Aristo W82
Contents
1. NOISE Excessive noise can damage hearing 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 A 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 PROTECT YOURSELF AND OTHERS 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 A CAUTION Read and understand the instruction manual before installing or operating ESAB can provide you with all necessary welding protection and accessories br07e2 2 INTRODUCTION 8 is a control unit that adjusts the communication between welding equipment and automation equi2. Aristo Instruction manual Valid for serial no 905 xxx xxxx 944 xxx xxxx 0460 971 001 GB 101103 1 SAFETY sisi sis Td cn VII KA ESK RUJ II USTI SIS SN MARKA KRIA RRRA 3 2 INTRODUCTION TE 5 CEN SE TEILT CETTE 5 TECHNICAL DATA 4 53 E bra E aO ag 5 a INSTALLATION PEER NER 6 Al Mans EE EE ENE JE EE 6 4 2 Assembly Eee EEE EE nE k a 6 4 3 ius 223 ea SS HESS KIE ESIR IR EINA REV EE TA TE aa r 4 4 How to set up the U82 for use with W82 2 0 0 22222 rj 4 4 1 ave VOU Slew HEBES Ja sl aan kE Rr ER Eg pu PM quib 4 4 2 Convert the U82 stand alone unit to a presentation unit 8 4 5 System diagrams sss ssxasksostkeekseske sus Gad s de added rir 8 5 OPERATION RER re I E ERR Ud HER ss kk 10 5 Connections and contruldevibes 10 52 Overheating proteci n ss 1 ses s sssi sus pesado quip eub 11 o MAINTENANCE 455244323 SSV ERRAT ERES 0000 ERE LENSA LINKO SS 11 6 1 lhuspeston ee se sis seno Kaneko ER RA SILAS SRI 11 4 ORDERING SPARE PARIS 11 DIAGRAM caT alni RE TIT KIS TR LG ELSTARANTA A 4444 12 ORDERING NUMBER KITA 600944008 KAD i ENESE ESPA DENN ENDA 14 ACCESSORIES sitessssusssaskisaskozssstesksa ssasasssssujesas ias 15 Rights reserved to alter specifications without notice TOCe 2 1 SAFETY NOTE The uni
3. Schematic diagrams showing the connection between different units follow 1 Connection between welding power source and W85 CAN to power source 2 Connection between W85 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 br07e2 Mig 5000i Mig 3001i Mig 4001i Mig 6502c br07e2 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 8 Integrated 8 DeviceNet W82 Profibus W82 CANopen 1 3 e E 7 Oe i Je Qe A 4 A LA e e MJ 2 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 o
4. Spare parts may be ordered through your nearest ESAB dealer see the last page of this publication 11 br07e2 Diagram 5 24AP4 Profibus CN18 24AP1 Communication Interface 3 4 5 5V BUS 217 6 7 8 9 Reserved CAN L CAN GND Reserved CAN SHIELD GND CAN H Reserved Reserved Power supply 2 OV Robot 24V Robot DeviceNet High DeviceNet OV DeviceNet Low bro7e gues Edition 101103 5 o mmm uu mm Mu ee GNO GN e jm s Ao m 2n 1 kej IZ 0 oom gt I l 17 3 L ul s0 N RR _ lt gt fa H 9 3 23 501603 e 9 RES Saabs ELS S 2 21 og m sxe a 2 b 4 2 9 5 3 EE 0 ELSXVE lo Oo 1 w 1331 3 pe e O IS 5 X z80 KN 6611 KU Ia 10 ele 3 661 J 6 9614 H 59852 58 Sees l I l S MOVIE C gt Ben dom JEF ERI 5 lt 3 61 L 34 H l Qo gt l I I 5 22 SEES 8 2 D x xoviaa D zeo Z ano LL Og 22 ORA o o 500090 44 kuki G S D 5 3 g O 8 5 5 Hemu 021 28 Saj BEN OM D 25 UBHULO Z r 7 samen un ueg i 5 10 S 2K e MOJ UED Z erem MOJ UES UEO AZI 6 4 Canus UEO AZL lu seno Sro NP AN UEO AO
5. o O 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 07 2 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 A 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 gt 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
6. 9 i gt y Senium UEO AO e 0202 s N oimo zenro 0 mm 8888 3 a z lt 5 MEG c YBIH Z MOTOR ueg 5 MOJ UBD Z uaa g 1 MOJ 3 ueo zi 6 UMOJQ Z a UBI AZI 5 en UBO AO 9 SUM 5 G 3 o 41 0102 8 HK sod a I 9 Ban don 3 r V Adb 52 Y lt ga acr N 8 a 9 ace an Edition 101103 13 br07e W8 Ordering number Ordering no Denomination 0460 891 880 Control box Aristo W82 Integrated 0460 891 881 Control box Aristo W82 DeviceNet 0460 891 882 Control box Aristo W82 Profibus 0460 891 883 Control box Aristo 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 br07o pes Edition 101103 W8 Accessories bi23a Control cable connectors included 0 45 m 12 poles 2 10 poles 12 poles Connection set CAN Robot for W82 Integrated USB Memory 2 Gb Termination resistor 15 0456 527 885 0462 000 880 0461 182 880 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 1100 Fax 32 2 745 11 28 THE CZECH REPUBLI
7. C 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 1000 Fax 47 33 11 5203 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 Ib rica S A Alcal 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 Di
8. arest 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 ESAB AB SE 695 81 LAXA SWEDEN Phone 46 584 81 000 www esab com 081016
9. etikon 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 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 amp Cutting Products Florence SC Tel 1 843 669 44 11 Fax 1 843 664 57 48 Asia Pacific 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 Representative offices BULGARIA ESAB Representative Office Sofia Tel Fax 359 2 974 42 88 EGYPT ESAB Egypt Dokki Cairo Tel 20 2 390 96 69 Fax 20 2 393 32 13 ROMANIA ESAB Representative Office Buch
10. le to see if the unit is a presentation unit or not Produc Presentation Version 0 03 ESAB AEE Copyright 2008 ESAB AB Sweden i COMMECTIMG 4 4 Howto set up the U8 for use with W8 gt Note t is necessary to change the U8 stand alone unit to a presentation unit before it is used together with a W8 unit 4 4 1 Save your stored data 1 Connect the U8 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 U825 instruction manual 4 Turn off the power source s main switch 5 Remove the USB memory br07e2 4 4 2 Convert the U8 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 UL NE 111 update txt _ update 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 W85 unit 4 5 System diagrams
11. me 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 A CAUTION This product is solely intended for arc welding br07e2 WARNING A 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 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 ARCRAYS 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
12. pment such as robots It receives control signals and settings via DeviceNet Profibus or CANopen 8 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 W8 DeviceNet W82 Profibus and W85 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 Supply voltage to feed unit through W82 42 V 50 60 Hz Supply voltage from robot 24 V DC Supply voltage from power source 12V DC Weight 4 kg Dimensions I 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 br07e2 4 INSTALLATION The installation must be executed by a professional See the service manual for W85 41 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 rega
13. rding 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 e Remove the welding power source s rear handle by removing the screws e Place the control box onto the welding power source see picture below e 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 07 2 4 3 System description It is possible to configure the U8 unit for stand alone usage stand alone unit or presentation usage presentation unit The presence of a W85 unit within the welding system determines which unit that is to be used The stand alone unit is used when there The presentation unit is used when there is no W8 unit in the system is a W8 gt unit in the system It is necessary to convert the U8 stand alone unit to a U82 presentation unit before itis used together with a W82 unit During unit start up it is possib
14. t 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 e its operation e location of emergency stops e its function e relevant safety precautions e welding and cutting 2 The operator must ensure that e no unauthorized person is stationed within the working area of the equipment when it is started up no one is unprotected when the arc is struck 3 The workplace must be suitable for the purpose e be free from drafts 4 Personal safety equipment Always wear recommended personal safety equipment such as safety glasses flame proof clothing safety gloves Note Do not use safety gloves when replacing wire Do not wear loose fitting items such as scarves bracelets rings etc which could beco
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