ESAB Tech Tips

Quick Guide Aristo U8 2 control panel.

 Tech Tips
Table of contents

Introduction Aristo U82 Quick guide 3

Section 1 Control panel layout 4

Section 2 Getting started 4

Section 3 General tips and considerations 5

Section 4 Synergic mode 6

Section 4a QSet an alternative to synergic lines when welding in short arc. 6

Section 5 Choosing a synergic line 7

Section 6 Start and Stop data 10

Section 7 Storing weld data 12

Section 7a Naming your synergic line / program 12

Section 8 Measure mode and Fast mode 13

Section 8a Modifying soft keys 14

Section 9 Overview of advanced key features 15

Scope

This quick guide takes you through the most critical areas/functions when setting up the weld package for MIG/
MAG (GMAW) welding using Short/Spray and Pulsed drop transfer on any material.

To ensure a good weld result and a short set up time, ESAB recommends the use of synergic lines. The U82 is
equipped with 255 lines which are based on a large number of material, wire and gas combinations where optimal
weld parameters (relationship between wire feed speed and voltage) have been identified. The parameters can be
fine tuned to suit individual preferences. Normally this is done by adjusting the voltage to change the arc behavior. If
the wire feed speed is changed, the voltage will follow in accordance to the synergic line.

For product demonstrations and an overview of all U82 capabilities, please contact to your local ESAB
representative.

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Aristo U82 Quick Guide
Get started and get results in no time!
The Aristo U82 control panel is used in combination
with Aristo Feed 3004 and 4804 to set and adjust
welding parameters. The U82 has been developed
to meet the most demanding requirements yet is
designed to be simple and easy to use. The system
allows you to perform Pulsed or Non pulsed welding
with solid or flux cored wire on mild/carbon steel as
well as on Stainless. Using solid wire, you can also
achieve optimal results in aluminum. The control
features 255 pre-programmed synergic lines for
quick and effortless set up and perfect results on any
material.
In this quick guide we will explain how easy it is to find
the right parameters even for the most demanding jobs
and we will also show you how to customize the panel
to enable you to quickly adjust and switch between
welding parameters and jobs.
Depending on the task at hand, the U82 can display
just the basic weld data for the day-to-day work or
offer a multitude of adjustments and fine tuning.
The U82 offers
The welder...
Once the weld data is set and the displays been
customized in line with this quick guide, programs and
functionality can be accessed by the push of a button
simple and efficient.
The production / weld engineer...
Possibility to optimize the weld performance through
all phases of the weld (Start weld Stop). Access to
Superpulse for detailed control of the heat input and
optimal weld control.
The quality control management...
Set limits to ensure that weld procedures are followed.
Create a lock code to limit access to critical settings.
Access to production/weld statistics.
Control panel connectivity
For MIG/MAG (GMAW) the U82 should be
connected to the front of the wire feeder. The
control cable (included) connects to the 10 pole
female connector on the Aristo Feed.
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 Control panel layout
Section 1

The large back lit display gives you a good overview of

your relevant settings. The information being displayed
can be customized to suit the welders requirements
and preferences. The five soft keys (S1 S5) and 1
3
their functionality is linked to whats being displayed in
the display window.

1. The covered USB connection allows transfer of

weld data settings between units, saving time when 2 4
installing and setting up multiple machines.
2. Selection knob to scroll through menus and lists
3. # Adjustment of values and setting of Voltage (V)
4. * Adjustment of values and setting of Wire feed 5
speed / Amperage (A)
5. Soft keys for quick access to functions and weld 6 7
data/programs
6. Soft key to take you back to the main menu
7. Enter/Return to select a value from a list or menu

Getting started
Section 2
Before getting started, the preferred language and unit
of length should be selected. Follow this procedure
to select either metric or imperial and one of the 18
languages available in the U82.

1. Press and use the selection knob to scroll

to Configuration then press
2. Place the cursor on Language then press

3. Use the selection knob to select the preferred

language then press

4. Use the selection knob to select unit of length

(fourth from bottom) then press
5. Use the selection knob to put cursor on either
Metric or Inch then press
6. Press to return to the main menu.

The preferred language and unit of

length has now been selected.

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General tips and considerations
Section 3

General points
Make sure that the contact tip, the feeding rolls and
the innerliner match the wire dimension.
Make sure that the gas nozzle is free from spatter. If
not the spatter might disturb the flow of the shielding
gas.
Always store the wire in a clean, dry environment and
at room temperature.
GMAW of Aluminum
GMAW of Stainless Steel with a
Solid Wire
Avoid welding with short arc. Preferrably use pulsed
arc instead.
For superior feeding properties when using pulse or
Super Pulse use a PTFE liner to ensure a stable arc.
Never use a grinding disc previously used on carbon
steels to avoid corrosion.

It is recommended that aluminum should be welded

hot and fast due to the aluminums thermal
coefficient. High welding parameters are needed to
ensure sufficient penetration and to avoid lack of
fusion. To minimize the heat affected zone at these
high welding parameters, the weld speed should be
increased to reduce the heat input.
GMAW of Nickel based materials
and Nickel steels with a Solid Wire
Avoid welding with short arc. Preferrably use pulsed
arc instead.
For superior feeding properties when using Super
Pulse, use a PTFE liner to ensure a stable arc.

To ensure good feeding properties when welding

aluminum, the torch assembly should be kept straight.
Keep the aluminum plates clean.
Keep the welding area clean.
Make sure that the correct feeding rolls, PTFE liner,
inlet-, intermediate- and outlet nozzle are used to avoid
damage to the wire surface.
Make sure that all the above components including the
contact tip and gas nozzle are never in contact with
carbon steels to avoid contamination.
The same rules apply to stainless steel brushes and
other tools that are in contact with the aluminum.
Avoid welding with short arc. Preferrably use pulsed
arc on thin material.
To avoid burnthrough on thin plates, consider using
Super Pulse.

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 Synergic mode
Section 4

For a quick set up and good weld results, ESAB

recommends that the synergic mode is On. This is
default when the unit is first switched on. This is how
you find and confirm that the synergic mode is On:

1. Press Then S1 to reach the Set menu.

2. Use the selection knob to select Synergic Mode
and press
3. Select On then press again.
4. Press to return to the main menu.
(Screenshots 5)

Synergic mode is now On.

Section 4a
QSet - An alternative to synergic lines when welding in short arc

The QSet functionality is a unique way of simplifying

the setting of weld parameters when welding in short
arc mode. The QSet functionality is built in to the U82
and can be accessed according to the instruction in
this section.

1. Press then select Method then press

2. Scroll to Short/Spray then press again.
3. Scroll to QSet then press then scroll to
On then press again.
4. Press S2 for Measure mode or S4 for Fast
Mode to set the wire feed speed.

The machine will now sense the wire/gas combination

and automatically select and correct welding
parameters. QSet will also adjust for changes in stick
out to maintain optimal arc characteristics.

Recommendations

Make a first weld (for 6 seconds) on a test piece

Easy weld pool heat adjustment
(Same material and thickness as the work piece
to be welded) to allow the machine to find and set Consistent weld quality

the correct weld parameters. From here on you will Low spatter level and reduced post weld cleaning
benefit from: Quick set up

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Choosing a synergic line
Section 5

By entering application specific data such as weld

process, method, wire type/diameter and gas, the
control box will select the most suitable synergic line
with related start/stop and weld data. This section will
guide you through the process step by step.

Press to acess the main menu.

Process and Method selection

For MIG/MAG (GMAW) either Pulsed or Non pulsed
welding can be selected. Both methods have their
advantages as per our recommendations.

1. Use the selection knob to select Process then

press Scroll to MIG/MAG then press

2. Scroll to Method then press Scroll to

preferred method (Short/Spay or Pulse) then
press again.

Note: The SuperPulse functionality is not included

in this quick guide.

Recommendations

Pulse arc benefits: Ideal for thinner gage material

where low levels of spatter are critical. With
optimal weld pool control, pulsed welding is
typically preferred for those high quality weld
requirements. Pulse welding also enables the
use of a larger diameter wire on a thinner gauge
material, reducing the overall production cost.

Short arc benefits: Used for thinner gage material

where avoiding spatter is not critical.

Spray arc benefits: Ideal for thicker gage material

where high welding speed is required. The
process generates low levels of spatter but also
slightly reduced arc control. Spray Arc is always
recommended for high quality welding on thick
gauge Aluminum.

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 Wire type selection
The U82 control box contains a large number of
different wire types specified in accordance with AWS
classification. To reach a good weld result the wire
type with the closest match should be selected. The
AWS classification can typically be found on the wire
bobbin or the package. The table provides an overview
and a conversion between the AWS denominations,
material type and examples of ESAB filler metal.

1. Remain in main menu and scroll to Wire type

then press

2. Scroll to the correct wire type then press

AWS For
Base Material Classification Materials Example of ESAB wire in this classification
Short / Spray Arc
Carbon steel (FE) ER70S ER70S OK Aristorod 12.50/12.63, OK Autrod 12.51/12.58/12.64, Spoolarc 29S/86
ER80S OK Aristorod 13.26/13.28/13.32
ER90S OK Aristorod 13.22/13.17
E70 MCW E70C MCW OK Tubrod 14.11/14.12, Coreweld 46 LS, Coreweld C6
E70 RFCW OK Tubrod 15.14, Dual shield 7100 Ultra
E70 BFCW OK Tubrod 15.00/15.06
FE RCW DualShield Dual shield 7100 Ultra
Stainless Steel (SS) ER316LSi OK Autrod 316LSi
SS MCW Arcaloy MC
SS RFCW Shield Bright
Duplex Steel E2209 FCAW Shield Bright 2209
ER2209 OK Autrod 2209
Aluminum ER5356 AL-5000 series OK Autrod 5356/5183/5087/5556/5554
ER4043 AL-4000 series OK Autrod 4043/4047/4643
Other ERCuSi-A OK Autrod 19.30
ERCuAl-A1 OK Autrod 19.40
ER NiCrMo OK Autrod NiCrMo-3
Pulse Arc
Carbon steel (FE) ER70S ER70S OK Aristorod 12.50/12.63, OK Autrod 12.51/12.58/12.64, Spoolarc 29S/86
ER80S OK Aristorod 13.26/13.28/13.32
ER90S OK Aristorod 13.22/13.17
E70 MCW E70C MCW OK Tubrod 14.11/14.12
Stainless Steel (SS) ER316LSi OK Autrod 316LSi
SS 309 MoL OK Autrod 309MoL
ER308LSi OK Autrod 308LSi
ER309LSi OK Autrod 309LSi
SS MCW ARCALOY MC
Duplex Steel ER2209 OK Autrod 2209
Aluminum ER5356 AL-5000 series OK Autrod 5356/5183/5087/5556/5554
ER5183 AL-5000 series Ok Autrod 5183
ER4043 AL-4000 series OK Autrod 4043/4643
ER4047 AL-4000 series OK Autrod 4047
ER1100 AL-1000 series OK Autrod 1070/1100/1450
MIG Brazing ERCuSi-A OK Autrod 19.30
ERCuAl-A1 OK Autrod 19.40
Other ER NiCrMo-3 OK Autrod NiCrMo-3
1.3964 1.3964

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Choosing a synergic line
Section 5

Gas selection
The U82 control panel contains the most suitable gas
mixes based on the wire type selected. If a specific gas
combination is not available then ESAB recommend
that the closest match is selected. Small variations
have a small impact on the weld performance which
can be corrected manually.

1. Remain in main menu and scroll to Shielding gas

then press

2. Scroll to the correct gas combination then

press again.

Wire diameter selection

1. Remain in main menu and scroll to Wire

diameter then press

2. Scroll to the correct diameter then

press again.

The appropriate synergic line has now been selected.

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 Start and Stop data
Section 6

With each synergic line there is a set of start and stop data set as default. Some of those functions (creep start,
hot start and crater fill) can be activated by using the soft keys described under section 6. To further fine tune
the weld settings, the start an stop data can be customized as described below. To store customized start and
stop data with weld data, the following actions should be taken in conjunction with selecting the synergic line and
subsequently storing it (see section 6).

Start data
1. Press followed by S1 for Set.
2. Scroll to Start data then press to acess
the following settings.

Gas Preflow
Use # to adjust from 0,1 s to 25 s

Slow run-in / Creep Start

Use selection knob to position cursor on slow
run-in then press Select On or Off by
placing the cursor and pressing again.

Hot start
Use selection knob to position cursor on Hot start then
press When selecting On by placing the cursor
and pressing you are opted to set hot start
time, wire speed and voltage. Change value by placing
the cursor on the value and turn #.

When all values are set, press Quit. The set values are now saved.
Proceed to set Stop data.

Hot Start

Hot Start prevents lack of fusion at the start of

the weld. If the values are set too high, the initial
deposition rate will result in an exessive weld
bead. Therefore, different materials and different
plate thicknesses might require different Hot
Start settings. Adjust accordingly.
The Hot Start wire feed speed value is added to the
set wire feed speed.
The Hot Start voltage represents the total voltage
during the hot start.

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Stop data
1. Press followed by S1 for Set
2. Scroll to Stop data then press to acess
the following settings.

Crater fill
Use selection knob to position cursor on crater fill then
press When selecting On placing the cursor
and pressing again you are promted to set the
crater fill time and final wire speed. Change value by
placing the cursor on the value and turn #.

Burn back time

Change value by placing the cursor on the value and
turn #.

SCT
Use selection knob to position cursor on SCT then
press Select On or Off by placing
the cursor and pressing again.

Pinch off pulse (only in Pulse mode)

Use # to adjust from 20% to 200%

Gas post flow

Use # to adjust from 0,1 s to 25 s

Press and proceed to section 7 to store the start, weld

and stop data.

SCT (Short Circuit Termination) Burn back

The SCT eliminates the need to manually set the If the stick out after the weld termination is either
burn back time when welding solid wire. SCT too short or too long, adjust the burn back time
produces a minimized ball at the wire end which accordingly.
ensures excellent start properties for the next weld.
The welding torch should be kept still through the
weld termination phase.

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 Storing weld data
Section 7

Storing the synergic line is a time saver when doing

repetitive jobs. Instead of re-entering all data, you can
recall the optimal settings by a push of a button.

1. Remain in main menu and press S3 for Memory

to enter the Weld data memory.
2. Press S1 for Store then turn # to reach your
preferred memory number.
3. In this case select 1. Then press S1 for Store.

You have now stored all your settings and created a

program under weld data 1. Easily acessible in the
fast mode (see section 8).

Section 7a
Naming your synergic line / program

A stored synergic line/program can be given a unique

name provided by the user. This is a key advantage
for easy recognition when switching between jobs
frequently. In this example, the program has been
given the name JOB1.

1. Press then S1 for Set.

2. Scroll to Edit description then press
to open a keyboard.
3. Use the Selection knob to navigate vertically and
soft keys S1 and S2 to navigate horizontally. A
letter or number is selected by pressing
4. When a name is complete press S5 for Done.
5. Press to return to main menu.

The weld data has now been stored

as JOB1. Proceed to section 8.

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Measure mode and fast mode
Section 8

Once the synergic line has been selected and stored, it can quickly be activated from the Fast mode view. In the
Measure mode a number of useful functions can be activated by a push of a button. These are listed below as
they are set as default upon delivery. Note that these can be changed to suit individual requirements (see section
8a). Both views are accessed by pressing followed by either S2 for Measure mode or S4 for Fast mode.

Measure mode
When in synergic mode an adjustment of voltage and wire feed speed will be in relation to the synergic line,
meaning that the voltage is adjusted as plus or minus by turning #. Soft keys S1 to S4 gives access to a number of
useful quick functions which can be activated or deactivated.

S1 Gas purge
Press and hold. Gas flushes through the hose
and torch assembly to ensure proper protection.
S2 Wire inch
Press and hold. Wire is fed through the torch assembly
without wasting gas. This functionality is preferably
used when changing wire.
S3 4-stroke
As default the machine is set to 2-stroke (push torch
trigger to start the weld and hold it. Terminate the weld
by releasing the trigger.) By pressing S3 you activate
the 4-stroke (Push torch trigger and release it to start
the weld. Terminate the weld by pressing and releasing
the trigger) this is used for longer welds.
S4 REM
To activate a remote source when connected.

Second menu S5

Press to access four more alternatives. The

corresponding functions for each soft key changes.

S1 Crater fill
Activate to create a smooth termination of the weld.
The weld current will automatically be reduced to elimi-
nate the risk of cracks and weld defects.
S2 Slow run-in / Creep start
Reduces spatter in the start sequence. Note: This
function is always on when the U82 is connected to an
Aristo 4004i Pulse 460V.
S3 Hot start
Gives a short boost of power which heats the wire,
ensuring a perfect result from the first drop transfer.
S4 Trigger switch
Activating the trigger switch functionality enables you
to switch between pre-set weld data during welding by
quickly double clicking the torch trigger.
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 Measure mode and fast mode
Section 8

Fast mode
In this view, a total of four synergic lines/programs can
easily and quickly be recalled by a push of a button.

Soft keys S1 to S4 correspond to programs set. See

section 7 where a synergic line was stored in memory
position 1. This will be activated by pushing S1 (Weld
data 1). By repeating the process under section 7 and
storing synergic lines/programs in memory position 2,
3 and 4, it is possible to switch between four programs
without leaving the fast mode view. The settings (or
name if applicable) of the synergic line is displayed at
the top left corner of the display. The voltage and wire
feed speed can also be set in Fast mode.

By pressing S5, four quick access functions can be

activated or deactivated also in Fast mode.

Section 8a
Modify soft keys S1 - S5

The soft key functionalities as described under section

6 are not static. The set up can be modified to suit
individual requirements. If a welder prefers to work in
Measure mode, then the preferred functions should
be in positions S1, S2, S3 and S4. If the Fast mode is
used the preferred functions should be placed under
the second set of S1, S2, S3 and S4 (the second set is
reached when S5 is pressed in Fast mode)

1. Press to return to main menu then scroll to

Configuration followed by again.
2. Scroll to MIG/MAG defaults then press
3. Scroll to Soft keys configuration then
press A list of all functions with position
numbers are shown.
4. Put the cursor on None then press S1, S2, S3
then S4 to enter next page and repeat pressing S1
to S4.
All soft key functions have now been reset to None.

5. Now use the selection knob to scroll to a preferred

function then press the soft key where it should be
positioned. Repeat until complete. Note: soft keys
can be left blank None.
6. Press to return to main menu.

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Overview of advanced key features
Section 9
The U82 control box offers a multitude of more
advanced features some to enable quality control and
others to improve the weld performance and weld
quality. This section provides a brief overview of some
of those features. For further details please refer to
the instruction manual or contact your local ESAB
representative.
Create synergic lines
The U82 supports creation of unique customer specific
synergic lines.
Quality functions
The last 99 welds can be stored in the control box and
be viewed at any time. Data such as mean voltage
and amperage and arc time is monitored and can be
exported and filed.
Setting limits
Both min and max values on voltage and amperage
can be set, ensuring that the operator cant step
outside of a set procedure. This is important when
following a weld procedure.
Production statistics
Statistics such as arc time and quantity of consumed
wire are stored in the control box. The statistics can be
exported and then reset when appropriate.
Export/Import
Reports and statistics can easily be exported using the
USB connection. Unique synergic lines and customized
programs can be stored on the USB and transferred to
multiple power sources/control boxes.
Lock code
Once the weld data has been set, the control box can
be locked, preventing unauthorized personnel from
changing the data.
SuperPulse
SuperPulse is a weld method where a short, spray
and pulsed arc can be combined in various set ups
to provide superior arc/weld performance. This weld
method enables high quality welding on very thin
material with excellent weld joint esthetics, high
requirement position welding and higher speed root
runs.
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 unrivaled service
and support
Every ESAB product is backed by our commitment to superior customer service and support. Our
skilled customer service department is prepared to quickly answer any questions, address problems,
and help with maintenance and upgrading of your equipment. Our products are backed with the most
comprehensive warranty in the business.

With ESAB, you can be sure that you purchased equipment that will meet your needs today and in the
future. Ask your ESAB sales representative or distributor for a complete ESAB solution.

For more information, visit www.esab.com

GE
IMA

ESAB / esab.com

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