ESAB EAC 10 User manual

Brand: ESAB

Model: EAC 10

Category: Welding System

Type: User manual

ESAB EAC 10 is a versatile control panel that offers precise control and monitoring of various welding processes. Its user-friendly interface and advanced features empower you to optimize welding performance, enhance productivity, and ensure consistent weld quality. With its ability to store multiple welding data memories, you can easily switch between different welding tasks or materials. The EAC 10 also provides real-time feedback on welding parameters, allowing you to make informed adjustments and maintain optimal welding conditions.

Instruction manual

0463 612 001 GB 20190305

Valid for: From software version: 1.01A

EAC 10 Control panel

TABLE OF CONTENTS

0463 612 001 © ESAB AB 2019

INTRODUCTION.......................................................................................... 4

1.1 Language................................................................................................. 4

1.2 Control panel .......................................................................................... 4

1.3 Initial configuration ................................................................................ 6

MENUS ........................................................................................................ 7

2.1 General .................................................................................................... 7

2.2 Startup..................................................................................................... 7

2.3 Measured screen .................................................................................... 8

2.4 Set screen ............................................................................................... 8

2.4.1 Set screen, AC power source............................................................... 9

2.5 Welding data memory ............................................................................ 9

2.6 Welding menu ......................................................................................... 10

2.7 Tools menu.............................................................................................. 11

2.8 General settings menu........................................................................... 11

2.9 Machine configuration menu................................................................. 11

SUBMERGED ARC WELDING (SAW)........................................................ 13

3.1 Settings for submerged arc welding .................................................... 13

GAS METAL ARC WELDING (GMAW)....................................................... 14

4.1 Settings for Gas Metal Arc Welding...................................................... 14

FUNCTION EXPLANATIONS ...................................................................... 15

5.1 Arc voltage.............................................................................................. 15

5.2 CA, constant welding current................................................................ 15

5.3 CW, constant wire feed speed............................................................... 15

5.4 Wire feed speed ...................................................................................... 15

5.5 Travel speed............................................................................................ 15

5.6 Welding direction ................................................................................... 15

5.7 AC frequency .......................................................................................... 15

5.8 AC balance.............................................................................................. 15

5.9 AC offset.................................................................................................. 16

5.10 Start type................................................................................................. 16

5.11 Crater filling ............................................................................................ 16

5.12 Burnback time ........................................................................................ 16

TOOLS ......................................................................................................... 17

6.1 Event handling........................................................................................ 17

6.1.1 Error log................................................................................................ 17

6.1.2 Active errors ......................................................................................... 18

6.2 Export/Import .......................................................................................... 18

6.3 Quality Functions ................................................................................... 18

6.4 Unit Information ..................................................................................... 18

6.5 Authorisation profiles ............................................................................ 19

TABLE OF CONTENTS

0463 612 001 © ESAB AB 2019

ERROR CODES........................................................................................... 20

ORDERING NUMBERS....................................................................................... 22

Rights reserved to alter specifications without notice.

1 INTRODUCTION

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1 INTRODUCTION

To benefit as much as possible from your welding equipment, we recommend that you read

this instruction manual.

For general information about the EAC 10 control unit, refer to the control unit instruction

manual.

1.1 Language

The control panel is set to English on delivery. Following languages are available: English,

Swedish, Finnish, Danish, German, French, Italian, Dutch, Spanish, Portuguese, Hungarian,

Polish, Czech, Norwegian, US English, Russian and Turkish.

To select or change language, follow the instructions in section "Initial configuration".

1.2 Control panel

NOTE!

Differences in the panel function may occur, depending on in which product it is

installed.

1. Welding stop 8. Manual travel motion direction

2. Welding start 9. Fast motion

3. Welding current / Wire feed

speed/balance*

10. Manual wire feed downwards

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.

1 INTRODUCTION

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The buttons are used for Up, Down, Right, Left and

Confirm (middle button) during configuration and

setting.

Left Right

Down

Welding stop (1). Stops all travel motions, all motors and welding current.

Welding start (2). The LED is lit when welding is in progress.

The OK button (5) is used to confirm a selected choice.

The Back button (6) is used to go back one step inte the menu.

Press Manual wire feed upwards button (7) to feed the wire upwards. The

wire is fed as long as the button is pressed.

Press Travel motion (8) button to drive in the direction of welding where the

symbol is indicated on the weld equipment.

Fast motion button (9) is used together with other buttons to increase speed.

Press the button to activate fast motion and then press manual wire feed (7,

10) or travel motion (8, 11) button. The LED on the fast motion button is lit

while fast motion is activated. Press again to deactivate fast motion.

During configuration, it is possible to confirm and save a value and return to

previous screen using the Fast motion button.

Press Manual wire feed downwards button (10) to feed the wire downwards.

The wire is fed as long as the button is pressed.

Press Travel motion (11) button to drive in the direction of welding where the

symbol is indicated on the weld equipment.

Three different welding data memories per welding head can be stored in the

control panel memory using the soft keys 1, 2 and 3 (12). The soft keys have

also varying functions depending on which menu currently is in use. The

current function can be seen from the text in the bottom row of the display.

The welding current / wire feed speed/balance knob

(3) is used for increasing

or decreasing set values.

The arc voltage / offset voltage knob

(4) is used for increasing or decreasing

set values.

The travel speed/frequency knob

(13) is used for increasing or decreasing

set values.

Only with Aristo®1000 in AC mode.

1 INTRODUCTION

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1.3 Initial configuration

At first startup after delivery, after a program update and after a completed reset, the control

panel requires initial configuration. The initial configuration starts automatically.

Initial configuration can also be initiated by pressing and holding OK during startup, while the

ESAB logo is shown.

It is possible for an authorised user to change the configuration in the GENERAL SETTINGS

menu.

1. Select language using the Up/Down/Right/Left buttons. Confirm with OK or with the

middle button.

2. Select measurement unit using the Right/Left buttons. Confirm with OK or with the

middle button.

3. Set date using the Up/Down buttons. Change between year, month and day with the

Right/Left buttons. Confirm with OK or with the middle button.

4. Set time using the Up/Down buttons. Change between hours and minutes with the

Right/Left buttons. Confirm with OK or with the middle button.

5. Select wire type using the Up/Down buttons. The wire types shown depend on the

welding head detected during startup. Confirm with OK or with the middle button.

6. Select wire dimension using the Up/Down buttons. Confirm with OK or with the middle

button.

7. After initial configuration, the control panel continues to the SET menu.

2 MENUS

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2 MENUS

2.1 General

NOTE!

A long press on the buttons is more than 3 seconds. A short press is less than 3

seconds.

When any of the screens SET or MEASURED is shown, press long on OK to open

the extended WELDING MENU. The information on the display depends on the

authorisation level. The authorisation level is shown with an icon in the upper right

corner of the display, and explained in section "Authorisation profiles".

2.2 Startup

1. The software version is shown on the control panel during startup. The control panel

automatically detects the welding head during startup.

NOTE!

The welding head is identified by the welding head cable. If the cable is

replaced, use ESAB original spare part to maintain the feature.

2. If no digital power source is attached, a menu for selecting type of analogue power

source is shown.

Previously used analogue power source is shown if on/off switch is in position II. Press

any button within 3 seconds to open the menu and change analogue power source

using the buttons Up/Down and OK.

If no button is pressed, the startup will proceed with no changes on power source.

3. Previously selected wire type and wire dimension is shown. Press any button within 7

seconds to open the menu. Select wire type and wire dimension using the buttons

Up/Down and OK.

If no button is pressed, the control panel continues to the SET menu with no changes

on wire type or wire dimension.

2 MENUS

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2.3 Measured screen

SET MEASURED

  

The MEASURED screen shows the measured values during welding. The information on the

screen depends on the selected welding method.

The screen shows information divided into four parts:

Method, wire, heat input Amperage

Travel speed Voltage

A short press on OK when an AC power source is connected will open the AC

settings screen. A long press on OK opens the WELDING MENU settings screen.

Turn any of the knobs after welding stop to open the SET screen. The values are

shown and the SET screen is kept open.

A short press on any of the keys 1, 2, or 3 recalls the corresponding memory slot.

The SET screen is opened and the values are displayed.

2.4 Set screen

NOTE!

The available functions of the SET screen depends on selected welding method.

SET MEASURED

  

The SET screen is used to change welding settings and save settings to the memory slots

using the keys 1, 2 and 3.

Turn any of the knobs during welding to open the SET screen from the MEASURED screen.

The values are shown during 2 seconds before returning to the MEASURED screen unless

any adjustments are made.

2 MENUS

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If the SET screen is opened without ongoing welding, it will stay active. When welding starts,

the MEASURED screen is activated.

Change the welding settings by using the knob next to the value shown on the display. It it

possible to save the settings for easy access.

A short press on any of the keys 1, 2 or 3 will display the saved welding data

memory settings, set the values and show the the MEASURED screen again. The

welding data memory number in use is shown on the SET tab and also with a bar

above the key with the corresponding number.

With AC power source: A short press on the OK button opens the AC SETTINGS

screen.

A long press on the OK button opens the WELDING MENU. Return by pressing

the Back button.

2.4.1 Set screen, AC power source

SET MEASURED

  

With AC power source: A short press on the OK button opens the AC SETTINGS

screen.

With Aristo®1000 power siurce and SAW welding head: A short press on the OK

button opens a screen where the knobs will control frequency, balance and offset.

Save values and return to the MEASURE screen by pressing the Back button.

2.5 Welding data memory

 

Three different welding data programs per welding head can be stored in the control panel

memory.

Save the settings in the welding data memory by a long press on one of the soft keys 1, 2 or

3. Previously saved settings will be overwritten.

The saved settings will be in use automatically.

To switch between the different welding data memories, press soft key 1, 2 or 3. The welding

data memory in use will be indicated with a line on the display above the soft key and the

number is shown in the SET tab.

The welding data memory has a back-up battery so that the settings remain even if the

equipment has been switched off.

2 MENUS

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2.6 Welding menu

When any of the screens SET or MEASURED is shown, press long on OK to open

the extended WELDING MENU.

The information on the display depends on the authorisation level, attached power source

and welding head. The authorisation level is shown with an icon in the upper right corner of

the display.

Example of welding menu for Aristo®1000 AC/DC

WELDING MENU

METHOD

REGULATION TYPE

START TYPE

CRATER FILL TIME

BURNBACK TIME

DC+

DIRECT

O.O s

0.50 s

Example of welding menu for GMAW welding

WELDING MENU

METHOD

REGULATION TYPE

START TYPE

CRATER FILL TIME

BURNBACK TIME

DC+

DIRECT

O.O s

0.50 s

Example of welding menu for SAW welding with LAF or TAF

WELDING MENU

REGULATION TYPE

START TYPE

CRATER FILL TIME

BURNBACK TIME

DIRECT

O.O s

0.7 s

Select the WELDING MENU by pressing the Right button.

Select a menu row using the Up/Down buttons and press OK or confirm

with the middle button.

Set a numerical value using the Arc voltage / Offset voltage knob (4).

Other values are selected using the Up and Down buttons.

2 MENUS

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Press OK or the Middle button to confirm and return to the previous menu

level. The new value is displayed.

Return to previous menu level WITHOUT changed settings with Back or

the Left button.

2.7 Tools menu

NOTE!

Authorisation level: Manager, see section "Authorisation profiles".

TOOLS MENU

EXPORT / IMPORT

QUALITY FUNCTIONS

UNIT INFORMATION

ERROR LOG

ACTIVE ERRORS

For more information, see chapter "TOOLS".

2.8 General settings menu

NOTE!

Authorisation level: Manager, see section "Authorisation profiles".

GENERAL SETTINGS

LANGUAGE

CALENDAR

TIME

UNIT OF LENGTH

English

2018-10-01

12.31.59

METRIC

The General settings menu is used to access and change the settings entered during initial

configuration.

DATE is always set in format YYYY-MM-DD.

TIME is entered in format HH:MM.

UNIT OF LENGTH is either metric or inch.

2.9 Machine configuration menu

NOTE!

Authorisation level: Service, see section "Authorisation profiles".

2 MENUS

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MACHINE CONFIGURATION

PRODUCT CODE VERSOTRAC

3 SUBMERGED ARC WELDING (SAW)

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3 SUBMERGED ARC WELDING (SAW)

Main menu » Process

During Submerged Arc Welding (SAW), an arc melts a continuously supplied wire. The weld

pool is protected by flux. When the SAW process is selected, select AC or DC. AC is

available only for Aristo®1000.

When the SAW process is selected, select REGULATION TYPE. Choose between constant

welding current (CA) or constant wire feed (CW).

3.1 Settings for submerged arc welding

Settings Setting range In steps of Value after

resetting

Arc voltage

14 - 50 V 0.1 V (1V) 30V

Welding current

(CA)

0 - 3200 A 1 A 400 A

Wire feed speed

(CW)

0 - 2500 cm/min 1 cm/min 300 cm/min

Travel speed* 0 - 200 cm/min 1 cm/min 50 cm/min

Welding direction ▲ - ▲

AC frequency

10 - 100 Hz 1 50 Hz

AC balance

25 - 75% 1 50%>

AC offset

-300 - +300 A/-10 - +10V 1 A / 0.1 V 0

Start data

Start type Direct or Scratch - Direct

Stop data

Crater filling time 0 - 10 s 0.1 s 1 s

Burnback time 0 - 10 s 0.01 s

0.55s DC

0.66s AC

The setting range is dependent on the product used.

The menu shows the settings that belong to the selected regulation type.

Applies only to Aristo®1000 power sources.

4 GAS METAL ARC WELDING (GMAW)

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4 GAS METAL ARC WELDING (GMAW)

MAIN MENU » PROCESS

During Gas Metal Arc Welding (GMAW), an arc melts a continuously supplied wire. The weld

pool is protected by shielding gas. When the Gas Metal Arc Welding (GMAW) process is

selected, you can choose between two control methods by marking REGULATION TYPE

using the positioning knob and pressing ENTER. Choose between constant welding current

(CA) or constant wire feed (CW) or constant current (CC). CC applies only to Aristo®1000,

see explanations in section "FUNCTION EXPLANATIONS".

4.1 Settings for Gas Metal Arc Welding

Settings Setting range In steps of Value after

resetting

Arc voltage* 14 - 50 V 0.1 V (1V) 30 V

Welding current* (CA) 0 - 3200 A 1 A 400 A

Wire feed speed* (CW) 0 - 2500 cm/min 1 cm/min 300 cm/min

Travel speed* 0 - 200 cm/min 1 cm/min 50 cm/min

Welding direction ▲ - ▲

Start data

Gas pre-flow 0 - 99.0 s 0.1 s 2.0 s

Start type Direct or Scrape - Direct

Wire creep start Auto or Set speed - Auto

Wire creep start speed 0 - 1000 cm/min 1 cm/min 20 cm/min

Start phases OFF or ON - OFF

Open-circuit voltage OFF or ON - OFF

Maximum open-circuit voltage 5 - 60 V 0.1 V 50 V

Stop data

Gas post-flow 0 - 99.0 s 0.1 s 2.0 s

Crater filling OFF or ON - OFF

Crater filling time 0 - 10 s 0.01 s 1 s

Burnback time 0 - 10 s 0.01 s 1 s

Stop phases OFF or ON - OFF

Dynamic regulation Auto or Set value - Auto

Setting limits - - -

Measure limits - - -

*) The setting range is dependent on the product used.

5 FUNCTION EXPLANATIONS

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5 FUNCTION EXPLANATIONS

5.1 Arc voltage

The arc voltage is set in the measurement display, weld data setting menu, or fast mode

menu.

Higher arc voltage increases the arc length and produces a hotter, wider weld pool.

5.2 CA, constant welding current

Constant welding current value can be selected in the main menu.

The wire feed is controlled by the power source in order to achieve a constant welding

current.

5.3 CW, constant wire feed speed

Constant wire feed can be selected in the main menu.

The welding current is a result of the selected wire feed speed.

5.4 Wire feed speed

The wire feed speed is set in the measurement display, weld data setting menu, or fast mode

menu.

This sets the required feed speed of the filler wire in cm/minute. A higher wire speed gives a

higher welding current.

5.5 Travel speed

The travel speed is set in the measurement display, weld data setting menu, or fast mode

menu.

Travel speed indicates the required speed (cm/min) at which a column and boom or trolley is

to move.

5.6 Welding direction

Travel motion in the direction that the symbol indicates on the welding equipment.

5.7 AC frequency

Applies only to Aristo®1000 power source.

AC frequency is selected in the weld data setting menu.

AC frequency refers to the number of oscillations per second through the zero level.

5.8 AC balance

Applies only to Aristo®1000 power source.

AC balance is selected in the weld data setting menu.

AC balance is the relationship between positive (+) and negative (-) pulses. The value that is

set indicates the percentage size of the period that is the positive section.

5 FUNCTION EXPLANATIONS

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5.9 AC offset

Applies only to Aristo®1000 power source.

AC offset is selected in the weld data setting menu.

With AC offset the AC level is offset positively or negatively in relation to the zero level.

5.10 Start type

Start type is selected in WELDING MENU » START DATA.

There are two options for start type:

• Direct start, means that the travel speed starts when the arc is struck.

• Scratch start, means that the travel speed starts at the same time as wire feed.

5.11 Crater filling

Crate filling is set in WELDING MENU » STOP DATA

Crater filling makes a controlled reduction in the heat and size of the weld pool possible

when completing the weld. This makes it easier to avoid pores, thermal cracking and crater

formation in the weld joint.

5.12 Burnback time

Burnback time is set in WELDING MENU » BURNBACK TIME

Burnback time is a delay between the time when the wire starts to brake until the time when

the power source switches off the arc voltage. Too short burnback time results in a long wire

stickout after completion of welding, with a risk of the wire being caught in the solidifying weld

pool. Too long a burnback time results in a shorter stickout, with increased risk of the arc

striking back to the contact tip.

6 TOOLS

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6 TOOLS

MAIN MENU » TOOLS

6.1 Event handling

MAIN MENU » TOOLS » EVENT HANDLING

6.1.1 Error log

MAIN MENU » TOOLS » EVENT HANDLING » ERROR LOG

ERROR LOG

Index Date Time Unit Error



180917

181021

11:24:13

10:15:36

DELETE DELETE ALL UPDATE QUIT VIEW TOTAL

All errors that occur during the use of the welding equipment are documented as error

messages in the error log.

Up to 99 error messages can be saved. If the error log becomes full, i.e. if 99 error messages

have been saved, the oldest message is automatically deleted when the next error occurs.

Only the most recent error message is displayed on the control panel.

Errors are monitored/detected in two ways: by test routines that are run on initiation and by

functions that can detect a error when it occurs.

Headings used in the error log:

• Index Error message number

• Date When the error occurred, in format YYMMDD

• Time When the error occurred, in format hh:mm:ss

• Unit Which unit has generated the error message

• Error Error code number

Unit ID for Aristo®1000 power source:

1= Power source 8 = Welding data unit

6 = Motor control board 9 = Analogue I/O board

Unit ID for LAF and TAF power source:

2= Power source 8= Welding data unit

6= Motor control board 9 = Analog I/O board

Delete error messages

To delete a single error message from the error log, position the marker at the error and

press the soft button DELETE.

To delete all error messages from the error log, press the soft button DELETE ALL. This

action will erase all messages from the error log.

6 TOOLS

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6.1.2 Active errors

MAIN MENU » TOOLS » EVENT HANDLING » ACTIVE ERRORS

This menu shows only the errors which are active for the moment.

6.2 Export/Import

MAIN MENU » TOOLS » EXPORT/IMPORT

In the EXPORT/IMPORT menu it is possible to transfer information to and from the control

panel via a USB memory.

The following information can be transferred:

• WELD DATA SETS Export / Import

• SYSTEM SETTINGS Export / Import

• ERROR LOG Export

• QUALITY FUNCTION LOG Export

• PRODUCTION STATISTICS Export

Save to and from USB memory

Insert the USB memory into the control panel.

Select the row with the information that is to be transferred. Press EXPORT or IMPORT,

depending on whether the information is to be exported or imported.

The transfer can take several seconds. The transfer is done when the display shows either

Exported or Imported. Remove the USB memory after the confirmation.

Memory numbers shown in the log

The memory numbers in the list below are shown only when information is exported using

IMPORT/EXPORT.

Memory number Welding head

0 - 2 1 EWH 1000 (SAW)

3 - 5 2 EWH 1000 twin (SAW)

9 - 11 4 EWH 1000 gmaw (MIG/MAG)

6.3 Quality Functions

MAIN MENU » TOOLS » QUALITY FUNCTIONS

Quality functions keep track of various interesting weld data for individual welds. These

functions are:

• Time of welding start.

• Duration of welding.

• Maximum, minimum and average current during welding.

• Maximum, minimum and average voltage during welding.

• Maximum, minimum and average energy per unit length during welding.

The number of welds since the most recent reset is displayed in the row at the top.

Information can be stored about a maximum of 100 welds. In the event of more than 100

welds, the first one is overwritten.

6.4 Unit Information

MAIN MENU » TOOLS » UNIT INFORMATION

6 TOOLS

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Unit information is mainly used by service and support.

UNIT INFORMATION

MACHINE ID

NODE ID

SOFTWARE VERSION

4.65C

SETTING WELD DATA UNIT

UPDATE

6.5 Authorisation profiles

Three different authorisation profiles are possible:

Normal Access to the Welder screens and to the WELDING

MENU.

Manager Access to all settings except the MACHINE

CONFIGURATION menu.

Service Access to all settings.

Change authorisation level

The equipent starts with authorisation level Normal if an authorisation level USB is not

available during startup.

To change authorisation level, turn off the EAC10 control panel. Insert the USB memory with

the authorisation profile. Start the EAC10 control panel. The EAC10 control panel will

confirm the USB memory with beep during startup.

NOTE!

Change back to authorisation level Normal by restart without the USB memory.

Only removing the USB memory will not change authorisation level.

Create authorisation profile USB

The authorisation profile are created using a USB memory. The USB memory must be

formatted as FAT 32 in order to work. Create separate authorisation profile USB memories

for manager and service personnel.

1. Create a text file named profiles.txt on the USB root level.

2. Edit the text file and enter MANAGER to create authorisation profile Manager

or enter SERVICE to create the authorisation profile Service.

NOTE!

The authorisation profile must be written in English using capital letters. The

text is case sensitive.

3. Save the text file.

7 ERROR CODES

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7 ERROR CODES

Error management codes are used to indicate that an error has occurred in the welding

process. It is indicated in the display via a pop-up menu.

This manual describes the error codes for the EAC10. The error codes for other units are

described in the manuals for these units.

Error code Description

LAF, TAF Aristo®

1000

6 4201, 4202,

4203

High temperature

The power source has overheated and cancels welding. Welding

is permitted again when the temperature falls below the

maximum temperature parameter.

Action: Check that the cooling air inlets or outlets are not

blocked or clogged with dirt. Check the duty cycle being used, to

make sure that the equipment is not being overloaded. If the

error persists, send for a service technician.

7 Low welding current

The weld arc has been shut down due to too low welding current

during the welding process.

Action: Is reset at next weld start. If the error persists, send for a

service technician.

8 Low battery voltage

Battery voltage too low. If the battery is not replaced, all stored

data will be lost. This error does not disable any functions.

Action: Send for a service technician to replace the battery.

11 8411

sub-code 0

Speed error on a motor, (wire feed, travel motor)

A motor cannot maintain its speed. Welding stops.

Action: Check that the wire feed has not jammed or runs too

fast. If the error persists, send for a service technician.

12 12, 93 Internal communication error (warning)

The load on the system's CAN-bus is temporarily too high. The

power source may have lost contact with the control unit.

Action: Check that all the equipment is correctly connected. If

the error persists, send for a service technician.

14 14, 95 Communication error

The system's CAN-bus has temporarily stopped working due to

the load being too high. The current welding process stops.

Action: Check that all the equipment is correctly connected. Turn

off the mains power supply to reset the unit. If the error persists,

send for a service technician.

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ESAB EAC 10 User manual

Brand: ESAB

Model: EAC 10

Category: Welding System

Type: User manual

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ESAB EAC 10 User manual

ESAB EAC 10 User manual

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