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Welding power source interface
115V, 230V
Instruction manual
0463 689 001 US 20200128
Valid for: serial no. 936-xxx-xxxx
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TABLE OF CONTENTS
1
SAFETY
1.1 Meaning of symbols
1.2 Safety precautions
2
INTRODUCTION
2.1 Equipment
3
TECHNICAL DATA
4
INSTALLATION
4.1 Location
4.2 Lifting instructions
4.3 Connections
5
OPERATION
5.1 Connections and control devices
5.2 Connecting welding cable
6
MAINTENANCE
7
TROUBLESHOOTING
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4
4
8
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9
10
10
10
11
12
12
13
14
15
8
ORDERING SPARE PARTS
DIAGRAM
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ORDERING NUMBERS
ACCESSORIES
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17
18
19
Rights reserved to alter specifications without notice.
0463 689 001 © ESAB AB 2020
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1 SAFETY
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
could result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ the location of emergency stops
○ its function
○ the relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorized person is 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 may cause injury 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 - Pose health risks
• Welders with pacemakers fitted should consult their doctor 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 the 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 your 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.
0463 689 001
NOISE - Excessive noise can damage hearing
Protect your ears. Use ear defenders 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 a fire. Make sure there are no inflammable
materials nearby.
• Do not use on closed containers.
HOT SURFACE - Parts can burn
• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.
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 such locations,
due to conducted as well as radiated disturbances.
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1 SAFETY
NOTE!
Dispose of electronic equipment at the recycling
facility!
To conform with the 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
2 INTRODUCTION
Welding power source interface is a piece of equipment used to connect general
analog-controlled SAW (Submerged-Arc Welding) power sources to the EAC10 control unit
when used together with the Versotrac EWT1000 welding equipment. The Welding power
source interface serves the following purposes:
• Provide supply voltage for EAC10
• Provide welding current and work piece voltage reference feedback to EAC10
• Connection means for non-ESAB analog power sources
The Welding power source interface is available in two versions:
• 115-V version
• 230-V version
For ordering numbers, see chapter ORDERING NUMBERS.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
Welding power source interface is delivered with:
• Instruction manual
Control cable is to be ordered separately, see chapter ACCESSORIES.
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3 TECHNICAL DATA
3 TECHNICAL DATA
Welding power source interface, from serial no. 936-xxx-xxxx
115-V version 230-V version
Main voltage 115V ±10%, 1 phase 50/60Hz 230V ±10%, 1 phase 50/60Hz
Input supply current 6.1A 3.0A
No-load power 15W 15W
Rated apparent power 700VA 700VA
Input fuse 10A (slow), size 5×20mm 3.15A (slow), size 5×20mm
Output voltage 42V ±10%, 1 phase 50/60Hz
48V ±10%, 1 phase 50/60Hz
Rated output current 16A
Output fuse 20A, size 5×20mm
Rated load for bus bars 1000A at 100%
Working temperature 32to+40°C(-10to104 °F)
Dimensions (l×w×h) 17.7×9.84×9.84in (450×250×250mm)
Weight 20kg (44.09Ibs)
Insulation class H
Enclosureclass IP23S
Mains supply, S
sc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 104°F (40°C) or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP23S is intended for indoor and outdoor use; however, it should not be
operated in precipitation.
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4 INSTALLATION
4 INSTALLATION
The installation must be carried out by a professional.
CAUTION!
This product is intended for industrial use. In a domestic environment, this product
may cause radio interference. It is the user's responsibility to take adequate
precautions.
4.1 Location
Position the Welding power source interface
less than 1m (40in.) from the analog power
source, on a flat surface.
4.2 Lifting instructions
When lifting, use the handle on top of the Welding power source interface box.
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4 INSTALLATION
4.3 Connections
1. Analog SAW power source 7. Welding cable to power source
2. Welding power source interface 8. Welding cable to Versotrac welding head
3. EWT1000 9. Control cable to analog power source
(12-pol)
4. Workpiece 10. Control cable between the welding power
source interface and EAC 10 Control unit
(28-pol – 23-pol)
5. To mains supply 11. Work piece voltage reference cable
6. Return cable
Rating plate with supply connection
1.
data
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5 OPERATION
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
NOTE!
When moving the equipment, use the handle. Never pull the cables.
WARNING!
Electric shock! Do not touch the workpiece or the welding head during operation!
WARNING!
The cover plate must be in place during operation.
5.1 Connections and control devices
1. On/Off switch 5. Connection to EAC10
2. Fuse holder 6. Connection for work piece voltage
reference cable
3. Power cable 7. Connections for welding cables
4. Connection to analogue power source
(12-pol)
0463 689 001
8. Cover plate
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5 OPERATION
Pinouts for control cable 0446 178 880
Cable no. Description
1 Ground reference for analog voltage
2 Analog voltage reference (0–10V)
58.3/3 Trigger common
58.3/4 Trigger input
58.3/5 Power source +ve terminal (U+)
5.2 Connecting welding cable
Connect the welding cables as shown in image.
Reinstall the cover plate.
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6 MAINTENANCE
6 MAINTENANCE
WARNING!
The mains supply must be disconnected during cleaning and maintenance.
CAUTION!
Only persons with appropriate electrical knowledge (authorized personnel) may
remove the safety plates.
CAUTION!
The product is covered by a manufacturer’s warranty. Any attempt to carry out repair
work by unauthorized service centers or personnel will invalidate the warranty.
NOTE!
Regular maintenance is important for safe and reliable operation.
NOTE!
Perform maintenance more often during severe dusty conditions.
Before each use, make sure that the:
• Product and cables are undamaged.
• All screwed joints are tightened properly.
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7 TROUBLESHOOTING
7 TROUBLESHOOTING
Perform these checks and inspections before contacting an authorized service technician.
Type of fault Possible cause Corrective action
Copper bars on
the welding
power source
interface
overheating.
Voltage reading
on EAC10
control pendant
shows zero or
has large
fluctuations.
While using the
welding power
source interface,
EAC10 control
unit does not
start, diode not
lit.
Poor electrical connection. Check the electrical connections and
ensure that the welding cables are
tightened properly to the copper bars.
Work piece voltage reference
signal missing.
Check that the work piece voltage
reference cable is connected properly on
the welding power source interface.
42 V missing. Check the electrical connections.
Check the control cable.
Check that On/Off switch on the welding
power source interface is in the ON
position.
Check that On/Off switch on EAC10 is in
the analog position.
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8 ORDERING SPARE PARTS
8 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.
The Welding power source interface is designed and tested in accordance with the
international and European standards IEC/EN 60974-1 and IEC/EN 60974-10. Upon
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
DIAGRAM
Component description
2T1 Transformer SW1 On/off switch
CS1 1000A/60mV current shunt XP1 Work piece voltage reference
FH1 Fuse holder XS1 12-pol Burndy socket
FU1 Input fuse XS2 28-pol Burndy socket
FU2 Output fuse RE1 Relay
FA1 Cooling fan 1C1 Interference suppression capacitor
1L1 Ferrite
For 230V version: Connect cable 202 to terminal 3 of 2T1. Use 3.15A fuse for FU1.
For 115V version: Connect cable 202 to terminal 2 of 2T1. Use 10A fuse for FU1.
NOTE!
When using control cables ≥50m, the voltage drop in the cable is more than 6V.
Use 48VAC tap instead of 42VAC. Connect cables 207 and 208 to terminal 6 of
2T1 to change the tap from 42VAC to 48VAC.
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ORDERING NUMBERS
ORDERING NUMBERS
Ordering number Denomination Type Notes
0446180880 Welding power source interface 115V version
0446 180 881 Welding power source interface 230V version
0463 690 001 Spare parts list
Technical documentation is available on the Internet at: www.esab.com
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ACCESSORIES
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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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
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