice in a menu or a list.

3 MENUS
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3 MENUS
The control panel uses several different menus. The menus are the Main, Configuration,
Tools, Weld data setting, Measure, Weld data memory and Fast mode menus. The menu
structures are presented in the "MENU STRUCTURE" appendix at the end of this manual.
During start-up, a start-up screen containing information about the current program version is
also displayed briefly.
Start-up screen
3.1 Main menu
In the MAIN MENU, you can change welding process, welding method, wire type, etc.
From this menu you can proceed to all other sub-menus.

3 MENUS
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3.1.1 Configuration menu
In the CONFIGURATION menu you can change language, alter other basic settings, unit of
measurement etc.
3.1.2 Tools menu
In the TOOLS menu you can transfer files, view quality and production statistics, error logs,
etc.

3 MENUS
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3.1.3 Weld data setting menu
In the WELD DATA SETTING menu you can alter various welding parameters. The menu
has different appearances depending on which welding process is selected. The example
shows MIG/MAG welding with short-/sprayarc.

3 MENUS
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3.1.4 Measure
In MEASURE, you can view measured values for various welding parameters while welding
is in progress.
You can change the value of certain parameters in the Measure screen. Which parameters
these are depends on which welding process is set. The parameter values that can be
adjusted are always marked with # or *.
The measured values remain in the display even after welding has been completed. You
can move to different menus without losing the measurement values. If the set value is
altered when welding is not in progress, the measurement value is changed to zero in order
to avoid confusion.
TIP:When pulsing, you can select whether the voltage value is to be displayed as an
average value or a peak value. This setting can be adjusted under MIG/MAG defaults, see
the "MIG/MAG defaults" section.

3 MENUS
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3.1.5 Weld data memory meny
In the WELD DATA MEMORY menu you can store, recall, delete and copy various set weld
data. The weld data sets can be stored in 255 different memory positions.
For further information, see the “MEMORY MANAGEMENT” chapter.
3.1.6 Fast mode menu
In the FAST MODE menu, you can “link” soft keys to weld data memory positions. These
settings are carried out in the Configuration menu. The number of the selected memory
position is displayed in the top right corner.
For further information, see the “Fast mode soft keys” section.

4 MIG/MAG WELDING
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4 MIG/MAG WELDING
Main menu → Process
MIG/MAG welding melts a continuously supplied filler wire, with the weld pool being
protected by shielding gas.
Pulsing is used to influence the transfer of the droplets from the arc so that it remains stable
and spatter-free, even with low weld data.
For wire diameters that can be used for MIG/MAG welding with SHORT-/SPRAYARC and
with PULSING, see the "WIRE AND GAS DIMENSIONS" appendix at the end of this manual.
When the MIG/MAG process is selected, you can choose between four methods by selecting
Method with the left-hand knob and then pressing ENTER. Choose between short-/sprayarc,
puls or superpulse and then press ENTER again.
4.1 Settings in the weld data setting menu
4.1.1 MIG/MAG welding with short-/sprayarc
Settings Setting range In steps of Synergy
dependent
Adjustable
in synergy
Voltage 8 - 60 V 0.25 V (displayed
with one decimal)
x x
Wire feed speed** 0.8 - 30.0 m/min 0.1 m/min x
Inductance 0 - 100% 1% x x
Regulator type 1 - 12 1 x -
Synergy* OFF or ON - - -
Gas pre-flow 0.1 - 25 s 0.1 s x
Creep start OFF or ON - x
“Hot start” OFF or ON - x
“Hot start” time 0 - 10 s 0.1 s x
“Hot start” wire feed Complete wire feed
range
0.1 m/min x
“Touch sense” 10 - 16 A
Soft start OFF or ON - x

4 MIG/MAG WELDING
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Settings Setting range In steps of Synergy
dependent
Adjustable
in synergy
Crater filling OFF or ON - x
Crater filling time 0 - 10 s 0.1 s x
Final crater filling wire
feed
1.5 m/min at current
wire feed speed
0.1 m/min x
Final crater filling voltage 8 - 24.7 V x
“Release pulse”*** OFF or ON
Burnback time 0 - 1 s 0.01 s x
Termination Final pulse or SCT - x
Gas post-flow 0.1 - 25 s 0.1 s x
Setting limits 1 - 50 - - -
Measure limits 1 - 50 - - -
Spot welding **** OFF or ON - x
Spot welding time 0 - 25 s 0.1 s x
*) The synergic line on delivery: solid wire (ER70S), shielding gas CO2 with wire 1.2 mm.
**)The setting range is dependent on the wire feed unit used.
***) Adjusted in the configuration menu MIG/MAG defaults.
****) It is not possible to select spot welding (ON) if gun trigger mode is 4-stroke.
4.1.2 MIG/MAG welding with pulsing
Settings Setting range In steps of Synergy
dependent
Adjustable
in synergy
Voltage 10 - 50 V 0.25 V (displayed
with one decimal)
x x
Wire feed speed* 0.8 - 30.0 m/min 0.1 m/min x
Pulse current** 100 - 650 A 4 A x
Pulse time 1.7 - 25.5 ms 0.1 ms x
Pulse frequency 16 - 312 Hz 2 Hz x
Background current 4 - 300 A 1 A x
Slope 1 - 9 1 x
Synergy*** OFF or ON - -
Ka 0 - 100% 1% x
Ki 0 - 100% 1% x
Gas pre-flow 0.1 - 25 s 0.1 s x
Creep start OFF or ON - x
Soft start OFF or ON - x
“Hot start” OFF or ON - x
“Hot start” time 0 - 10 s 0.1 s x
“Hot start” wire feed Complete wire feed
range
0.1 m/min x
“Touch sense” 10 - 16 A

4 MIG/MAG WELDING
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Settings Setting range In steps of Synergy
dependent
Adjustable
in synergy
Crater filling (pulsed/not
pulsed)
OFF or ON - x
Crater filling time 0 - 10 s 0.1 s x
Final crater filling wire
feed
1.5 m/min at current
wire feed speed
0.1 m/min x
Final crater filling voltage 8 - 33.2 V x
Final pulse current 100 - max A x
Final background current 12 - 50 A x
Final frequency 20 - 270 Hz x
“Release pulse”**** OFF or ON
Burnback time 0 - 1 s 0.01 s x
Termination Final pulse or SCT - x
Gas post-flow 0.1 - 25 s 0.1 s x
Setting limits 1 - 50 - - -
Measure limits 1 - 50 - - -
Spot welding ***** OFF or ON - x
Spot welding time 0 - 25 s 0.1 s x
*) The setting range is dependent on the wire feed unit used.
**) Minimal background current and pulse current are dependent on which machine type is
used.
***) The synergic line on delivery: solid wire (ER70S), shielding gas CO2 with wire 1.2 mm.
****) Adjusted in the configuration menu MIG/MAG defaults.
*****) It is not possible to select spot welding (ON) if gun trigger mode is 4-stroke.
4.1.3 MIG/MAG welding with SuperPulse, primary/secondary,
short-/sprayarc/pulsing
Main menu → Process → Method → Phase → Method
Settings Setting range In steps of Synergy
dependent
Adjustable
in synergy
Phase Primary or
Secondary
- x
Method Short-/sprayarc or
pulsing
- x
Voltage 10 - 50 V 0.25 V(displayed
with 1 decimal)
x x
Wire feed speed* 0.8 - 30.0 m/min 0.1 m/min x
Inductance 0 - 100% 1% x x
Pulse current** 100 - 650 A 4 A x
Pulse time 1.7 - 25.5 ms 0.1 ms x
Pulse frequency 16 - 312 Hz 2 Hz x
Background current 4 - 300 A 1 A x