Aristo W82
GB
Aristo ®
W82
Instruction manual
0460 971 001 GB 101103
Valid for serial no. 905-xxx-xxxx, 944-xxx-xxxx
1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
3
5
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
3 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
6
4.1 Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Assembly instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 How to set-up the U82 for use with W82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1
Save your stored data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2
Convert the U82 stand alone unit to a presentation unit . . . . . . . . . . . . . . . . . . . .
4.5 System diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
7
7
7
8
8
5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
5.1
5.2
Connections and control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
6.1
Inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
7 ORDERING SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
14
15
Rights reserved to alter specifications without notice.
TOCe
-2-
GB
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 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. Note! Do not use safety gloves when replacing wire.
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!
This product is solely intended for arc welding.
-3br07e2
GB
WARNING
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
S
Install and earth the unit in accordance with applicable standards.
S
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S
Insulate yourself from earth and the workpiece.
S
Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
S
Keep your head out of the fumes.
S
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.
S
Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S
Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S
Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
S
Protect your ears. Use earmuffs or other hearing protection.
S
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.
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.
CAUTION!
Read and understand the instruction manual before
installing or operating.
ESAB can provide you with all necessary welding protection and accessories.
-4br07e2
GB
2
INTRODUCTION
W82 is a control unit that adjusts the communication between welding equipment
and automation equipment, such as robots. It receives control signals and settings
via DeviceNet, Profibus or CANopen.
W82 is 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.
2.1
Equipment
W82 DeviceNet, W82 Profibus and W82 CANopen are supplied with a USB memory,
the software WeldPoint and an instruction manual.
W82 Integrated is supplied with an instruction manual.
Measurement cable kit and connection cables for different power sources are
available as accessories, see page 15 and separate spare parts list.
Instruction manuals can be downloaded from www.esab.com.
3
TECHNICAL DATA
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 x w x h)
366 x 101 x 159 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 designed for indoor and outdoor use.
-5br07e2
GB
4
INSTALLATION
The installation must be executed by a professional.
See the service manual for 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
distrubution network operator if necessary, that the equipment may be connected.
4.2
Assembly instruction
Connection to ESAB's Mig 5000i power source
S
S
S
Remove the welding power source's rear handle by removing the screws.
Place the control box onto the welding power source, see picture below.
Screw the control box and the handle into place in the same screw holes.
Connection to ESAB's Mig 3001i, Mig 4001i and Mig 6502c power sources
Connect the control box with a 2 m cable and place it on the floor or on a stand next
to the power source.
-6br07e2
GB
4.3
System description
It is possible to configure the U82 unit for stand-alone usage (stand-alone unit) or
presentation usage (presentation unit). The presence of a W82 unit within the
welding system determines which unit that is to be used.
The stand-alone unit is used when there
is no W82 unit in the system
The presentation unit is used when there
is a W82 unit in the system
It is necessary to convert the U82 stand-alone unit to a U82 presentation unit before
it is used together with a W82 unit.
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 U82 stand-alone unit to a presentation unit
before it is used together with a W82 unit.
4.4.1
Save your stored data
1. Connect the U82 stand-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 U82 memory to a USB memory (see chapter
Export/Import in the U82 instruction manual).
4. Turn off the power source's main switch.
5. Remove the USB memory.
-7br07e2
GB
4.4.2
Convert the U82 stand alone 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 the file's below (located in the enclosed USB memory)
From
To
update.txt_
update.txt
reset.txt_
reset.txt
3. Open the cover on the left-hand 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 convert process is 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 W82 unit!
4.5
System 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 wire feed unit, RoboFeed, is not used, a separate arc voltage feedback
is required to the measurement contact on the control unit.
-8br07e2
GB
-9br07e2
GB
5
OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
5.1
Connections and control devices
W82 Integrated
W82 DeviceNet
W82 Profibus
W82 CANopen
Indicating lamp from serial number 944-xxx-xxxx
Orange indicating lamp - Overheating
Fieldbus
Connection for communication with robot system
Measure
Connection for measurement cable for arc voltage feedback and emergency
stop signal, measurement kit
Internal CAN
Connections for communication with ESAB wire feed unit and control panel
LAN
Connection to network, Ethernet
CAN to welding power source
Connection for communication with welding power source
USB
USB memory connection
- 10 br07e2
GB
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 is
on.
The overheating protection resets automatically when the temperature has fallen and
the lamp goes out.
6
MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.
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.
6.1
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 correctly connected.
7
ORDERING SPARE PARTS
W82 is designed and tested in accordance with the international and European stan­
dards 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 product still conforms to the said
standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
- 11 br07e2
Diagram
- 12 br07e
Edition 101103
- 13 br07e
Edition 101103
W82
Ordering number
Ordering no.
Denomination
0460 891 880 Control box Aristoä W82, Integrated
0460 891 881 Control box Aristoä W82, DeviceNet
0460 891 882 Control box Aristoä W82, Profibus
0460 891 883 Control box Aristoä W82, CANopen
0459 839 038 Spare parts list W82
0740 800 203 Service manual W82
Manuals and spare parts list are to be downloaded from the website www.esab.com.
- 14 br07o
Edition 101103
W82
Accessories
Control cable (connectors included)
0.45 m 12 poles . . . . . . . . . . . . . . . . . . . . . . . . . . 0456 527 885
2 m 10 poles - 12 poles . . . . . . . . . . . . . . . . . . . 0462 000 880
Connection set CAN Robot for W82
Integrated
0461 182 880
7.5 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USB Memory 2 Gb
Termination resistor
- 15 bi23a
.
0462 062 001
0459 314 880
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.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
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
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
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
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel: +39 02 97 96 81
Fax: +39 02 97 28 91 81
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
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
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
Asia/Pacific
Representative offices
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
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
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA
LLC ESAB
Moscow
Tel: +7 095 543 9281
Fax: +7 095 543 9280
LLC ESAB
St Petersburg
Tel: +7 812 336 7080
Fax: +7 812 336 7060
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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
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
ESAB AB
SE-695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.com
081016
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