ESAB EAC 10 Control unit Instruction manual

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EAC 10 Control unit

Instruction manual

0463 609 001 GB 20190918

Valid for: from serial no. 841-xxx-xxxx

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SAFETY ....................................................................................................... 4

1.1 Meaning of symbols ............................................................................... 4

1.2 Safety precautions ................................................................................. 4

INTRODUCTION.......................................................................................... 7

2.1 Equipment ............................................................................................... 7

TECHNICAL DATA ...................................................................................... 8

INSTALLATION............................................................................................ 9

OPERATION ................................................................................................ 10

5.1 Control pendant...................................................................................... 10

5.2 Connections............................................................................................ 11

5.2.1 Connecting to digital power source ...................................................... 12

5.2.2 Connecting to compatible DC analogue power source ........................ 13

5.3 USB connection...................................................................................... 14

5.3.1 Insert the USB memory ........................................................................ 14

MAINTENANCE........................................................................................... 15

6.1 Inspection and cleaning......................................................................... 15

ORDERING SPARE PARTS........................................................................ 16

DIAGRAM ............................................................................................................ 17

ORDERING NUMBERS ....................................................................................... 20

ACCESSORIES ................................................................................................... 21

Rights reserved to alter specifications without notice.

0463 609 001 © ESAB AB 2019

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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

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1 SAFETY

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!

Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your body between the torch and work cables. Never coil the torch or work cable around your body. Keep welding power source and cables as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

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.

ARC RAYS - 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.

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NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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1 SAFETY

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only qualified people remove covers for maintenance and troubleshooting as necessary. Reinstall panels or covers and close doors when service is finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure that there are no inflammable materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

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.

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.

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2 INTRODUCTION

EAC10 is a control unit intended for submerged arc welding (SAW) and for gas metal arc welding (GMAW). The control unit is included in VersotracEWT1000 and can be used to control automated welding equipment, for example welding portals, column and booms. The control unit can be used with the following ESAB CAN based power sources: LAF, TAF and Aristo®1000.

For information about the control panel EAC10 features, refer to the control panel instruction manual.

For general information about operation, see the instruction manuals for the power source.

ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual.

2.1 Equipment

EAC10 can be connected to ESAB CAN based (digital) and compatible analogue based power sources. EAC10 control unit consists of:

• Motor drive unit – contains control electronics to drive the wire feed and carrier motors.

• Control pendant – provides a user interface to select the desired settings.

The control unit is supplied with:

• A control pendant holder with screws

• An instruction manual for the control unit

• An instruction manual for the control panel

A USB memory is available as accessory, see the "ACCESSORIES" chapter of this manual.

Instruction manuals in other languages can be downloaded from the Internet: www.esab.com

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3 TECHNICAL DATA

EAC 10, from serial no. 841-xxx-xxxx

Supply voltage 60VDC or 42VAC, 50/60Hz

Supply voltage to control

12VDC

pendant

Power requirement Max 900VA

Motor connections adapted

6A 100%

for ESAB motors

Speed control Feedback from pulse encoder

Operating temperature -10to +40°C (-14to +104°F)

Storage temperature -20to +55°C (-4 to +131°F)

Relative air humidity Max 95%

Dimensions l×w×h

EAC 10, complete control unit 275×300×165mm (10.8×11.8×6.5in.)

EAC 10 control pendant 245×225×50mm (9.7×8.9×2.0in.)

Weight

EAC 10, complete control unit 6.8kg (15lb)

EAC10 control pendant 1.25 kg (2.8 lb)

Enclosure class IP23

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4 INSTALLATION

The installation must be executed by a professional.

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5 OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY" chapter of this manual and the "SAFETY" chapter of the manual for the power source. Read it through before you start using the equipment!

5.1 Control pendant

See separate instruction manual for description of the features of the control panel.

1. Welding stop 8. Manual travel motion direction

2. Welding start 9. Fast motion

3. Welding current / Wire feed

speed/balance*

4. Arc voltage / Offset voltage* 11. Manual travel motion direction

5. OK / Setting menu 12. Memory 1, 2, 3 / Soft keys

6. Back 13. Travel speed / frequency*

7. Manual wire feed upwards 14. USB connection

*Only with Aristo®1000 in AC mode.

10. Manual wire feed downwards

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5 OPERATION

5.2 Connections

1. On/Off indicator 6. Connection tractor carriage

2. On/Off switch 7. Connection digital power source

3. Connection work piece voltage reference

8. Connection anlogue power source

brush

4. Accessory cable entries 9. Cable to control pendant

5. Connection welding head

NOTE!

Connect only digital power source or analogue power source at a time.

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5 OPERATION

5.2.1 Connecting to digital power source

Connect the interconnection cable to connector marked with I.

Interconnection cable between CAN based ESAB power source and EAC10 are available as accessories in different lengths.

ESAB CAN based power sources are LAFxxx1, TAFxxx1 and Aristo®1000.

For further information about connecting welding power source, see separate instruction manual.

Always use the dust cover on the connections where no cable is connected.

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5 OPERATION

5.2.2 Connecting to compatible DC analogue power source

Connect the interconnection cable to connector marked with II.

Interconnection cable between analogue based ESAB power source and EAC10 control unit are available as accessories in different lengths.

Always use the dust cover on the connections where no cable is connected.

Requirements on the analogue power source

• Supply voltage 60 V DC or 42 V AC, 50/60 Hz from welding power source or by external means.

• Voltage feedback from negative welding terminal (for welding voltage measurement for display in pendant).

• Start input to initiate welding, analogue input (0–10VDC) for setting welding parameter (control signal).

• 1000A/60mV shunt output for welding current measurement.

Power source connection socket XP2 pinouts

B, C 42VAC

E, F 42VAC return

J Power source negative terminal (U-)

W Power source positive terminal (U+)

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5 OPERATION

Power source connection socket XP2 pinouts

X Arc voltage from welding head

K Power source start

L 0V, common for power source start and reference

M 0-10V reference

N Current shunt negative (-mV)

P Current shunt positive (+mV)

R Emergency stop

Y Emergency stop

S 24VAC / trigger input. For non-ESAB power sources.

T Contact closure to pin S / trigger common. For non-ESAB power sources.

U Reserved for future use.

To connect EAC10 with non-ESAB SAW analogue power source, an analogue power source interface box and control cables are available as accessories.

See chapter "ACCESSORIES".

5.3 USB connection

The external USB memory can be used to transfer programs to and from the control panel.

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.

NOTE!

The USB memory used with this equipment shall not be used for any other purpose.

Certain USB memories may not work with this equipment. Use a USB memory from a reputable supplier.

NOTE!

ESAB assumes no responsibility for any damage caused as a consequence of incorrect use of the USB memory.

5.3.1 Insert the USB memory

• Turn off the main switch of the power source.

• Open the cover on the left-hand end of the control panel (14).

• Insert the USB memory in the USB connector.

• Close the cover.

• Turn on the power source's main switch.

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6 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Maintenance may only be carried out by an authorised technician. Only personnel with the appropriate electrical skills (authorised staff) may remove safety plates.

CAUTION!

All warranty undertakings from the supplier cease to apply if the customer attempts any work to rectify any faults in the product during the warranty period.

6.1 Inspection and cleaning

Check regularly that the control unit is not clogged with dirt.

How often and which cleaning methods apply depend on:

• welding process

• arc time

• location of the unit

• surrounding environment

Usually it will be sufficient to blow the unit clean once a year, using dry compressed air (reduced pressure).

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7 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.

EAC10 is designed and tested in accordance with the international and European standards EN 60974-1 and EN 60974-10. On completion of service or repair work, it is the responsibility of the person(s) performing the work to ensure that the product still complies with the requirements of the above standards.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see

esab.com. When ordering, please state product type, serial number, designation and spare

part number in accordance with the spare parts list. This facilitates dispatch and ensures correct delivery.

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DIAGRAM

Component Description

1AP1 MMC module

1AP2 Display

1AP3 Buttons, rubber keypad

24AP1 Analogue interface board

26AP1 Motor control board

26AP2 Motor driver board

1L1, 26L1, X1L1 Ferrite ring cores

H1 On/off indicator

BR1 Rectifier bridge

C2 Filter capacitor

S1 Power switch

X1 Terminal block

XP1 Connector for digital power source

XP2 Connector for analogue power source

XP3 Connector for carrier

XP4 Connector for weld head

XP5 Connector for work piece voltage reference

CAUTION!

STATIC ELECTRICITY can damage circuit boards and electronic components.

• Observe precautions for handling electrostatic sensitive devices.

• Use proper static-proof bags and boxes.

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DIAGRAM

Digital power source

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DIAGRAM

Analogue power source

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ORDERING NUMBERS

Ordering number Denomination Type Notes

0446 225 880 Control unit EAC 10

0463 612 * Control panel, instruction manual

0463 611 001 Spare parts list

Technical documentation is available on the Internet at: www.esab.com

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ACCESSORIES

EAC 10

Control cable EAC 10 - digital power source

0460 910 880 5 m (16 ft)

0460 910 881 15m (49ft)

0460 910 882 25m (82ft)

0460 910 883 35m (115ft)

0460 910 884 50m (164ft)

0460 910 885 75m (246ft)

0460 910 886 100m (328 ft)

Control cable EAC 10 - digital power source and work piece voltage reference brush

0446 146 880 5 m (16 ft)

0446 146 881 15m (49ft)

0446 146 882 25m (82ft)

0446 146 883 35m (115ft)

0446 146 884 50 m (164 ft)

0446 146 885 75m (246ft)

Control cable EAC 10 - ESAB analogue power source

0449 500 880 15m (49ft)

0449 500 881 25m (82ft)

0449 500 882 35m (115ft)

0449 500 883 50 m (164 ft)

0449 500 884 75m (246ft)

0449 500 885 100m (328 ft)

Welding power source interface, for non-ESAB analogue SAW power source

0446 180 880 115 V version

0446 181 880 230 V version

0462 062 001 USB Memory stick 2 Gb

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ACCESSORIES

Welding power source interface

Control cable EAC 10 - Welding power source interface

0446 179 880 15 m (49 ft)

0446 179 881 25 m (82 ft)

0446 179 882 35 m (115 ft)

0446 179 883 50 m (164 ft)

0446 179 884 75 m (246 ft)

0446 179 885 100 m (328 ft)

Control cable for welding power source interface - general analogue controlled power source

0446 157 880 Cable with 14-pin MS3106 20-27PX plug

Suitable for power sources:

• Lincoln Flextec 650/650x

• Lincoln DC 600

• Lincoln DC 655

0446 156 880 Control cable 14-pin, CPC type

Suitable for power sources:

• Miller dimension 650, 652, 452

0446 178 880 Control cable, terminal block

Suitable for power sources:

• Miller SubArc DC 650, 800, 1000, 1250

• Lincoln DC 1000

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ACCESSORIES

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ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00

http://manuals.esab.com

For contact information visit esab.com

ESAB EAC 10 Control unit Instruction manual

TABLE OF CONTENTS

1 SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2 INTRODUCTION

2.1 Equipment

3 TECHNICAL DATA

4 INSTALLATION

5 OPERATION

5.1 Control pendant

5.2 Connections

5.2.1 Connecting to digital power source

5.2.2 Connecting to compatible DC analogue power source

5.3 USB connection

5.3.1 Insert the USB memory

6 MAINTENANCE

6.1 Inspection and cleaning

7 ORDERING SPARE PARTS

DIAGRAM

ORDERING NUMBERS

ACCESSORIES